JP3288532B2 - Method of manufacturing header tank for heat exchanger - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a header tank for a heat exchanger formed by rolling a flat material into a tube using a mold or the like, and a header tank manufactured by the method.

[0002]

2. Description of the Related Art In a conventional heat exchanger, for example, a stacked heat exchanger, a plurality of tubes and fins are alternately stacked, and both ends of the stacked tubes are inserted into insertion holes provided in a header tank. It is inserted and joined, and the openings at the upper and lower ends of each header tank are closed by blind caps.
Further, a partition plate is provided at a predetermined position of each header tank, and a heat exchange medium is meandered a plurality of times between an inlet joint and an outlet joint to which the header tank is attached.

A header tank used in such a laminated heat exchanger is made of a flat brazing sheet coated with a clad material, and this material is formed into a tubular shape by rolling the material by press molding or the like. It has been known.

In this type of header tank, a rectangular material is successively transferred and press-formed by dies having various molds, for example, as shown in FIG.
It is manufactured by rolling from a flat plate shape to continuously forming a circular tube shape, cutting it to a predetermined length in the final step, and joining ends of the material by brazing. That is, from the flat material 4A shown in FIG. 9A, both ends of the material 4A are slightly bent as shown in FIG. 9B, and then, as shown in FIGS. 4A is bent so as to gradually become round, and finally, as shown in FIG. 9E, the joining ends 4B and 4B are brought into contact and rounded so as to become round.

Further, in this type of header tank, as shown in the figure, in order to increase the area of the joint end and ensure the brazing property, the joint end of the material is inclined before the bending step. It is formed on a surface and then rounded in a rounding process.

[0006]

However, in the conventional method for manufacturing a header tank for a heat exchanger, a material having a predetermined shape is manufactured by press molding using a mold.
In particular, the material may be displaced when the joining end of the material is formed on the inclined surface, or the material may be inclined or the center position may be displaced during setting in the bending step shown in the drawing. The joining end of the material is formed on the inclined surface by pressing, but in this case, a force in an oblique direction is applied to the material, and the material is likely to be displaced.

When such a material displacement occurs,
Subsequent processing, for example, the number of defects in the header tank processing step increases, greatly affecting the assembly failure of the heat exchanger, and the inconvenience that attached parts such as brackets cannot be attached.

Accordingly, the present invention provides a header tank for a heat exchanger and a method for manufacturing the header tank, which enables processing while preventing displacement of the material when forming the joint end of the material on an inclined surface or bending the material. It is intended to provide a way.

[0009]

Means for Solving the Problems] header tank production process according to claim 1, the plate-like material the brazing material is coated on at least one side, by a variety of molds, in sequence, rounding Ju
A method for manufacturing a header tank of a heat exchanger for forming a header tank having a hole for inserting a heat sink , comprising:
A plastically deformed portion is formed in advance on at least one of the upper and lower ends of the material constituting the header tank after molding, and the material is sequentially formed while positioning the material by the plastically deformed portion, and then forming a tube. An insertion hole is formed to form a header tank.

[0010]

[0011]

According to the header tank manufacturing method of the present invention, when manufacturing the header tank, a plate-shaped material having a predetermined width is formed while being sequentially transferred by various dies, and prior to various forming steps. A plastically deformed portion is formed on at least one of the upper and lower ends of the material. In various forming steps, for example, if the plastically deformed portion is a cutout, an engagement provided on a mold is provided. This is performed in a state where the cutout portion of the material is engaged with the projection and positioned.

Therefore, it is possible to perform various forming steps while positioning by the plastically deformed portion provided at the end of the material, and when forming the joining end of the material on the inclined surface in the forming step. When bending is performed, processing can be performed while preventing displacement of the material. As a result, in-process defects, shape defects, and the like, which occur due to displacement of the material, and inconsistencies with accessory parts such as brackets are reduced, and it is possible to reduce costs in header tank production.

[0013]

[0014]

An embodiment of the present invention will be described below with reference to the drawings.

