JP3209856B2 - Manufacturing method of heat exchanger made of aluminum material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

Method of manufacturing an aluminum material-made heat exchanger according to the present invention relates to a radiator for cooling water radiator of an automobile engine, or aluminum material which can be used as a capacitor for coolant radiator of an automotive air conditioner Made heat exchanger
On how to build.

[0002]

2. Description of the Related Art As a condenser for an air conditioner for an automobile, for example, an aluminum material as shown in FIG.
Heat exchangers are widely used. This heat exchanger is
Core part 3 including a number of heat transfer tubes 1 and 1 and fins 2 and 2
Header pipes 4 are provided at both ends in the length direction (left-right direction in FIG. 9), and the ends of the heat transfer tubes 1 are communicated inside the header pipes 4. When heat is exchanged between a fluid such as a refrigerant and air by such a heat exchanger, the fluid is fed from the header pipe 4 on the inlet side via the inlet pipe 20 and the header on the outlet side. Take out from the outlet pipe 21 of the pipe 4. During this time, the fluid
A large number of heat transfer tubes 1 and 1 flow from the inlet header pipe 4 to the outlet header pipe 4. Then, while flowing through these many heat transfer tubes 1, 1, heat exchange is performed with air flowing around the core portion 3.

As shown in FIG. 11 described later, the heat transfer tubes 1, 1 and a pair of header pipes 4 are connected to first through holes 9a, 9a formed in the header pipe 4, respectively. The inside of each other is made to communicate with each other by inserting the ends of them and further brazing. The first through holes 9a, 9a are formed at regular intervals in the axial direction of the header pipe 4 (vertical direction in FIGS. 9 and 11). End caps are provided at both ends of the header pipe 4 to close both ends of the header pipe 4 in a liquid-tight manner.

On both sides of the core 3 in the height direction (vertical direction in FIG. 9), side plates 5a and 5b extending in the length direction of the core 3 are provided. Each side plate 5
Both ends in the length direction a, 5b (left-right direction in FIG. 9) are joined to the header pipes 4, 4 to improve the strength of the core portion 3.

The side plate 5a is shown in FIG.
As shown in the figure, the board part 6 is composed of a plate-like substrate part 6 and bonding pieces 7 protruding from both ends of the substrate part 6 in the longitudinal direction (the direction of arrow a in the figure). The width direction of the joining piece 7 (arrow b in FIG.
Direction) is the size of the substrate 6 as shown in FIG.
In some cases, the width may be smaller than the width l of the substrate portion 6 or the same as the width l of the substrate portion 6. On the other hand, as shown in FIG. 10 (B), the side plate 5b is formed by bending both ends in the width direction of the substrate portion 6 at right angles in the same direction.
A pair of mounting plate portions 8 are formed in a U-shaped cross section. The substrate 6 is fixed to an end of the core 3. still,
Shows a pair of side plates, both in FIG 1 0 (B)
Heat exchangers having the side plates 5b and 5b are also known.

The structure of the joint between the side plates 5a, 5b and the pair of header pipes 4, 4 is as follows. That is, as shown in FIG. 11, the first through holes 9a,
Out of the first through holes 9a at both ends of the 9a, the second through holes 9b are formed outside (the end in the axial direction of the header pipe 4). The joining piece 7 at the end of the side plate 5a (5b) is inserted into the second through hole 9b. The portion of the joining piece 7 inserted into the second through hole 9b is brazed to improve the strength of the core portion 3.

[0007] Japanese Patent Application Laid-Open No. 3-279798 discloses that
As shown in FIGS. 12 and 13, a structure is described in which the joining piece 7 at the end of the side plate 5 a (5 b) is fitted into a fitting hole 10 formed in the header pipe 4. Among them, FIG. 12 shows a fitting state where the joining piece 7 is smaller than the width dimension l of the substrate portion 6 like the side plates 5a and 5b shown in FIG. or,
FIG. 13 shows a fitting state in which the joining piece 7 has the same dimension as the width dimension l of the substrate portion 6. Even in such a structure, the fitting portion between the side plate 5a (5b) and the fitting hole 10 is brazed to improve the strength of the core portion 3.

