JP3899419B2

JP3899419B2 - Flat heat exchange tube and manufacturing method thereof

Info

Publication number: JP3899419B2
Application number: JP14170797A
Authority: JP
Inventors: 敏穂積; 喬田村; 哲貝村; 雅司坂口
Original assignee: Showa Denko KK
Current assignee: Showa Denko KK
Priority date: 1997-05-30
Filing date: 1997-05-30
Publication date: 2007-03-28
Anticipated expiration: 2017-05-30
Also published as: JPH10328773A

Description

【０００１】
【発明の属する技術分野】
この発明は、カーエアコン用コンデンサ、カーエアコン用エバポレータ、自動車用オイルクーラ等の自動車用熱交換器や、ルームエアコン用コンデンサ等の電気機器用熱交換器や、オイルクーラ等の産業機械用熱交換器に用いられる偏平状熱交換管に関する。
【０００２】
この明細書において、図１、図２および図５〜図７の上下、左右をそれぞれ上下、左右というものとする。但し、図８に関する説明については、同図の上下、左右をそれぞれ上下、左右というものとする。
【０００３】
【従来の技術と発明が解決しようとする課題】
近時、たとえばカーエアコン用コンデンサとして、図８に示すように、互いに間隔をおいて左右に平行に配置された一対のヘッダ(51)(52)と、両端がそれぞれ両ヘッダ(51)(52)に接続された並列状の偏平状冷媒流通管(53)（熱交換管）と、隣り合う冷媒流通管(53)の間の通風間隙に配置されるとともに、両冷媒流通管(53)にろう付されたコルゲート・フィン(54)と、左のヘッダ(51)の周壁上端部に接続された入口管(55)と、右ヘッダ(52)の周壁下端部に接続された出口管(56)と、左ヘッダ(51)の中程より上方位置の内部に設けられた左仕切板(57)と、右ヘッダ(52)の中程より下方位置の内部に設けられた右仕切板(58)とを備えており、入口管(55)と左仕切板(57)間の冷媒流通管(53)の本数、左仕切板(57)と右仕切板(58)間の冷媒流通管(53)の本数、右仕切板(58)と出口管(56)間の冷媒流通管(53)の本数がそれぞれ上から順次減少されて通路群を構成しており、入口管(55)から流入した気相の冷媒が、出口管(56)より液相となって流出するまでに、コンデンサ内を各通路群単位に蛇行状に流れるようになされているいわゆるマルチフロー型と称されるコンデンサ（特公平３−４５３００号公報参照）が、従来のサーペンタイン型コンデンサに代わり高性能化、低圧力損失化および超コンパクト化を実現しうるものとして広く使用されてきている。
【０００４】
上記コンデンサに用いられる偏平状冷媒流通管は、その内部に高圧ガス冷媒が導入されるため、耐圧性が要求される。この要求にこたえるとともに熱交換効率を高めるために、冷媒流通管には、平らな上下壁と、上下壁にまたがるとともに長さ方向にのびた補強壁を備えたアルミニウム中空押出形材よりなるものが用いられていた。ところで、熱交換効率の向上およびコンデンサのコンパクト化の関係上、偏平状冷媒流通管は薄肉で、かつ高さはできるだけ低い方が望ましい。しかしながら、押出形材製の場合、押出技術上の制約から管高さを低くしかつ薄肉化するには限界があった。
【０００５】
