JP2022112573A - Heat exchanger and manufacturing method thereof - Google Patents

Abstract

To provide a heat exchanger which is easily manufactured, and which has a sufficiently large attachment strength to a support object using a bracket.SOLUTION: A tank body 9 of a header tank 5 of a capacitor 1 (heat exchanger) includes an inner member 30 and an outer member 40 in which a bracket 8 is integrally formed. The outer member 40 includes; a first formation part 50; a second formation part 60; and an outward projected ridge 70 provided astride the first formation part 50 and the second formation part 60. The projected ridge 70 includes four projected formation parts 71, 72, 73, 74 laminated on one another. The projected formation part 71 on one end in a lamination direction is integrally provided on a downstream edge part of the first formation part 50, and the projected formation part 72 on the other end is integrally provided on an upstream edge part of the second formation part 60. The bracket 8 is constituted by a bracket formation part 80 integrally provided on a part of a longitudinal direction of the projected formation parts 71, 72 of the first formation part 50 and the second formation part 60.SELECTED DRAWING: Figure 2

Description

The present invention relates to a heat exchanger and its manufacturing method.

In this specification and claims, joining by brazing material is referred to as "brazing".

As a heat exchanger used in a vehicle air conditioner, there is provided a cylindrical tank body and a closing member for closing openings at both ends of the tank body, and the longitudinal directions thereof are oriented in the same direction and are spaced apart from each other. A heat exchanger is known that includes a pair of header tanks, a heat exchange core provided between the two header tanks, and a bracket brazed to the tank body of at least one of the header tanks (Patent Reference 1).

The heat exchanger described in Patent Document 1 is attached to a support using brackets. For example, when the heat exchanger described in Patent Document 1 is applied to a condenser for a vehicle air conditioner, it is placed on the windward side (front side of the vehicle) of a radiator that cools the engine coolant in the engine room of an automobile, It is common to use a bracket to attach to the mounting portion provided on the radiator, and it is necessary to ensure not only the strength of the bracket alone, but also sufficient brazing strength of the bracket to the tank body. By the way, the heat exchanger described in Patent Document 1 includes a tank body and a closing member of a header tank, a tank body and a heat exchange tube forming a heat exchange core, a heat exchange tube and fins forming a heat exchange core, and a header tank. is manufactured by collectively brazing the tank body and the bracket in a furnace, but in order to make the brazing strength of the bracket to the tank body sufficiently large, the above-mentioned collective brazing In order to prevent the position of the bracket from slipping, it is necessary to temporarily fix the bracket to the tank body by hooking, mechanical caulking, riveting, welding, or other methods.

JP 2016-138690 A

However, in the heat exchanger described in Patent Document 1, there is a problem that the work of temporarily fixing the bracket to the tank body of the header tank is troublesome at the time of manufacturing, and thus the manufacturing work becomes troublesome.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems and to provide a heat exchanger and a method of manufacturing the same, which can be easily manufactured and can be attached to a support with sufficient strength using brackets.

The present invention consists of the following aspects in order to achieve the above object.

1) Between a pair of header tanks consisting of a cylindrical tank body and closing members for closing the openings at both ends of the tank body, and arranged with a gap between them with their longitudinal directions facing in the same direction. and a bracket provided on the tank body of at least one of the header tanks,
The tank body of the header tank provided with the bracket comprises an inner member forming an inner portion of the tank body on the side of the heat exchange core portion, and an inner member brazed to the inner member and on the opposite side of the heat exchange core portion in the tank body. an outer member forming an outer portion and integrally provided with a bracket;
The outer member of the tank body has a first formation forming a windward portion of the outer member and partially superimposed on the windward portion of the inner member, and a leeward portion of the outer member and leeward of the inner member. a second forming portion partially overlapped with the side portion; The ridge is formed by stacking an even number of plate-shaped ridge-forming portions, and the ridge-forming portion at one end in the stacking direction is integrally provided at the leeward edge of the first forming portion. , the convex streak forming portion at the other end is provided integrally with the windward side edge of the second forming portion,
A heat exchanger, wherein the bracket is constituted by a bracket forming portion that is integrally provided with a portion of the longitudinal direction of the ridge forming portions of the first forming portion and the second forming portion and extends outward.

2) The ridges of the outer member are a plate-shaped first ridge-forming portion integrally formed with the first formation portion, and a second plate-shaped ridge-forming portion integrally formed with the second formation portion. , and an intermediate member disposed between both ridge-forming portions over the entire length of both ridge-forming portions. A third ridge-forming portion, a fourth ridge-forming portion brazed in an overlapping state to the second ridge-forming portion and the third ridge-forming portion of the second forming portion, a third ridge-forming portion, and It comprises an inner connecting portion that integrally connects the fourth ridge forming portion at the inner end,
The bracket forming portion has a plate-like first portion extending outward from the first ridge forming portion of the first forming portion, and a plate-like first portion extending outward from the second ridge forming portion of the second forming portion. a plate-shaped second portion connected to the third ridge-forming portion of the intermediate member and extending outward; a first outer connecting portion integrally connecting the outer ends of the first portion and the third portion; and a second outer connecting portion integrally connecting the outer ends of the second portion and the fourth portion. , the heat exchanger according to 1) above, wherein the first to fourth portions are laminated and adjacent ones are brazed.