[0008] When the heat exchanger made of aluminum as described above is manufactured, the following is performed. First, a number of heat transfer tubes 1, 1, fins 2, 2, a pair of header pipes 4,
4. Temporarily assemble the side plates 5a and 5b. Then, the heat exchanger is heated in the heating furnace in the temporarily assembled state. At least one of the two components that are in contact with each other to be joined among the above components has a brazing material laminated on the surface in contact. For example,
The brazing material is laminated on the surfaces of the header pipes 4 and 4 and a brazing material layer is not provided on the side plates 5a and 5b, or the brazing material layer is provided on the side plates 5a and 5b and the header is provided. The pipes 4 and 4 have a structure in which no brazing material layer is provided. Of course, a brazing material layer may be provided on each component. The brazing material layer is always provided on the surfaces of the heat transfer tubes 1 and 1 because it is necessary to braze the fins 2 and 2 having no brazing material layer. In any case, since the brazing material layer is provided, if the brazing material is melted by heating the temporarily assembled heat exchanger and then solidified by cooling, the components can be brazed to each other.

As described above, when the components are brazed by heating, they are temporarily assembled using, for example, a jig 13 shown in FIG. 14 described in Japanese Patent Application Laid-Open No. 1-192467. Hold down each component. This jig 13
Each of the steel members has a sufficient rigidity, and is constituted by a pair of movement stoppers 14 and 14 and a pair of holding plates 15 and 15 formed in a rectangular shape. When brazing an aluminum heat exchanger, the core 3 is
The pair of holding plates 15, 15 are sandwiched, and the pair of movement preventing members 14, 14 are used to hold both holding plates 15, 1.
Prevent the interval between the five from widening. Each movement prevention tool 1
The dimensions of 4 and 14 are formed in accordance with the dimensions of the core 3 to be produced. Therefore, by assembling the jig 13, problems such as detachment of each component are prevented.

In some aluminum heat exchangers, the header plate 4 does not have the second through-hole 9b or the fitting hole 10, and the side plate 5 as shown in FIG.
There is also a structure in which the edges of the joint pieces 7a and 5b are abutted against the peripheral surface of the header tank 4 and further brazed. When such a structure is temporarily assembled and brazed by heating, the pair of header tanks 4 and 4 are bound together by a wire or the like. Thereby, the side plate 5a,
5b is prevented from coming off from between the pair of header tanks 4,4. However, in the case of such a structure, there is a problem that brazing tends to be insufficient, and therefore, in a normal case, the joining piece 7 is connected to the second through-hole 9b or the fitting hole 1 as described above.
A structure is adopted in which it is inserted into or fitted with zero.

[0011]

However, as described above ,
When manufacturing a heat exchanger made of an aluminum material, there are the following problems to be solved. That is, at the time of the heating brazing, the header pipe 4 and the side plates 5a and 5b each tend to thermally expand. The header pipe 4 thermally expands in its axial direction . The side plates 5a and 5b thermally expand in the length direction . As a result of such thermal expansion, the positional relationship between the joining piece 7 and the second through hole 9b or the fitting hole 10 is shifted, and the contact state between these side plates 5a, 5b and the header pipe 4 is poor. Therefore, brazing failure between these two members 5a, 5b, 4 is likely to occur.

Further, the brazing material laminated on the surfaces of the heat transfer tubes 1 and 1 constituting the core portion 3 is melted by the heating, and the contact portions between the side surfaces of the heat transfer tubes 1 and the fins 2 are formed. It is inevitable that it will flow out (run away). As a result, after the heat brazing, the so-called core shrinkage in which the dimension in the height direction of the core portion 3 is reduced occurs. Due to such core shrinkage, the contact state between the two members 5a, 5b, and 4 is likely to be poor, and the brazing failure is also likely to occur. If a brazing defect occurs, the joint cannot have a predetermined strength, resulting in a shortened life of the heat exchanger after completion. In a severe case, it must be discarded as a defective product. The method for manufacturing an aluminum-made heat exchanger of the present invention has been conceived in order to eliminate such disadvantages.