As shown in FIG. 1, in the heat exchanger 1 of the present embodiment, a plurality of flat tubes 2 and corrugated fins 3 are alternately stacked, and both ends of the stacked flat tubes 2 are connected to a header tank 4 respectively. It is inserted into the insertion hole 5 and connected for communication. Reference numeral 6 denotes side plates having a U-shaped cross section disposed at the upper end and the lower end of the laminated flat tubes 2. Both ends of the side plates 6 are also provided with dedicated insertion holes provided in the header tank 4. 7 and joined.

As shown in FIGS. 2 and 3, each of the header tanks 4 has an opening formed at the upper and lower ends, and a plastically deformed portion, in this example, a rectangular shape, is formed at the upper and lower ends of the front face of each header tank 4. A notch 9 having a shape is provided. The notch 9 is formed by press molding so as to be located on the center line L of the raw material 4A before molding, and
A notch 9 along the axial direction of the notch 9 is formed so as to be substantially flush with an outer surface of a closing plate 10 described later.

An insertion hole 11 is provided at an end of each of the header tanks 4, that is, at a position inside the notch 9, and a closing plate 10 inserted through the insertion hole 11 is provided. The upper and lower openings of the header tank 4 are closed. Further, a partition plate 13 is inserted through an insertion hole 12 provided at a required portion of the header tank 4.
Are arranged.

Further, as shown in FIG.
An inlet joint 16 and an outlet joint 17 are inserted into and joined to the holes 14 and 15 provided in the hole, and the heat exchange medium flows between the inlet joint 16 and the outlet joint 17 in a meandering manner a plurality of times. It has a structure.

As shown in FIG. 4, the flat tube 2 is inserted into an insertion hole 5 provided in the header tank 4 and joined by integral brazing, and the insertion hole 5 traverses the flat tube 2. It is formed in a shape corresponding to the surface shape.

The header tank 4 is made of a brazing sheet having a clad material coated on both sides in a predetermined shape.
As shown in FIG. 4, the material 4A is formed into a tubular shape by rounding the material 4A and joining the joining ends 4B, 4B at both ends. Further, both joining ends 4B and 4B of the rounded material 4A are formed on an inclined surface which is obliquely inclined with respect to the circumferential direction of the header tank 4.

As shown in the drawing, insertion holes 11 of the closing plate 10 and the partition plate 13 are provided at required positions of the header tank 4.
12, insertion holes 5, 7 for inserting the flat tube 2 and the side plate 6 in addition to the holes 14, 15 for inserting the entrance / exit joints 12, 13 are provided by press molding using a mold.

Hereinafter, a case where the header tank 4 having the above configuration is manufactured will be described.

The header tank 4 is manufactured by press molding using various dies including upper and lower dies.

These dies are arranged along the feeding direction of the raw material 4A, and the molding of the header tank 4 is sequentially performed.
It is performed continuously.

First, notches 9 are formed at upper and lower ends located on the center line of a rectangular material 4A having a predetermined size as shown in FIGS. 5 (a) and 5 (b). As shown in FIG. 6, a joining end portion 4 in which both side ends of the material 4A are inclined surfaces.
B, 4B. Joining ends 4B, 4
In the case of forming B, for example, the material 4A is attached to an engagement protrusion 23 provided on a mold 20 including an upper mold 21 and a lower mold 22.
This is performed in a state where the notch 9 formed in the above is engaged and positioned, and the displacement of the material 4A is prevented.

Thereafter, the insertion holes 11 and 12 of the closing plate 10 and the partition plate 13, the entrance and exit joint holes 14 and 15 for connecting the entrance and exit joints 16 and 17, and the insertion hole 5 of the flat tube 2 are formed.
Alternatively, the insertion hole 7 of the side plate 6 is formed by press molding, and the process proceeds to a bending process.

In the rounding process, both ends of the material 4A are slightly bent from the flat material 4A shown in FIG. 9A as shown in FIG. 9B, and then as shown in FIGS. 9C and 9D. Then, the material 4A is sequentially bent so as to gradually become round, and finally, as shown in FIG. 9E, the joining ends 4B and 4B come into contact with each other and are rounded.