3) The ridges of the outer member are formed integrally with the first ridge forming portion, and integrally formed with the second ridge formation portion and overlapped with the first ridge formation portion of the first formation portion. and a second ridge-forming portion brazed together,
The bracket forming portion has a first portion extending outward from the first ridge forming portion of the first forming portion, and a second portion extending outward from the second ridge forming portion of the second forming portion. The heat exchanger according to 1), wherein the first and second parts are laminated and brazed together, and the outer connecting part integrally connects the outer ends of the first and second parts. .

4) A method for manufacturing the heat exchanger according to 2) above,
A first base plate forming an inner member of a tank body of a header tank, which is made of a sheet material having at least one bare surface and is provided with a bracket, and a brazing sheet having a brazing material layer on both sides and a bracket. preparing a second blank plate forming an outer member of the tank body of the header tank provided with, and a closing member brazed to the tank body and closing the openings at both ends thereof;
forming an inner member having a bare surface facing the outer surface of the tank body by processing the first base plate;
a step of bending both side edges of the second base plate to form two bent portions that will be the first forming portion and the second forming portion; and one valley fold located between the two mountain folds and on the side of the bent portion. is positioned on the edge of the outermost flat plate portion opposite to the mountain fold, and forming the first forming portion and the second forming portion by forming both bending portions of the folding body. and cutting the four flat plate portions of the folded body from the mountain fold side so that a part in the longitudinal direction remains, thereby forming the first ridge forming portion of the first forming portion and the second forming portion of the second forming portion. A ridge-forming portion, a third ridge-forming portion of an intermediate member, a fourth ridge-forming portion and an inner connecting portion, and a first portion, a second portion, a third portion, a fourth portion, and a first portion of a bracket-forming portion. forming an outer link and a second outer link on a second material to form an outer member;
The inner member and the outer member are combined and combined such that the first formation of the outer member partially overlaps the windward portion of the inner member and the second formation partially overlaps the leeward portion of the inner member. getting a body
and thereafter brazing the inner and outer members of said assembly to obtain a tank body and brazing a closing member to the tank body to form a header tank.

5) pressing the four flat plate portions of the folded body in the thickness direction between the step of making the folded body and the step of making the first forming portion and the second forming portion among the plurality of steps of making the outer member; The method for manufacturing a heat exchanger according to 4) above, wherein the step of making the thickness of each flat plate portion thinner than the thickness of the second base plate is performed.

6) A method for manufacturing the heat exchanger according to 3) above,
A first base plate forming an inner member of a tank body of a header tank, which is made of a sheet material having at least one bare surface and is provided with a bracket, and a brazing sheet having a brazing material layer on both sides and a bracket. preparing a second blank plate forming an outer member of the tank body of the header tank provided with, and a closing member brazed to the tank body and closing the openings at both ends thereof;
forming an inner member having a bare surface facing the outer surface of the tank body by processing the first base plate;
a step of bending both side edges of the second base plate to form two bent portions that will be the first forming portion and the second forming portion; a step of forming a folded body having two stacked flat plate portions and having a bent portion located at the edge opposite to the mountain fold portion of both flat plate portions by bending and folding at one place so as to be able to a step of forming a first forming portion and a second forming portion by forming a first forming portion and a second forming portion on both bent portions of the bent body; forming the first ridge forming portion of the first forming portion, the second ridge forming portion of the second forming portion, and the first portion, the second portion and the outer connecting portion of the bracket forming portion by to a second material to form an outer member;
The inner member and the outer member are combined and combined such that the first formation of the outer member partially overlaps the windward portion of the inner member and the second formation partially overlaps the leeward portion of the inner member. getting a body
and thereafter brazing the inner and outer members of said assembly to obtain a tank body and brazing a closing member to the tank body to form a header tank.

7) pressing the two flat plate portions of the folded body in the thickness direction between the step of making the folded body and the step of making the first forming portion and the second forming portion among the plurality of steps of making the outer member; The method for manufacturing a heat exchanger according to 6) above, wherein the step of making the thickness of each flat plate portion thinner than the thickness of the second base plate is performed.