[0013]

Aluminum material manufactured by the manufacturing method of the heat exchanger of the present invention SUMMARY OF], like the method of manufacturing a conventional aluminum material-made heat exchanger described above, each made of aluminum material, the spacing A pair of header pipes provided in parallel with each other, and a plurality of heat transfer tubes arranged at an interval from each other while connecting both ends to the respective header pipes, and a plurality of heat transfer tubes outside the outermost heat transfer tubes. 1 with both ends joined to a pair of header pipes
An aluminum heat exchanger including a pair of side plates, fins provided between adjacent heat transfer tubes, and between the outermost heat transfer tubes and the side plates is manufactured.
Therefore, when joining the above header pipe and side plate
To, in a recess provided in the axial end portions side of the header pipe, is abutted against the joining pieces provided at both ends of the side plates, further brazed.

In particular, the aluminum heat exchanger of the present invention
In the manufacturing method , the outer inclined surface forming the outer half of the recess is formed as a flat inclined surface that becomes deeper toward the center of the header pipe , and the joining piece is
Although it is close to the angle of inclination of this outer slope ,
Even after bending to a large inclination angle , the above outer inclination
Surface of the header pipe from the bottom to the outside of the header pipe
With the tip of the above-mentioned joint piece in contact and temporarily assembled
And the joint piece is brazed to the recess.

[0015]

The aluminum material obtained by the method for manufacturing the aluminum heat exchanger of the present invention having the above-described structure is manufactured.
Using a heat exchanger, the action itself when performing heat exchange between a fluid such as a refrigerant flowing inside and air flowing outside,
This is the same as the above-described conventional aluminum heat exchanger. In particular, the method of manufacturing the aluminum heat exchanger of the present invention
In the method , the displacement of the header pipe and the side plate accompanying the core contraction and thermal expansion can be absorbed by the outer inclined surface of the concave portion and the joint piece of the side plate. Therefore, regardless of the core contraction and the thermal expansion, the joining piece comes into contact with the concave portion with a sufficient pressing force. Further, since the molten brazing material easily enters the portion between the outer surface and the outer inclined surface of the joining piece, the brazing of this joining portion is performed with sufficient strength. As a result, the brazing property between the header pipe and the side plate is improved, the occurrence of defective products is reduced, and a heat exchanger made of aluminum having a predetermined performance can be efficiently manufactured.

[0016]

Next, the present invention will be described in more detail with reference to the illustrated embodiment. The method for manufacturing an aluminum-made heat exchanger of the present invention is characterized in that brazing of a joint piece of a side plate and a recess provided in a header pipe is securely performed. For other configurations and functions, see the method of manufacturing the above-described conventional aluminum heat exchanger.
Since this is the same as the method , a duplicate description will be omitted, and the following description will focus on features of the present invention.

Header pipes 4, 4 and side plate 5
a, 5b are connected to the recesses 16, 1 provided at both ends of the header pipes 4, 4 in the axial direction (vertical direction in FIGS. 1 and 2).
6, joining pieces 7, 7 at both ends of the side plates 5a, 5b.
(FIG. 5) is elastically contacted and brazed.
Thus, the header pipes 4, 4 and the side plates 5a, 5a
In the present invention, in order to braze and join
Not, the recess 16, as shown in FIGS. 3-4, on the outer half portion (refers to half of the side away from the central portion of the header pipe 4, 4, upper half portion of FIG. 3), the becomes deeper toward the central portion of the header pipe 4, to form an outer inclined surface 17
You . In addition, the inner inclined surface 1 is formed such that the inner half thereof (the half near the center of the header pipes 4 and 4 and the lower half of FIG. 3) becomes shallower toward the center of the header pipe 4.
8 to the formation. The inclination angle of the inner inclined surface 18 is larger than that of the outer inclined surface 17. The continuous portion of the outer and inner inclined surfaces 17 and 18 is formed at the bottom 1
It becomes 9.

As described above, the outer inclined surface 17 has a small inclination angle θ ₁₇ with respect to the straight line a parallel to the axis of the header pipe 4. The outer inclined surface 17 is a flat surface. The inclination angle θ _{18 of the} inner inclined surface 18 with respect to the straight line a is larger than the inclination angle θ ₁₇ . Further, in this embodiment, the front shape of the concave portion 16 is substantially triangular as shown in FIG. Then, the outer inclined surface 1
7 is the width W of the bottom 19, which is the continuation of the inner slope 18
Is the largest of the recesses 16. Therefore, when the joining piece 7 comes into contact with the lowermost portion 19, the contact area of the joining piece 7 with the concave portion 16 is maximized.