In this rounding step, for example, when a rounding operation corresponding to FIG. 9C is performed, as shown in FIG. 10, the rounding operation is performed by a mold 26 composed of an upper die 24 and a lower die 25, and The notch 9 of the material 4A is engaged with an engaging projection (not shown) provided on the mold 25 for positioning, and a rounding operation is performed while the material 4A is not displaced from the lower mold 25.

The flat tube 2, the corrugated fins 3, the side plate 6, the closing plate 10, the partition plate 13, and the entrance / exit joint 16,
17 and the like, and the respective members are joined by integral brazing, and the joining ends 4B, 4B formed on the inclined surface of the header tank 4 are joined.

Therefore, in the present embodiment, the notch is provided at the end of the material prior to various processing operations on the material formed of the brazing sheet. Positioning can be performed by the portion, and processing can be performed while forming the joining end portion of the material on an inclined surface or rolling the material while preventing the material from being displaced.

As a result, it is possible to reduce in-process defects, shape defects, and the like, which occur due to the displacement of the material, and inconsistencies with the attached parts such as brackets, thereby making it possible to reduce the cost in manufacturing the header tank. Become.

Further, since the header tank is closed by the closing plate on the inner side of the notch at the upper and lower ends of the header tank after the manufacture, especially the vertically arranged stacked heat exchanger is provided. In the container, water, mud, etc., which enter the upper part of the closing plate in the header tank, are discharged to the outside of the header tank by the notch remaining at the upper end of the header tank, so that the inside of the header tank is removed. It is possible to reliably prevent the water, mud, and the like that enter the upper portion of the closing plate from accumulating and corroding the header tank shape.

In the above embodiment, the notches are formed at the upper and lower ends of the material 4A, but the notches may be provided at least at the upper end of the material. Further, the cutouts are formed at the upper and lower ends located on the center line of the material 4A, but the cutouts are not limited to the center line.

Further, the plastically deformed portion of the present invention is not limited to the notch, but may be a groove or any other positionable one. In the case of using a groove in this plastic deformation portion, for example, a groove having a groove depth of about 0.5 mm is formed, and the plate is pressed from above and below and pressed obliquely to prevent the plate from shifting. You can do it.

[0035]

As described above, according to the header tank manufacturing method of the present invention, it is possible to perform various forming steps while positioning by the plastic deformation portion provided at the end of the material. In the process, when forming the joining end portion of the material on the inclined surface or bending the material, the processing can be performed while preventing displacement of the material. As a result, in-process defects, shape defects, and the like, which occur due to displacement of the material, and inconsistencies with accessory parts such as brackets are reduced, and it is possible to reduce costs in header tank production.

[0036]

[Brief description of the drawings]

FIG. 1 is a front view of a heat exchanger according to an embodiment of the present invention.

FIG. 2 is a side view showing a header tank.

FIG. 3 is a front view showing a header tank.

FIG. 4 is a cross-sectional view taken along the line AA in FIG. 2 showing the header tank.

5A is a plan view showing a material, and FIG. 5B is an end view of the material.

FIG. 6 is an end view showing a material in which inclined joining ends are formed at both ends.

FIG. 7 is a front view showing a mold for forming a joint end portion on both side ends of the material.

FIG. 8 is a front view showing an example of a mold for rounding a material.

FIGS. 9A to 9E are schematic end views showing materials that are sequentially rolled.

[Explanation of symbols]

 Reference Signs List 1 heat exchanger 4 header tank 4A material (brazing sheet) 9 notch 9a inner edge 10 closing plate 20 mold 26 mold

Continuation of the front page (56) References JP-A-6-15390 (JP, A) JP-A-3-112667 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) F28F 9 / 00-9/26 B21D 53/08

Claims (1)

(57) [Claims] 1. A plate-like material having at least one surface coated with a brazing material is successively rolled by various dies to form a chip.
A method for manufacturing a header tank for a heat exchanger that forms a header tank having a tube insertion hole , wherein the header tank after molding is formed from the flat material.
At least one of the upper and lower ends of the material to be
A plastically deformed portion is formed in advance, and the material is sequentially formed while positioning the material using the plastically deformed portion, and then inserted into a tube.
A header tank manufacturing method for a heat exchanger, comprising forming an inlet hole to form a header tank.