そこで、この問題を解決するために、本出願人は、先に、上下壁と、上下壁の左右両側縁にまたがる左右両側壁と、上下壁にまたがるとともに長さ方向に伸びかつ相互に間隔をおいて設けられた複数の補強壁とを備え、内部に並列状の流体通路を有するとともに補強壁に並列状の流体通路どうしを通じさせる連通孔が長さ方向に間隔をおいて複数あけられている偏平状熱交換管であって、板材を圧延することにより形成され、かつ下壁形成部、下壁形成部に立上り状に一体成形された左右両側壁形成部、および左右両側壁形成部間において長さ方向にのびかつ相互に所定間隔をおくように下壁形成部に立上り状に一体成形された複数の補強壁形成部を有する板状下構成部材と、下構成部材の左右両側壁形成部にまたがる上壁形成部を有する平らな板状上構成部材とよりなり、下構成部材の左右両側壁形成部の肉厚が補強壁形成部の肉厚よりも大きくなされるとともに、左右両側壁形成部の上端に段部を介して補強壁形成部よりも上方に突出した薄肉部が形成され、補強壁形成部の上縁にその長さ方向に間隔をおいて複数の連通孔形成用切欠きが形成され、上構成部材の左右両側縁部が左右両側壁形成部の段部にのせられるとともに薄肉部が内側に折り曲げられて上構成部材に係合させられ、この状態で両構成部材が相互にろう付されている偏平状熱交換管を提案した（特開平９−２６２７８号公報参照）。
【０００６】
上述した従来の偏平状熱交換管は、次のようにして製造される。すなわち、圧延機の一方のワークロールの周面に、左右両側壁形成部成形用環状溝および複数の補強壁形成部形成用環状溝を、両環状溝の深さが等しくなるように形成しておき、全ての補強壁形成部成形用環状溝の幅および深さを等しくするとともに、左右両側壁形成部成形用環状溝の幅を補強壁形成部形成用環状溝の幅よりも大きくし、左右両側壁形成部成形用環状溝の底面に薄肉部成形用幅狭環状溝を形成し、さらに補強壁形成部成形用環状溝の底面に周方向に間隔をおいて複数の切欠き成形用凸部を設けておき、この圧延機に金属素板を通すことにより下構成部材をつくる。また、これとは別個に上構成部材をつくる。その後、上構成部材の左右両側縁部を左右両側壁形成部の段部にのせるとともに薄肉部を内側に折り曲げて上構成部材に係合させ、この状態で両構成部材を相互にろう付することにより製造される。
【０００７】
しかしながら、従来の偏平状熱交換管の製造方法では、左右両側壁形成部成形用環状溝の幅が補強壁形成部形成用環状溝の幅よりも大きくなっているとともに、薄肉部成形用幅狭環状溝を含めた左右両側壁形成部成形用環状溝の深さが補強壁形成部形成用環状溝の深さよりも大きくなっており、しかも補強壁形成部形成用環状溝の底面には切欠き形成用凸部が設けられているので、左右両側壁形成部成形用環状溝の容積が補強壁形成部形成用環状溝の容積よりも大きくなり、その結果圧延のさいに金属素板から流れる金属材料が、左右両端の補強壁形成部成形用環状溝、すなわち左右両側壁形成部成形用環状溝の隣に位置する補強壁形成部成形用環状溝よりも左右両側壁形成部成形用環状溝内に流入し易くなる。したがって、成形された下構成部材において、両端の補強壁形成部の高さが、他の補強壁形成部よりも低くなるという問題があった。
【０００８】
しかも、成形された下構成部材において、両端の補強壁形成部の高さが、他の補強壁形成部よりも低くなっているので、両端の補強壁形成部の上端と上構成部材の上壁形成部との間に大きな隙間が生じ、製造された偏平状熱交換管においては、両端の補強壁形成部と、上構成部材の上壁形成部との間にろう付不良が発生して、要求される耐圧性が得られないという問題があった。また、ろう付不良の発生した部分が起点となって、両構成部材が剥離するおそれもあった。
【０００９】
この発明の目的は、上記問題を解決し、補強壁と上壁形成部との間にろう付不良が発生することなく、耐圧性が向上した偏平状熱交換管およびその製造方法を提供することにある。
【００１０】
【課題を解決するための手段と発明の効果】
請求項１の発明による偏平状熱交換管は、上下壁と、上下壁の左右両側縁にまたがる左右両側壁と、左右両側壁間において上下壁にまたがるとともに長さ方向にのびかつ相互に所定間隔をおいて設けられた複数の補強壁とを備え、内部に並列状の流体通路を有するとともに、補強壁に並列状の流体通路どうしを通じさせる複数の連通孔があけられている偏平状熱交換管であって、上壁形成部、および上壁形成部の左右両側縁に垂下状に一体成形された左右両側壁形成部を有する板状上構成部材と、下壁形成部、下壁形成部の左右両側縁に立上り状に一体成形された左右両側壁形成部、および左右両側壁形成部間において長さ方向にのびかつ相互に所定間隔をおくように下壁形成部に立上り状に一体成形された複数の補強壁形成部を有する