JP3642644B2 - Method of manufacturing header for heat exchanger having partition wall and flow rate adjusting wall - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a header that constitutes a heat exchanger such as an evaporator or a condenser that is incorporated in an air conditioner for an automobile to exchange heat between refrigerant and air, and in particular, a partition wall and a flow rate adjusting wall are provided inside the header body. The purpose is to produce a header with low cost.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, among heat exchangers incorporated in an automobile air conditioner, an evaporator having a structure shown in FIGS. 11 to 12 is conventionally known as an evaporator that cools air for air conditioning with a refrigerant. The heat exchanger 1 is formed by combining a plurality of members made of an aluminum alloy, and has a core portion 2. The core portion 2 includes a plurality of heat transfer tube elements 3 and 3 arranged in parallel with each other at an appropriate interval in the lateral direction, and a corrugated fin sandwiched between adjacent heat transfer tube elements 3 and 3. 4 and 4. Side plates 5 and 5 are attached to both side surfaces of the core portion 2. Fins 4, 4 are also sandwiched between the inner side surfaces of the side plates 5, 5 and the outer side surfaces of the heat transfer tube elements 3, 3 located at both ends of the core portion. A pair of tubular headers 6a and 6b arranged in parallel to each other are provided on the upper end side of the core portion 2. The interiors of the headers 6a and 6b and the interiors of the heat transfer tube elements 3 and 3 are communicated with each other in a state where the airtightness and liquid tightness of the connecting portions are maintained. Further, a feed pipe 7 for feeding the refrigerant and a feed pipe 8 for sending the refrigerant that has passed through the core portion 2 are joined to the side surface of the one header 6a.
[0003]
Among the headers 6a and 6b, at least one of the headers 6a includes a tubular header body 9a, a partition wall 10 for tightly partitioning an inner middle portion of the header body 9a, and the header body sandwiching the partition wall 10 therebetween. The first chamber 11a and the second chamber 11b provided in 9a, and the flow rate adjusting wall 12 provided in at least one of the first chamber 11a and the second chamber 11b. On the other hand, the other header 6b is composed of only the header body 9b.
[0004]
Each of the header bodies 9a and 9b is formed by combining a ship-shaped first member 13a and 13b and a ship-shaped second member 14a and 14b in the middle. The header bodies 9a and 9b are formed by press-molding a so-called clad material in which a brazing material is laminated on the surface of an aluminum alloy core material (base material), so that both ends in the axial direction (left and right directions in FIGS. 11 to 12). It is formed into a closed ship shape. In order to combine the first members 13a and 13b and the second members 14a and 14b to form the header bodies 9a and 9b, the openings of the first members 13a and 13b are changed to the openings of the second members 14a and 14b. Fit and braze and join the fitting.
[0005]
Further, among the first members 13a and 13b, locking holes 15a and 15b are formed at the top in the longitudinal direction of one of the first members 13a as shown in FIG. In addition, slit-shaped connection holes 16 and 16 are formed at the bottoms of the second members 14a and 14b, respectively. Each of the connection holes 16 and 16 has a shape and a dimension in which one end portions of the heat transfer tube elements 3 and 3 can be inserted without gaps. Of the header bodies 9a and 9b, a feed port 17 for connecting the proximal end portions of the feed pipe 7 and the feed pipe 8 to the side surface of the first member 13a constituting one header body 9a. And a delivery port 18 is formed.
[0006]
The partition wall 10 and the flow rate adjusting wall 12 are formed by stamping from a plate material which is a clad material in which a brazing material is laminated on at least one surface of an aluminum alloy core material, like the header bodies 9a and 9b. The external shapes and dimensions of both the walls 10 and 12 are such that the engaging projections 19 and 20 formed at the upper ends of the walls 10 and 12 are engaged with the locking holes 15a and 15b of the first member 13a. The outer peripheral edge coincides with the inner peripheral surface of the header body 9a so that the outer peripheral edge and the inner peripheral surface are in close contact with each other. A flow rate adjusting through-hole 21 is formed in the central portion of the flow rate adjusting wall 12 for allowing the refrigerant to pass therethrough.