According to the heat exchangers 1) to 3) above, the tank body of the header tank provided with the bracket is brazed to the inner member forming the inner portion of the tank body on the heat exchange core side and the inner member. and an outer member forming an outer portion of the tank body opposite to the heat exchange core portion and integrally provided with a bracket, the outer member of the tank body forming the windward portion of the outer member, and a first formation partially superimposed on the windward portion of the inner member; a second formation forming a leeward portion of the outer member and partially superimposed on the leeward portion of the inner member; Consists of an outwardly protruding ridge extending over the leeward side edge of the forming portion and the windward side edge of the second forming portion, and the ridge is formed by laminating an even number of plate-shaped ridge forming portions. The ridge-forming portion at one end in the stacking direction is provided integrally with the leeward side edge of the first forming portion, and the ridge-forming portion at the other end is the windward side of the second forming portion. The bracket is formed integrally with the ridge forming portion of the first forming portion and the second forming portion in the longitudinal direction of the bracket forming portion and extends outwardly. Therefore, in manufacturing by the methods described in 4) to 7) above, a bracket, which is a separate part from the tank body, is temporarily fixed to the outer member forming the tank body, like the heat exchanger described in Patent Document 1. no longer needed. Therefore, the manufacturing work of the heat exchanger is facilitated. Moreover, since the bracket is formed integrally with the outer member of the tank body of the header tank and is constituted by the bracket forming portion extending outward, the heat exchanger can be sufficiently attached to the support using the bracket. can be as large as

According to the heat exchanger of 2) above, the bracket is formed by laminating the first to fourth parts of the bracket forming part and brazing the adjacent ones, and the heat exchanger of 3) above According to this, since the bracket is formed by laminating and brazing the first and second portions of the bracket forming portion, the first portion of the outer member forming the tank body of the header tank provided with the bracket is formed by brazing. It is possible to increase the thickness of the bracket while reducing the thickness of the forming portion and the second forming portion, thereby increasing the mounting strength of the heat exchanger to a support such as a radiator. Moreover, the strength of the bracket alone is increased, and the mounting strength to a support such as a radiator is increased.

In addition, since the outer member of the tank body is made of a brazing sheet having brazing material layers on both sides, it becomes possible to braze heat exchanger parts such as a refrigerant inlet member and a refrigerant outlet member to the tank body. No need to use materials.

According to the heat exchanger manufacturing methods of 4) and 6) above, the bracket can be formed by the bracket forming portion integrally provided on the outer member of the tank body. Thus, there is no need to temporarily fix the bracket, which is a component separate from the tank body, to the outer member forming the tank body. Therefore, the manufacturing work of the heat exchanger is facilitated. Moreover, the thickness of the first forming portion and the second forming portion of the outer member forming the tank main body of the header tank provided with the bracket is reduced, and the thickness of the bracket is increased so that it can be attached to a support such as a radiator. The mounting strength of the heat exchanger can be increased.

According to the heat exchanger manufacturing methods of 5) and 7) above, the flatness of the bracket surface in the manufactured heat exchanger can be optimized. Moreover, it is possible to prevent the wall thickness of the bracket from becoming excessively large while satisfying the pressure resistance required for the tank body.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows the overall configuration of a condenser to which the heat exchanger of the present invention is applied, (a) being a partially omitted front view, and (b) being a plan view. FIG. 2 is an enlarged perspective view showing an upper portion of a header tank of the capacitor of FIG. 1; FIG. 1(a) is an enlarged cross-sectional view taken along line AA of FIG. 1(a); Fig. 1(b) is an enlarged cross-sectional view taken along line BB of Fig. 1(b); 1. It is a perspective view which shows in order of process the method of making the outer member which forms the tank main body of the header tank of the capacitor|condenser of FIG. FIG. 3 is a perspective view corresponding to FIG. 2 showing a modification of the header tank of the capacitor in FIG. 1; FIG. 3 is a cross-sectional view corresponding to FIG. 3 showing a modification of the header tank of the capacitor of FIG. 1; FIG. 5 is a cross-sectional view corresponding to FIG. 4 showing a modification of the header tank of the capacitor in FIG. 1; 7A and 7B are perspective views showing, in order of steps, a method of making an outer member forming the tank body of the header tank of FIG. 6;

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings. This embodiment applies the heat exchanger according to the present invention to a condenser of a vehicle air conditioner.

In the following description, up and down and left and right in FIG. 1A are referred to as up and down and left and right. 1(a) is referred to as the front-rear direction, the front side of FIG. 1(a) (the lower side of FIG. 1(b)) is referred to as the front, and the opposite side is referred to as the rear. In this embodiment, the front side is the windward side and the rear side is the leeward side.

Also, in the following description, the term "aluminum" includes aluminum alloys in addition to pure aluminum.

Further, the same reference numerals are given to the same objects and the same parts throughout the drawings.

FIG. 1 shows the overall construction of a condenser to which the heat exchanger of the present invention is applied, and FIGS. 2 to 4 show the construction of its essential parts. FIG. 5 shows part of the process of manufacturing the left header tank of the capacitor of FIG. 1 in manufacturing the capacitor of FIG.

In FIG. 1, the condenser (1) of the vehicle air conditioner has a condensation section (2), a supercooling section (3) provided below the condensation section (2), and a state in which the longitudinal direction is directed vertically. is provided between the condensation section (2) and the subcooling section (3), and the gas-liquid mixed phase refrigerant condensed in the condensation section (2) is separated into a gas phase refrigerant and a liquid phase refrigerant, and the liquid phase refrigerant is separated. It consists of an aluminum tank-like liquid receiver (4) that stores the liquid phase refrigerant and supplies it to the supercooling section (3). The condenser (1), together with the compressor, expansion valve (reducer) and evaporator, constitutes a refrigeration cycle using a freon-based refrigerant, and is mounted on a vehicle as a car air conditioner.