Meanwhile, the joining pieces 7, 7 formed at both ends of the side plates 5a (5b) is directed to the middle portion of the header pipe 4, 4 as shown in FIG. 5, bending angle theta ₇
To form a bend. The bending angle theta ₇ is close to the tilt angle theta _17, is slightly larger (θ _7> θ ₁₇₎ than the inclination angle theta _17. In a state in which the components of the aluminum heat exchanger are temporarily assembled, the leading edge of the joining piece 7 is the outer inclined surface 17 and the lowermost portion.
The elastic pipe 19 is elastically brought into contact with a portion deviating from the header pipe 4 to the outside . Further, in the present embodiment, the length and the arrangement position of the joining pieces 7, 7 are regulated as follows. That is, the header pipe 4 and the side plate 5a
Is at after brazing with (5b), the brazing at the core shrinkage, or based on <br/> stretched about the length direction of the header pipe 4, the joining pieces 7,7 distal edge above Recess 16
To the bottom 19 of. Therefore, before the brazing, the tips of the joining pieces 7, 7 are the outer inclined surfaces 17 , and the outer ends of the header pipe 4 extend from the lowermost portion 19.
The length and the disposition position of the joining piece 7 are regulated so as to be located in the portion deviated from the above.

That is, as shown in FIG. 1, there are two types of heat exchangers known at present, such as a type using 24 heat transfer tubes 1 and 1 (hereinafter referred to as a type 1). Although not shown, there is a type using 31 heat transfer tubes 1 and 1 (hereinafter referred to as a type 2). In each of these types of heat exchangers, in the first type, the side plates 5a and 5b each have about 1.
It shrinks by about 1 mm toward the middle of the header pipes 4, 4. In the case of the second type, it shrinks by about 1.5 mm. For this reason, at the time of heating brazing, the joining pieces 7, 7
The bending angle and length of the joint pieces 7 and 7, the dimensions of the outer inclined surface 17, and the joint pieces 7 and 7 in order to absorb the displacement of
And the recess 16 are determined. For example, in the case of the illustrated embodiment, taking into account that the core shrinkage is about 1.1 mm, the tip of the joining piece 7 at the time of temporary assembly is positioned about 1 mm from the bottom at an intermediate position of the outer inclined surface 17. It is located above.

As mentioned aboveThe above joining during temporary assembly
Regulate the positional relationship between the tip of the piece 7 and the outer inclined surface 17
Therefore, if heating is performed in a temporarily assembled state for manufacturing,
Core shrinkage due to the heating of
Therefore, as shown by a chain line in FIG.
It contacts the bottom 19. And the outer surface of the joining piece 7 and the above
It is easy for molten brazing material to flow between the outer inclined surface 17
A wedge-shaped gap is formed. This gap is
The molten brazing material flows in due to surface tension,
Brazing the outer surface and the outer inclined surface 17 with a sufficiently large area
In order to do this, the joint of this part is made with sufficient strength
You. As a result, the occurrence of defective products is reduced, and
It becomes possible to efficiently manufacture a heat exchanger made of aluminium material.
In the present embodiment, the header pipe 4 and the
As a material constituting the plate 5a (5b), a core material is
A3003 material, aluminum material whose skin material is A4343 material
Alloy is used. And made of this material
Need for header pipe 4 and side plate 5a (5b)
A brazing material layer is provided on the surface to be formed. The above header pipe
4 is an extruded tube made of the above material, or
ERW pipes are used.

On the other hand, in the heat exchanger of the second type, the above-described regulation is performed in the same manner as in the heat exchanger of the first type. Therefore, the joining of the header pipe 4 and the side plates 5a (5b) in this type 2 heat exchanger can be performed well. However, in the case of this type 2 heat exchanger, the heat transfer tubes 1, 1
As the number of cores increases, the amount of core shrinkage is about 1.5 mm on one side, and in consideration of the amount of shrinkage, the bending angle, length, and The size and the positional relationship between the joint pieces 7 and the recess 16 are regulated.