[0007]
As shown in FIG. 11, the first member 13a and the second member 14a, the partition wall 10 and the flow rate adjusting wall 12 formed as described above are divided between the first member 13a and the second member 14a. 10 and the flow rate adjusting wall 12 are combined with each other. And the header 6a is comprised by brazing the contact part of each member 13a, 14a, 10, 12 with each other. Further, the first member 13b and the second member 14b constitute the header 6b by fitting the openings to each other and brazing the contact portions with each other as shown in FIG. In addition, the brazing operation | work of each structural member of these headers 6a and 6b is performed in a heating furnace simultaneously with brazing of the structural members of the core part 2 mentioned above.
[0008]
As described above, the header 6a having the conventional partition wall 10 and the flow rate adjusting wall 12 is separated from both the members 13a and 14a by the ship-shaped first member 13a and the second member 14a constituting the header body 9a. The partition wall 10 and the flow rate adjusting wall 12 made in the above are sandwiched. For this reason, the number of parts constituting the header 6a is large, and the combination of these constituent parts is troublesome, resulting in high costs. Furthermore, if the assembling accuracy becomes unstable, refrigerant leakage may occur at the installation portion of the partition wall 10, and the performance of the heat exchanger may deteriorate.
[0009]
In order to solve such problems, for example, Japanese Patent Application Laid-Open No. 7-314035 discloses a cylindrical header body and an axially intermediate portion of the header body by press-molding a flat plate cut into a predetermined size and shape. The manufacturing method of the header for heat exchangers which forms a partition wall is described. As shown in FIGS. 13 to 14, the heat exchanger header 23 manufactured by this manufacturing method partitions the inside of the intermediate portion of the tubular header body 24 by a partition wall 25. Such a header 23 is manufactured by a process as shown in FIGS.
[0010]
First, as shown in FIG. 15, a plate material 28, which is a clad material, is prepared by laminating a brazing material layer 27 on the surface of a core material 26, which is an aluminum alloy. Next, by pressing the plate material, a pair of half-cylinder portions 29 and 29 as shown in FIG. 16 are formed. The pair of half-cylinder portions 29 and 29 are formed in parallel with each other via an arc-shaped continuous portion 30. In addition, at a position where the pair of half-cylinder portions 29 and 29 are aligned with each other in the middle portion in the axial direction, a partition having a U-shaped cross section projecting inward in the diameter direction of each of the half-tube portions 29 and 29. Wall forming portions 31 and 31 are formed.
[0011]
Next, a part of the continuous portion 30 shown by hatching in FIG. 17A in the cutting process, a portion located between the partition wall forming portions 31, 31 and the both partition wall forming portions. The excess portions 33 and 33 of the edge portion 32 located outside the 31 and 31 are excised. This excision work is performed by trim piercing using a press machine.
[0012]
After the cutting step, the partition wall forming portions 31 are compressed from both sides in the axial direction of the half cylinder portion 29 by the compression step performed as shown in FIG. In this compression step, as shown in FIG. 19, the outer side of each half cylinder part 29 is restrained by a work restraint 36 biased by a spring 35, while the partition wall molding part 31 inside each half cylinder part 29 is restrained. The compression members 37 and 37 are disposed on both sides, and the partition wall forming portion 31 is crushed by the compression members 37 and 37. At this time, the protruding amount of the partition wall forming portion 31 is corrected by the correction block 38.
[0013]
Next, in the edge forming step shown in FIG. 20, the edge portions 32, 32 of the pair of half tube portions 29, 29 are moved from the state shown in FIG. 20 (a) to the state shown in FIG. The edges 29 and 29 are deformed inwardly in the diameter direction of the portions 29 and 29, and the edge portions 32 and 32 are formed in a circular arc shape continuous from the half cylinder portions 29 and 29.