The capacitor (1) consists of a pair of left and right aluminum header tanks (5) and (6) which are arranged at intervals in the left and right direction with their longitudinal directions facing up and down, and both header tanks (5) and (6). ) and a heat exchange core portion (7) provided between the header tanks (5) and (6) using a plurality of brackets (8) provided at intervals in the vertical direction to It is installed in the vehicle by being attached to the support of the

Both header tanks (5) and (6) consist of an aluminum cylindrical tank body (9) which is open at both upper and lower ends, and are arranged at the upper and lower ends of the tank body (9) and brazed to the tank body (9). and an aluminum closing member (10) for closing the upper and lower openings of the tank body (9). Inside both header tanks (5) and (6), two header tanks (5) and (6) are vertically arranged by an aluminum partition member (11) which is placed in the lower part of the tank body (9) and brazed to the tank body (9). The condenser (1) is partitioned into compartments, and the portion of the condenser (1) located above the partition members (11) serves as the condensation section (2), and the portion located below the partition members (11) serves as the supercooling section. (3).

A refrigerant inlet (not shown) into which vapor-phase refrigerant compressed by the compressor flows is formed in a portion of the tank body (9) of the left header tank (5) above the partition member (11). A refrigerant outlet (not shown) through which the liquid-phase refrigerant flows out toward the expansion valve is formed in a portion below (11). In the tank body (9) of the left header tank (5), an aluminum coolant inlet member (12) leading to the coolant inlet and an aluminum coolant outlet member (13) leading to the coolant outlet are vertically spaced apart. brazed. The section above the partition member (11) of the left header tank (5) is the condenser section inlet header (14), and the section above the partition member (11) of the right header tank (6) is the condenser section outlet header. (15), the section below the partition member (11) of the right header tank (6) is the supercooling section inlet header (16), and the section below the partition member (11) of the left header tank (5) is the supercooling section. It is a cooling section outlet header (17).

The heat exchange core part (7) of the condenser (1) is vertically spaced with the width direction facing forward and backward (ventilation direction), the longitudinal direction facing the left and right direction, and the height direction facing up and down. A plurality of flat aluminum heat exchange tubes (18) arranged at intervals and both ends of which are connected to both header tanks (5) and (6), and between and above and below adjacent heat exchange tubes (18) Aluminum corrugated fins (19) arranged outside the heat exchange tubes (18) at both ends and brazed to the heat exchange tubes (18), and corrugated fins (19) arranged outside the corrugated fins (19) at both upper and lower ends. It consists of an aluminum side plate (20) brazed to (19). The left end of the heat exchange tube (18) above the partition member (11) is connected to the condenser inlet header (11), and the right end thereof is connected to the condenser outlet header (15) to form a partition. The right end of the heat exchange tube (18) below the member (11) is connected to the supercooling section inlet header (16), and the left end thereof is connected to the supercooling section outlet header (17). .

The liquid receiver (4) has a hollow, sealed shape with its longitudinal direction oriented vertically, and communicates with the condensation section outlet header (15) and the supercooling section inlet header (16). The gas-liquid mixed-phase refrigerant that has flowed from the inlet header (16) is separated into a liquid-phase refrigerant and a gas-phase refrigerant, and the liquid-phase refrigerant flows out to the subcooling section inlet header (16).

Therefore, after the high-temperature and high-pressure gas-liquid mixed-phase refrigerant compressed by the compressor passes through the inlet member (12) and enters the condenser inlet header (11), the heat exchange tubes (18) above the partition member (11) ) into the condenser outlet header (15) and then into the receiver (4). The gas-liquid mixed phase refrigerant entering the liquid receiver (4) is separated into two phases, gas and liquid. It flows through the heat exchange tubes (18) below and enters the supercooling section outlet header (17). Refrigerant entering the supercooling section outlet header (17) flows out through the outlet member (13) and is sent to the evaporator via the expansion valve.

The tank body (9) and bracket (8) of the left header tank (5) will be described in detail below with reference to FIGS. 2 to 4. FIG.

As shown in FIGS. 2 to 4, the tank body (9) of the left header tank (5) is the inner part of the tank body (9) on the side of the heat exchange core (7) (the right side in the left header tank (5)). and an outer portion (left header tank (5)) of the tank body (9) which is brazed to the inner member (30) and which is on the opposite side of the heat exchange core (7). It consists of an outer member (40) that forms a left side portion in the case of FIG.

The inner member (30) of the tank body (9) of the left header tank (5) is made of an aluminum brazing sheet having a brazing material layer on one side and is formed in a substantially U-shape with the brazing material layer facing inward. , a pipe joint (31) formed with an insertion hole (not shown) into which the end of the heat exchange pipe (18) is inserted; It consists of both side wall forming portions (32) and (33), and is arranged with the opening facing leftward.