In FIG. 1, reference numerals 11 and 12 denote mounting brackets for mounting the aluminum heat exchanger to a vehicle body. One of the mounting brackets 11 is fixed to a plurality of locations on the lower side plate 5b. The mounting brackets 12, 12 are fixed to the upper side surfaces of the header pipes 4, 4. Since these mounting brackets 11 and 12 are not the gist of the present invention, detailed description is omitted. Further, in the above-described embodiment, the example in which the present invention is applied to the side plate 5a (5b) having the narrow joining piece 7 as shown in FIG. 10 has been described. Of course, the present invention can be applied to the case where the width dimension 1 of the substrate 7 is the same as the substrate 6. In addition, as a heat exchanger made of aluminum material, there is a heat exchanger in which a partition wall is provided at an intermediate portion of one header pipe, an inlet pipe is provided on one side of the header pipe, and an outlet pipe is provided on the other side. Of course, the present invention can be applied to such a method of manufacturing a heat exchanger. Further, the front shape of the concave portion 16 is not limited to the illustrated shape, and may be an oval or the like.

[0024]

The aluminum heat exchanger of the present invention is manufactured.
Since the manufacturing method is configured and operates as described above, the side plate and the header pipe are joined with sufficient strength. As a result, the occurrence of defective products is reduced. Further, since there is no through hole into which the joining piece of the side plate is inserted, manufacturing becomes easy. As a result, an aluminum heat exchanger having a predetermined performance can be efficiently manufactured.

[Brief description of the drawings]

FIG. 1 shows an aluminum material obtained according to an embodiment of the present invention.
The front view which shows a heat exchanger .

FIG. 2 is a front view of the header pipe according to the present invention.

FIG. 3 is a partially enlarged side view showing a concave portion.

4A is a longitudinal sectional view of a concave portion provided at an upper portion of a header pipe, and FIG.

5A and 5B show a side plate, wherein FIG. 5A is a front view and FIG. 5B is a plan view.

FIG. 6 is an enlarged view of an upper right corner of FIG. 1;

FIG. 7 is an enlarged view as viewed from above in FIG. 6;

FIG. 8 is an enlarged view of a part X in FIG. 6;

FIG. 9 is a perspective view showing a conventional heat exchanger.

FIG. 10 is a perspective view showing two examples of a conventionally known side plate.

FIG. 11 is a partial longitudinal side view showing a first example of a joint portion between the header pipe and the side plate.

12A and 12B show the second example, wherein FIG. 12A is a partial cross-sectional plan view, and FIG. 12B is a partial vertical cross-sectional side view.

FIG. 13 is a view similar to FIG. 12, showing the third example;

FIG. 14 is a perspective view showing a state in which components of the aluminum heat exchanger are temporarily assembled by a jig.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Heat transfer tube 2 Fin 3 Core part 4 Header pipe 5a, 5b Side plate 6 Substrate part 7 Joint piece 8 Mounting plate part 9a First through hole 9b Second through hole 10 Fitting holes 11, 12 Mounting bracket 13 Jig DESCRIPTION OF SYMBOLS 14 Movement inhibiting tool 15 Holding plate 16 Recess 17 Outer inclined surface 18 Inner inclined surface 19 Bottom part 20 Inlet pipe 21 Outlet pipe

Continuation of front page (58) Field surveyed (Int.Cl. ⁷ , DB name) F28F 9/00-9/26

Claims (1)

(57) [Claims] 1. A pair of header pipes each made of an aluminum material and provided in parallel with each other at an interval, and both ends are respectively connected to each header pipe and arranged at an interval from each other. A plurality of heat transfer tubes, a pair of side plates provided outside the outermost heat transfer tube and having both ends joined to a pair of header pipes, between adjacent heat transfer tubes, and the outermost heat transfer tube. Fins provided between the heat tube and the side plate
When the header pipe and the side plate are joined in order to produce a heat exchanger made of aluminum, a joining piece provided at both ends of the side plate is provided in a concave portion provided at both ends of the header pipe in the axial direction. Contact and further brazing
In the method for manufacturing an aluminum heat exchanger, the outer inclined surface forming the outer half of the recess is formed as a flat inclined surface that becomes deeper toward the center of the header pipe. The joint piece is bent at an inclination angle close to, but greater than, the inclination angle of the outer inclined surface, and then the outer inclined surface is bent from the bottom at the bottom.
Apply the tip of the joint piece to the part
Heat in the state of contact and temporary assembly, and
A method for manufacturing an aluminum-made heat exchanger, comprising brazing the joined pieces .