[0014]
Thereafter, in the facing step shown in FIG. 21, the continuous portion 30 is protruded from the inner side in the diameter direction toward the outer side, and the pair of half-cylinder portions 29, 29 are arranged to face each other. This facing step is performed by pressing the continuous portion 30 against the arc portion 41 of the mold 39 by the punch 40 in a state where the pair of half cylinder portions 29 and 29 are accommodated in the mold 39. Next, by the alignment step shown in FIG. 22, the pair of half-cylinder portions 29, 29 in an opposed state are brought together and the opposed edge portions of both the half-cylinder portions 29, 29 are brought into contact with each other. Thereafter, the abutting portions between the opposing edge portions of the half cylinder portions 29 and 29 and the abutting portion between the pair of partition wall forming portions 31 and 31 are brazed and joined. By this joining, a header 23 with a partition wall 25 as shown in FIGS.
[0015]
[Problems to be solved by the invention]
Since the header 23 manufactured by the manufacturing method as described above has a small number of parts and can be easily assembled, the cost can be reduced. However, the partition wall 25 is only provided inside the header 23 and cannot be applied to a header that requires a flow rate adjusting wall.
In view of such circumstances, the present invention provides a manufacturing method for obtaining a heat exchanger header having not only a partition wall but also a flow rate adjusting wall at low cost.
[0016]
[Means for Solving the Problems]
A method of manufacturing a header for a heat exchanger having a partition wall and a flow rate adjusting wall according to the present invention includes a tubular header body closed at both ends in the axial direction, a partition wall that tightly partitions an inner middle portion of the header body, A first chamber and a second chamber provided in the header body across the partition wall, and an outer peripheral edge provided inside at least one of the first chamber and the second chamber is defined as the header. A header for a heat exchanger having a partition wall and a flow rate adjusting wall, comprising a flow rate adjusting wall which is continuous with the inner peripheral surface of the main body and has a flow rate adjusting hole formed at the center for allowing a fluid flowing through the header body to pass therethrough. Is to be manufactured.
[0017]
Such a method for manufacturing a header for a heat exchanger having a partition wall and a flow rate adjusting wall according to the present invention is a part of a plate material that is a clad material in which a brazing material is laminated on at least one side of a core material made of an aluminum alloy. The through holes are respectively formed at two positions separated in the width direction in the above, and then the plate material is plastically deformed at the intermediate portion in the width direction of the plate material at the boundary between the two through holes. A pair of half-cylinder portions that are continuous with each other via a bent continuous portion provided in an intermediate portion, and the brazing material on at least one of the inner peripheral surface side and the outer peripheral surface side of each of the half-tube portions. The partition wall half part which partitions off a part of each half cylinder part is formed by folding back so that the axial direction middle part of each half cylinder part may be crushed in the length direction of the plate material. The portion where each through hole is formed is the length of the plate material. The flow rate adjusting wall has a notch at the center of each end edge by dividing the half cylinder part in the axial direction by folding back in such a way that it crushes at the middle part of each through hole. Forming a half part, and then plastically deforming the bent continuous part, the edges of the pair of half tube parts and the edges of the partition wall half parts and the flow rate adjusting wall half parts are mutually connected. It heats after butt | matching, and each butt | matching part is brazed.
[0018]
[Action]
According to the manufacturing method of the header for a heat exchanger having the partition wall and the flow rate adjusting wall according to the present invention configured as described above, the header for the heat exchanger having the partition wall and the flow rate adjusting wall is formed from one plate material. I can make it.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
1-10 has shown one example of embodiment of the manufacturing method of the header for heat exchangers which has the partition wall and flow volume adjustment wall of this invention. In addition, the same code | symbol is attached | subjected about the part which is common in the prior art mentioned above, and the illustration and description about the part which overlaps on structure are abbreviate | omitted or simplified. In particular, with respect to the embodiment of the present invention shown in FIGS. 1 to 10, the heat exchanger 1 shown in FIG. 11 described above and the method of manufacturing the header 23 having the conventional partition wall 25 shown in FIGS. Since there are many common parts, the explanation will be simplified.