The outer member (40) of the tank body (9) of the left header tank (5) is made of aluminum brazing sheets having brazing material layers on both sides and is formed to have a substantially semi-elliptical cross section. The front flat plate portion (51) that overlaps the front surface of the front wall portion (32) (windward side portion) of the front plate portion (51) and the curved portion that is continuous with the left edge of the front flat plate portion (51) and curves backward to the left A first forming portion (50) consisting of (52), a rear flat plate portion (61) overlapping the rear surface of the rear wall portion (33) (leeward side portion) of the inner member (30), and the rear flat plate portion (61). A second forming portion (60) consisting of a curved portion (62) that is continuous with the left edge and curves forward toward the left, and a leeward edge (left edge) of the first forming portion (50). and a ridge (70) provided to extend over the windward edge (left edge) of the second forming portion (60) and protrude outward.

The ridges (70) of the outer member (40) are composed of a plate-like first ridge formation portion (71) integrally formed with the front curved portion (52) of the first formation portion (50) and a second formation portion (71). A plate-like second ridge-forming portion (72) integrally formed with the rear curved portion (62) of the portion (60), and a double ridge-forming portion (72) between both ridge-forming portions (71) and (72). 71) and an intermediate member (73) arranged over the entire length of (72). The intermediate member (73) includes a plate-shaped third ridge-forming portion (74) superimposed and brazed to the first ridge-forming portion (71), and the second ridge-forming portion (60) of the second ridge-forming portion (60). A fourth ridge-forming portion (75) superimposed and brazed to the ridge-forming portion (72) and the third ridge-forming portion (74), and the third ridge-forming portion (74) and the fourth ridge-forming portion (75). It consists of a right connecting part (76) (inner connecting part) that connects the forming part (75) together at the right end. Therefore, in the ridges (70) of the outer member (40), the first to fourth ridge-forming portions (71), (72), (74), and (75) are laminated and adjacent to each other are brazed. The first ridge-forming portion (71) at one end in the stacking direction is integrally provided with the leeward side edge of the first formation portion (50), and the second ridge-forming portion ( 72) is provided integrally with the windward edge of the second forming portion (60).

The two brackets (8) of the left header tank (5) are attached to the first ridge formation portion (71) of the first formation portion (50) of the outer member (40) and the second ridge formation portion (60) of the second formation portion (60). It consists of a bracket forming part (80) integrally provided with a part of the longitudinal direction of the strip forming part (72) and extending outward. A through hole (8a) is formed through which a fastener such as a bolt is passed for fixing to the support portion of the housing.

The bracket forming portion (80) includes a plate-like first portion (81) extending outward from the first ridge forming portion (71) of the first forming portion (50) of the outer member (40), A plate-like second portion (82) extending outward in continuation with the second ridge forming portion (72) of the second forming portion (60) of the outer member (40) and the third portion of the intermediate member (73). A third portion (83) connecting with the ridge-forming portion (74) and extending outward, and a fourth portion (83) connecting with the fourth ridge-forming portion (75) of the intermediate member (73) and extending outward ( 84), a first outer connecting portion (85) connecting the outer ends of the first portion (81) and the third portion (83) together, and the second portion (82) and the fourth portion (84). and a second outer connecting portion (86) connecting the outer ends together. The first to fourth portions (81), (82), (83), (84) of the bracket forming portion (80) are laminated and adjacent ones are brazed.

The right header tank (6) has the same structure as the left header tank (5) but is arranged in the left-right reversed direction. A communication port that communicates with the vessel (4) and a communication port that communicates the subcooling section inlet header (18) with the liquid receiver (4) are formed. The inner member 30 of the left header tank 5 forms the left side of the right header tank 6 and the outer member 40 likewise forms the right side.

A method of manufacturing the capacitor (1) described above will now be described with reference to FIG.

First, a first base plate made of an aluminum brazing sheet having a bare surface on one side and forming the inner member (30) of the tank bodies (9) of both header tanks (5) and (6), and a brazing material on both sides. A second blank plate (90) made of an aluminum brazing sheet having a layer and forming an outer member (40) of the tank body (9) of both header tanks, and a second blank plate (90) brazed to the tank body (9) to open both ends thereof. A closing member (10) to be closed and other aluminum heat exchanger members are prepared.

Then, by bending or drilling the first base plate, the outer surface of the tank body (9) is formed from the pipe connecting portion (31) having pipe insertion holes and the front and rear side walls (32) and (33). An inner member (30) is made with the side facing side being the bare side.

Also, the outer member (40) is made by subjecting the second base plate (90) to the following steps (a) to (e).

In step (a), both side edges of the second base plate (90) are bent in the same direction to form flat plate portions (51) (61) and curved portions (52) of the first and second forming portions (50) (60). )(62), which is the step of forming two bends (91) (see FIG. 5(a)).