[0020]
First, FIGS. 1-2 has shown the header 43 produced by the manufacturing method of this invention described below. The header 43 includes a header main body 44 in which both end portions in the axial direction are closed by a lid portion (not shown), and a partition wall 25 and a flow rate adjusting wall 45 formed inside the intermediate portion in the axial direction of the header main body 44. . In the same manner as the conventional manufacturing method shown in FIGS. 13 to 22, the partition wall 25 is formed by plastically deforming a plate material 28 (FIG. 3) to be described later, and a U-shaped bent continuous portion 30 provided on the plate material 28. A pair of half-cylinder portions 29 and 29 that are continuous with each other are formed through {FIG. 16 (c)}. Next, by folding back the intermediate portions of the half tube portions 29, 29 so as to be crushed in the longitudinal direction of the plate member 28, a pair of the half tube portions 29 is separated from each other at positions aligned with each other in the axial direction. Partition wall halves 34, 34 are formed. Next, the end portions of the pair of half tube portions 29 and 29 and the edge portions of the partition wall half portions 34 and 34 are formed by plastically deforming the continuous portion 30 that makes the both half tube portions 29 and 29 continuous. Butts are brought together and brazed together. The partition wall 25 is formed in parallel with the flow rate adjusting wall 45 described below.
[0021]
Next, a method of forming the flow rate adjusting wall 45 performed inside the header main body 44 constituting the header 43 in parallel with the above-described operation of forming the partition wall 25 will be described. First, as shown in FIG. 3, a plate material 28, which is a double-sided clad material in which brazing material layers 27, 27 are provided on both surfaces of a core material 26 made of an aluminum alloy, is prepared. Next, through holes 47 and 47 are formed at two positions separated in the width direction (left and right direction in FIG. 3) in a part of the plate material 28, respectively. This drilling operation can be easily performed by pressing. In FIG. 3, the dimension in the thickness direction is exaggerated as compared with the dimension in the surface direction.
[0022]
After the pair of through holes 47, 47 are formed, next, in the molding step shown in FIG. 4, the plate material 28 is subjected to press molding for pressing between a pair of dies, and the plate material 28 A pair of half-cylinder portions 29 and 29 are formed at a middle portion in the width direction with a portion between the through holes 47 and 47 as a boundary. The pair 29 and 29 are formed in parallel with each other via the arc-shaped continuous portion 30. In addition, by pushing each half cylinder part 29, 29 in the thickness direction of the plate material 28 into a part where each of the through holes 47, 47 is formed in a part of the pair of half cylinder parts 29, 29, The adjusting wall forming portions 48 and 48 having a U-shaped cross section for forming the flow rate adjusting wall 45 are formed.
[0023]
Next, by the excision process shown in FIG. 5, a part of the continuous part 30 indicated by hatching in FIG. 5A is located between the adjustment wall forming parts 48, 48, and both of these parts. The excess portion 33 of the edge portion 32 located outside the adjustment wall forming portions 48 and 48 is cut off. This cutting process is performed by trim piercing using a press machine.
[0024]
After the cutting step, the adjusting wall forming portions 48 are compressed from both sides by a compressing step shown in FIG. 6 to form flow rate adjusting wall half portions 49 each having a semicircular cutout 50. In this compression step, as shown in FIG. 7, the outside of each half cylinder part 29 is restrained by a work restraint 36 biased by a spring 35, while the adjustment wall forming part 48 inside each half cylinder part 29 is restrained. The compression members 37 and 37 are arranged on both sides, and the adjustment wall forming portion 48 is crushed by these compression members 37 and 37. At this time, the protruding amount of the adjustment wall forming portion 48 is corrected by the correction block 38.
[0025]
Next, by the edge forming step shown in FIG. 8, the edge portions 32, 32 of the pair of half tube portions 29, 29 are moved from the state shown in FIG. 8 (a) to the state shown in FIG. 8 (b). 29, 29 is deformed inward in the diametrical direction, and each of the edge portions 32, 32 is formed in a cross-sectional arc shape continuous from the half tube portions 29, 29.
[0026]
Thereafter, in the facing step shown in FIG. 9, the continuous portion 30 is protruded from the inside to the outside in the diametrical direction, and the pair of half-tube portions 29 and 29 are arranged to face each other. This facing step is performed by pressing the continuous portion 30 against the arc portion 41 of the mold 39 by the punch 40 in a state where the pair of half cylinder portions 29 and 29 are accommodated in the mold 39. Next, in the alignment step shown in FIG. 10, the pair of half-cylinder portions 29, 29 in an opposed state are aligned, and the opposed edge portions of both the semi-cylindrical portions 29, 29 are butted together. Thereafter, the abutting portions between the opposed edge portions of the half cylinder portions 29 and 29 and the abutting portion between the pair of partition wall forming portions 31 and 31 are brazed and joined. By this joining, the header 43 with the partition wall 25 and the flow rate adjusting wall 45 as shown in FIGS. Further, in the illustrated example, since the header 43 is made of a double-sided clad material, the overlapping plate members are simultaneously brazed to form the partition wall 25 and the flow rate adjusting wall 45.
[0027]
In the manufacturing process shown in FIGS. 3 to 10 described above, the partition wall 25 is also molded. Therefore, in the above joining step, the edges of the pair of half tube portions 29, 29 and the edges of the partition wall half portions 34, 34 and the flow rate adjusting wall half portions 49, 49 are brazed and joined simultaneously. Then, the header 43 with the partition wall 25 and the flow rate adjusting wall 45 is made. In the illustrated example, the evaporator header has been described. However, the present invention can also be applied to the manufacture of headers for other heat exchangers such as condenser headers. The header body is a tubular body having a circular cross section, but may be a flat shape as disclosed in the prior art, and the shape is not particularly limited. Furthermore, the brazing material layers 27, 27 constituting the plate material 28 are not necessarily provided on both surfaces of the core material 26, and may be provided on at least one surface. Even when the brazing material layer 27 is provided only on one side, the brazing material melted by heating for brazing enters the butt portion to be brazed by capillary action, and this butt portion is made airtight and liquid tight. Braze.
[0028]
【The invention's effect】
Since the manufacturing method of the header for heat exchangers having the partition wall and the flow rate adjusting wall according to the present invention is configured as described above, the header for the heat exchanger having the partition wall and the flow rate adjusting wall is formed as one plate material. Can be made from For this reason, the number of parts can be reduced, the labor required for the assembly can be reduced, and a header with low cost and stable accuracy can be obtained.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a main part of a header having a partition wall and a flow rate adjusting wall produced by the method of the present invention.
2 is a cross-sectional view taken along the line II in FIG. 1;
3 is a partial perspective view of a plate material for manufacturing the header shown in FIG. 1. FIG.
FIGS. 4A and 4B show molding steps when the manufacturing method of the present invention is carried out, in which FIG. 4A is a plan view of an intermediate material, FIG. 4B is a cross-sectional view of FIG. The ha sectional drawing of a).
5A and 5B show a cutting process when the manufacturing method of the present invention is carried out, in which FIG. 5A is a plan view of an intermediate material, and FIG. 5B is a knee cross-sectional view of FIG.
6A and 6B show a compression step when the manufacturing method of the present invention is carried out, in which FIG. 6A is a cross-sectional view showing a state before compression, and FIG. 6B is a cross-sectional view showing a state after compression.
FIGS. 7A and 7B show a more specific structure of an apparatus for performing the compression step, wherein FIG. 7A is a cross-sectional view showing a state before compression, and FIG. 7B is a cross-sectional view showing a state after compression.
FIGS. 8A and 8B show edge forming steps when the manufacturing method of the present invention is carried out, in which FIG. 8A is a sectional view showing a state before molding, and FIG. 8B is a state after molding.
FIGS. 9A and 9B are cross-sectional views showing a facing process when the manufacturing method of the present invention is carried out, in which FIG. 9A shows a preparation process and FIG.
10A and 10B are cross-sectional views showing an alignment process when the manufacturing method of the present invention is performed, in which FIG. 10A shows an initial stage continuous from the facing process, and FIG. 10B shows a completion stage.
FIG. 11 is a schematic perspective view of an evaporator that is a kind of heat exchanger incorporating a header for a heat exchanger having a conventional partition wall and a flow rate adjusting wall.
12 is an exploded perspective view of main parts of a header constituting the evaporator shown in FIG.
FIG. 13 is a partial cross-sectional view of a header manufactured by another conventional method.