In step (b), the portion between the two bent portions (91) of the second base plate (90) is folded between the two mountain-folded portions (92) and both mountain-folded portions (92) and between the bent portions (91). It is bent at three points in a bellows shape so that one valley fold portion (93) located on the side is formed (see FIG. 5(b)), and further folded to form four stacked flat plate portions (95) and (96). ) (97) and (98), and the bent portion (91) is located at the edge of the outermost flat plate portions (95) and (98) opposite to the mountain fold portion (92). (See FIG. 5(c)).

In the step (c), the four flat plate portions (95), (96), (97), and (98) of the folded body (94) are pressed in the thickness direction, and each flat plate portion (95), (96), (97), (98) is made thinner than the thickness of the second base plate (90).

Step (d) is a step of forming the first and second forming portions (50) and (60) by forming both bent portions (91) of the bent body (94) (see FIG. 5(d)). .

In step (e), the four flat plate portions (95), (96), (97), and (98) of the folded body (94) are cut off from the mountain fold portion (92) side so that a portion in the longitudinal direction remains. , the first ridge-forming portion (71) of the first forming portion (50), the second ridge-forming portion (72) of the second forming portion (60), and the third ridge-forming portion of the intermediate member (73). part (74), fourth ridge forming part (75) and inner connecting part (76), first part (81), second part (82) and third part (83) of bracket forming part (80) , fourth portion 84, first outer connecting portion 85, second outer connecting portion 86, and bracket 8 (see FIG. 5(e)).

After the steps (a) to (e) are performed on the second base plate (90) as described above to form the outer member (40), the inner member (30) and the outer member (40) are separated from each other. The flat plate portion (51) of the first forming portion (50) of (40) overlaps the outside of the front wall portion (32) of the inner member (30), and the flat plate portion (61) of the second forming portion (60) A combined body is obtained by combining the inner member (30) so that it overlaps the outside of the rear wall portion (33).

Next, the two header tank assemblies are arranged with a space therebetween, and the heat exchange tube (18), the corrugated fin (19) and the side plate (20) are arranged between the two header tank assemblies, and the heat exchange tubes are arranged. Both ends of (18) are inserted into the tube insertion holes of the inner member (30) of both assemblies, and further the closing member (10), the partition member (11), the refrigerant inlet member (12), the refrigerant outlet member (13). Combine heat exchanger members such as

After that, the inner member (30) and the outer member (40) of the assembly are brazed to obtain the tank body (9), and the closing member (10) and the partition member (11) are brazed to the tank body (9). Then, the header tanks (5) and (6) are made, and at the same time other heat exchanger members are collectively brazed.

Thus, the capacitor (1) is manufactured.

6 to 8 show a modification of the left header tank of the capacitor (1) of FIG. 1, and FIG. 9 shows the process steps of making the outer member forming the tank body of the left header tank of FIG.

6 to 8, the inner portion of the tank body (101) of the tank body (101) of the left header tank (5) on the heat exchange core (7) side (the right side portion of the left header tank (5)) is The outer portion of the tank body (101) opposite to the heat exchange core (7) is formed by an inner member (30) having a structure similar to that shown in FIGS. It is formed by a brazed outer member (110).

The outer member (110) is formed of an aluminum brazing sheet having brazing material layers on both sides, and includes a front flat plate portion (121) overlapping the front surface of the front wall portion (32) of the inner member (30) and a front wall portion (121). A first forming portion (120) consisting of a curved portion (122) that is connected to the left edge of the flat plate portion (121) and curves backward toward the left, and a rear wall portion (33) of the inner member (30). ) and a curved portion (132) connected to the left edge of the rear flat plate portion (131) and curved forward to the left. ), the leeward edge (left edge) of the first forming portion (120) and the windward edge (left edge) of the second forming portion (130), and projecting outward. It consists of a ridge (140).

The ridges (140) of the outer member (110) are composed of a plate-like first ridge formation portion (141) formed integrally with the front curved portion (122) of the first formation portion (120) and a second formation portion (120). It is formed by laminating and brazing a plate-shaped second ridge-forming portion (142) integrally formed with the rear curved portion (132) of the portion (130), and is formed at one end in the lamination direction. The first ridge-forming portion (141) is integrally provided on the leeward side edge of the first forming portion (120), and the second ridge-forming portion (142) on the other end of the first ridge-forming portion (120) is formed on the second forming portion (130). It is provided integrally with the windward edge.

The two brackets (8) of the left header tank (5) are attached to the first ridge formation portion (141) of the first formation portion (120) of the outer member (110) and the second ridge formation portion (130) of the second formation portion (130). It is formed by a bracket forming portion (150) that is integrally provided with a part of the strip forming portion (142) in the longitudinal direction and extends outward. The bracket forming portion (150) includes a plate-like first portion (151) that extends outward from the first ridge forming portion (141) of the first forming portion (120) of the outer member (110), A plate-shaped second portion (152) extending outwards in continuation with the second ridge forming portion (142) of the second forming portion (130) of the outer member (110), the first portion (151) and the second It consists of an outer connecting part (153) connecting the outer ends of the two parts (152) together. The first and second portions 152 of the bracket formation 150 are laminated and brazed adjacent to each other.

A method of making the outer member (110) of the tank body (101) of the left header tank (5) described above will now be described with reference to FIG.

First, a first base plate made of an aluminum brazing sheet having a bare surface on one side and forming the inner member (30) of the tank body (101), and an aluminum brazing sheet having a brazing material layer on both sides and a tank A second base plate (160) forming the outer member (110) of the main body (101) is prepared.

Next, by bending or drilling the first base plate, the outer surface of the tank body (101) is formed from the pipe connecting portion (31) having pipe insertion holes and the front and rear side walls (32) and (33). An inner member (30) is made with the side facing side being the bare side.

Also, the outer member (110) is made by subjecting the second base plate (160) to the following steps (a) to (e).

In step (a), the two side edges of the second base plate (160) are bent to form flat portions (121) (131) and curved portions (122) (132) of the first and second forming portions (120) (130). ) to form two bent portions (161) (see FIG. 9(a)).

In step (b), the portion between the two bent portions (161) of the second base plate (160) is bent at one point so as to form one mountain fold (162) (see FIG. 9(b)). By further folding, it has two stacked flat plate portions (164) and (165), and the bent portion (161) is on the side opposite to the mountain fold portion (162) in both flat plate portions (164) and (165). This is the step of forming the folded body (163) positioned at the edge (see FIG. 9(c)).

In step (c), the two flat plate portions (164) and (165) of the bent body (163) are pressed in the thickness direction, and the thickness of each flat plate portion (164) and (165) is reduced to the thickness of the second base plate (160). It is a process to make it thinner than

Step (d) is a step of forming the first and second forming portions (120) and (130) by forming both bent portions (161) of the bent body (163) (see FIG. 9(d)). .

In step (e), the two flat plate portions (164) and (165) of the folded body (163) are cut from the side of the mountain fold (162) so that a portion in the longitudinal direction remains, thereby forming the first forming portion ( 120), the first ridge-forming portion (141), the second ridge-forming portion (142) of the second forming portion (130), and the first portion (151) and second portion of the bracket-forming portion (150). This is the step of forming (152), the outer connecting portion (153), and the bracket (8) (see FIG. 9(e)).

In the above embodiment, the heat exchanger according to the present invention is applied to the condenser (1) of the vehicle air conditioner, but the present invention is not limited to this, and can be applied to heat exchangers for other uses. be.

A heat exchanger according to the present invention is suitably used as a condenser for a vehicle air conditioner.

(1): Condenser (heat exchanger)
(5)(6)(100): Header tank
(7): Heat exchange core
(8): Bracket
(9) (101): Tank body
(10): Closing member
(30): inner member
(40)(110): Outer member
(50) (120): First formation part
(60) (130): Second formation part
(70) (140): ridge
(71)(72)(74)(75)(141)(142): Protruding part
(73): Intermediate member
(76): Inner connecting part
(80): bracket forming part
(81)(82)(83)(84): 1st to 4th parts
(85)(86): Outer connecting part
(90): Second base plate
(91): bending part
(92): mountain folding part
(93): valley fold
(94): bending body
(95)(96)(97)(98): Flat plate
(150): Bracket forming part
(151)(152): 1st and 2nd parts
(153): Outer connecting part
(160): Second base plate
(161): bend
(162): mountain folding part
(163): folded body
(164)(165): flat plate

Claims (7)