14 is a sectional view of the hoe of FIG. 13;
15 is a partially cut perspective view of a plate material that is a material of the header shown in FIG. 13;
16 shows a molding process in the case of manufacturing the header shown in FIG. 13. (a) is a plan view of an intermediate material, (b) is a cross-sectional view of (a), and (c) is ( FIG.
17 shows a cutting process in manufacturing the header shown in FIG. 13, wherein (a) is a plan view of the intermediate material, and (b) is a cross-sectional view of the teach of (a).
18A and 18B show a compression process when manufacturing the header shown in FIG. 13, wherein FIG. 18A is a cross-sectional view showing a state before compression, and FIG. 18B is a cross-sectional view showing a state after compression.
FIG. 19 shows a more specific structure of an apparatus for performing the compression step, wherein (a) is a sectional view showing a state before compression, and (b) is a sectional view showing a state after compression.
20 shows an edge forming step in manufacturing the header shown in FIG. 13, wherein (a) is a cross-sectional view showing a state before forming, and (b) is a state after forming.
FIGS. 21A and 21B are cross-sectional views showing a facing process when the header shown in FIG. 13 is manufactured, wherein FIG. 21A shows a preparation process, and FIG.
22A and 22B are cross-sectional views showing an alignment process when manufacturing the header shown in FIG. 13, wherein FIG. 22A shows an initial stage continuous from the facing process, and FIG. 22B shows a completion stage.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Heat exchanger 2 Core part 3 Heat exchanger tube element 4 Fin 5 Side plate 6a, 6b Header 7 Feed pipe 8 Feed pipe 9a, 9b Header main body 10 Partition wall 11a First chamber 11b Second chamber 12 Flow rate adjustment walls 13a, 13b First One member 14a, 14b Second member 15a, 15b Locking hole 16 Connection hole 17 Feeding port 18 Feeding port 19, 20 Engaging projection 21 Through hole 23 Header 24 Header body 25 Partition wall 26 Core material 27 Brazing material layer 28 Plate material 29 Half cylinder part 30 Continuous part 31 Partition wall molding part 32 Edge part 33 Overfill part 34 Partition wall half part 35 Spring 36 Work restraint 37 Compression member 38 Correction block 39 Mold 40 Punch 41 Arc part 43 Header 44 Header body 45 Flow rate Adjustment wall 46 Flow rate adjustment hole 47 Through hole 48 Adjustment wall forming part 49 Flow rate adjustment wall half part 50 Notch

Claims (1)

Tubular header body closed at both ends in the axial direction, a partition wall for tightly partitioning the inner intermediate portion of the header body, and a first chamber and a second chamber provided in the header body across the partition wall And the outer periphery provided inside at least one of the first chamber and the second chamber is made continuous with the inner peripheral surface of the header body, and the fluid flowing in the header body is flown at the center. A method of manufacturing a heat exchanger header having a partition wall and a flow rate adjusting wall, comprising a flow rate adjusting wall having a flow rate adjusting hole for allowing passage, wherein each of the core members is made of an aluminum alloy. After a through-hole is formed at two positions separated in the width direction by a part of the plate material that is a clad material in which brazing material is laminated, a portion between the two through-holes is defined at the intermediate portion in the width direction of the plate material. These plates are plastically deformed to A pair of semi-cylindrical portions that are continuous with each other via a bent continuous portion provided in a portion between the through holes are disposed on at least one of the inner peripheral surface side and the outer peripheral surface side of each of the semi-cylindrical portions. The brazing material is formed in a state in which it exists, and a part of each half cylinder part is axially folded by folding back the axial middle part of each half cylinder part in the length direction of the plate material. Each half cylinder part is formed by forming a partition wall half part for partitioning and folding the part where each through hole is formed in the longitudinal direction of the plate material so as to crush the intermediate part of each through hole as a boundary. A pair of the half-tube portions are formed by partitioning a part of each of the half-tube portions in the axial direction, forming a flow-adjusting wall half portion having a notch at the center of each edge, and then plastically deforming the bent continuous portion. And the edges of the partition wall halves and the flow rate adjusting wall halves are Heated after the butt, each butt portion brazed, manufacturing process of the heat exchanger header with a partition wall and a flow rate adjustment wall.

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