A pair of header tanks consisting of a cylindrical tank body and closing members for closing the openings at both ends of the tank body, the header tanks being arranged with their longitudinal directions in the same direction and spaced apart from each other; and a bracket provided on the tank body of at least one of the header tanks,
The tank body of the header tank provided with the bracket comprises an inner member forming an inner portion of the tank body on the side of the heat exchange core portion, and an inner member brazed to the inner member and on the opposite side of the heat exchange core portion in the tank body. an outer member forming an outer portion and integrally provided with a bracket;
The outer member of the tank body has a first formation forming a windward portion of the outer member and partially superimposed on the windward portion of the inner member, and a leeward portion of the outer member and leeward of the inner member. a second forming portion partially overlapped with the side portion; The ridge is formed by stacking an even number of plate-shaped ridge-forming portions, and the ridge-forming portion at one end in the stacking direction is integrally provided at the leeward edge of the first forming portion. , the convex streak forming portion at the other end is provided integrally with the windward side edge of the second forming portion,
A heat exchanger, wherein the bracket is constituted by a bracket forming portion that is integrally provided with a portion of the longitudinal direction of the ridge forming portions of the first forming portion and the second forming portion and extends outward. The ridges of the outer member comprise a plate-shaped first ridge-forming portion integrally formed with the first formation portion and a second plate-shaped ridge-forming portion integrally formed with the second formation portion. and an intermediate member disposed between the ridge-forming portions over the entire length of both ridge-forming portions, and the intermediate member is a plate-like third plate brazed to the first ridge-forming portion in an overlapping state. A ridge-forming portion, a fourth ridge-forming portion superimposed and brazed to the second ridge-forming portion and the third ridge-forming portion of the second forming portion, the third ridge-forming portion and the fourth It comprises an inner connecting portion that integrally connects the ridge forming portion at the inner end,
The bracket forming portion has a plate-like first portion extending outward from the first ridge forming portion of the first forming portion, and a plate-like first portion extending outward from the second ridge forming portion of the second forming portion. a plate-shaped second portion connected to the third ridge-forming portion of the intermediate member and extending outward; a first outer connecting portion integrally connecting the outer ends of the first portion and the third portion; and a second outer connecting portion integrally connecting the outer ends of the second portion and the fourth portion. 2. The heat exchanger according to claim 1, wherein the first to fourth portions are laminated and adjacent ones are brazed. The ridges of the outer member overlap the first ridge forming portion formed integrally with the first formation portion and the first ridge formation portion of the first formation portion integrally formed with the second formation portion. and a second ridge-forming portion brazed with
The bracket forming portion has a first portion extending outward from the first ridge forming portion of the first forming portion, and a second portion extending outward from the second ridge forming portion of the second forming portion. and an outer connecting portion connecting the outer ends of the first and second portions together, wherein the first and second portions are laminated and brazed together. . A method of manufacturing a heat exchanger according to claim 2, comprising:
A first base plate forming an inner member of a tank body of a header tank, which is made of a sheet material having at least one bare surface and is provided with a bracket, and a brazing sheet having a brazing material layer on both sides and a bracket. preparing a second blank plate forming an outer member of the tank body of the header tank provided with, and a closing member brazed to the tank body and closing the openings at both ends thereof;
forming an inner member having a bare surface facing the outer surface of the tank body by processing the first base plate;
a step of bending both side edges of the second base plate to form two bent portions that will be the first forming portion and the second forming portion; and one valley fold located between the two mountain folds and on the side of the bent portion. is positioned on the edge of the outermost flat plate portion opposite to the mountain fold, and forming the first forming portion and the second forming portion by forming both bending portions of the folding body. and cutting the four flat plate portions of the folded body from the mountain fold side so that a part in the longitudinal direction remains, thereby forming the first ridge forming portion of the first forming portion and the second forming portion of the second forming portion. A ridge-forming portion, a third ridge-forming portion of an intermediate member, a fourth ridge-forming portion and an inner connecting portion, and a first portion, a second portion, a third portion, a fourth portion, and a first portion of a bracket-forming portion. forming an outer link and a second outer link on a second material to form an outer member;
The inner member and the outer member are combined and combined such that the first formation of the outer member partially overlaps the windward portion of the inner member and the second formation partially overlaps the leeward portion of the inner member. getting a body
and thereafter brazing the inner and outer members of said assembly to obtain a tank body and brazing a closing member to the tank body to form a header tank. Between the step of forming the bent body and the step of forming the first forming portion and the second forming portion among the plurality of steps of forming the outer member, the four flat plate portions of the bent body are pressed in the thickness direction, and each flat plate is 5. The method of manufacturing a heat exchanger according to claim 4, wherein the step of making the thickness of the portion thinner than the thickness of the second base plate is performed. A method of manufacturing a heat exchanger according to claim 3, comprising:
A first base plate forming an inner member of a tank body of a header tank, which is made of a sheet material having at least one bare surface and is provided with a bracket, and a brazing sheet having a brazing material layer on both sides and a bracket. preparing a second blank plate forming an outer member of the tank body of the header tank provided with, and a closing member brazed to the tank body and closing the openings at both ends thereof;
forming an inner member having a bare surface facing the outer surface of the tank body by processing the first base plate;
a step of bending both side edges of the second base plate to form two bent portions that will be the first forming portion and the second forming portion; a step of forming a folded body having two stacked flat plate portions and having a bent portion located at the edge opposite to the mountain fold portion of both flat plate portions by bending and folding at one place so as to be able to a step of forming a first forming portion and a second forming portion by forming a first forming portion and a second forming portion on both bent portions of the bent body; forming the first ridge forming portion of the first forming portion, the second ridge forming portion of the second forming portion, and the first portion, the second portion and the outer connecting portion of the bracket forming portion by to a second material to form an outer member;
The inner member and the outer member are combined and combined such that the first formation of the outer member partially overlaps the windward portion of the inner member and the second formation partially overlaps the leeward portion of the inner member. getting a body
and thereafter brazing the inner and outer members of said assembly to obtain a tank body and brazing a closing member to the tank body to form a header tank. Between the step of forming the bent body and the step of forming the first forming portion and the second forming portion among the plurality of steps of forming the outer member, the two flat plate portions of the bent body are pressed in the thickness direction, and each flat plate is 7. The method of manufacturing a heat exchanger according to claim 6, wherein the step of making the thickness of the portion thinner than the thickness of the second base plate is performed.

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