板状下構成部材とよりなり、下構成部材の全ての補強壁形成部の高さ、および左右両側壁形成部と補強壁形成部の高さがそれぞれ等しくなされ、下構成部材の左右両側壁形成部および全ての補強壁形成部の上縁にそれぞれ長さ方向に間隔をおいて複数の切欠きが形成され、上構成部材が下構成部材に被せられてその左右両側壁形成部が下構成部材の左右両側壁形成部の外側に重なり合った状態で両構成部材が相互にろう付され、上構成部材の左右両側壁形成部の下端部が、下壁よりも下方に伸ばされるとともに、下構成部材下面の左右両側縁部に形成されかつ左右方向外方に向かって上方に傾斜した傾斜面に係合させられてろう付されているものである。
【００１１】
請求項１の発明の偏平状熱交換管によれば、下構成部材の全ての補強壁形成部の高さ、および左右両側壁形成部と補強壁形成部の高さがそれぞれ等しくなされているので、上構成部材が下構成部材に被せられた状態において、左右両側壁形成部および全ての補強壁形成部の上端が上構成部材の上壁形成部の下面に当接する。そして、この状態で両構成部材が相互にろう付されているので、下構成部材の全ての補強壁形成部と上構成部材の上壁形成部との間でのろう付不良の発生が防止される。したがって、偏平状熱交換管の耐圧性が向上する。しかも、下構成部材の全ての補強壁形成部と上構成部材の上壁形成部との間でのろう付不良の発生が防止されるので、ろう付不良が発生した部分を起点とする上下両構成部材の剥がれを防止することができる。
【００１２】
また、請求項１の発明の偏平状熱交換管によれば、左右両側壁形成部および補強壁形成部の高さが等しく、かつ左右両側壁形成部および補強壁形成部の上縁にそれぞれその長さ方向に間隔をおいて複数の切欠きが形成されているので、全ての補強壁形成部の高さを等しくすることができる。すなわち、この偏平状熱交換管は、請求項１０記載の方法で製造されるが、この場合、一方のワークロールの周面に形成される全ての環状溝の容積を等しくすることができる。したがって、金属素板から流れた金属材料は、左右両側壁形成部成形用環状溝と左右両端の補強壁形成部成形用環状溝とに均等に流れ込み、成形された下構成部材の左右両端の補強壁形成部の高さが、他の補強壁形成部の高さと等しくなる。その結果、上述したような効果が導出される。
【００１３】
また、請求項１の発明の偏平状熱交換管によれば、上構成部材の左右両側壁形成部が下構成部材の左右両側壁形成部の外側に重なり合った状態で両構成部材が相互にろう付されているので、左右両側壁形成部の切欠きからの流体の漏れが防止される。
【００１４】
請求項２の発明による偏平状熱交換管は、請求項１の発明による偏平状熱交換管において、各補強壁におけるすべての連通孔の占める割合である開口率が１０〜４０％であるものである。
【００１５】
請求項３の発明による偏平状熱交換管は、請求項１または２の発明による偏平状熱交換管において、各補強壁におけるすべての連通孔の占める割合である開口率が１０〜３０％であるものである。
【００１６】
請求項４の発明による偏平状熱交換管は、請求項１〜３のうちのいずれかの発明による偏平状熱交換管において、複数の補強壁にあけられた連通孔が平面から見て千鳥配置となっているものである。
【００１７】
請求項５の発明による自動車用熱交換器は、請求項１〜４のうちのいずれかの発明による偏平状熱交換管を用いたものである。
【００１８】
請求項６の発明による自動車は、請求項５の発明による自動車用熱交換器を用いたカーエアコンが搭載されたものである。
【００１９】
請求項７の発明による電気機器用熱交換器は、請求項１〜４のうちのいずれかの発明による偏平状熱交換管を用いたものである。
【００２０】
請求項８の発明による産業機械用熱交換器は、請求項１〜４のうちのいずれかの発明による偏平状熱交換管を用いたものである。
【００２１】
請求項９の発明による偏平状熱交換管の製造方法は、上下壁と、上下壁の左右両側縁にまたがる左右両側壁と、左右両側壁間において上下壁にまたがるとともに長さ方向にのびかつ相互に所定間隔をおいて設けられた複数の補強壁とを備え、内部に並列状の流体通路を有するとともに、補強壁に並列状の流体通路どうしを通じさせる複数の連通孔があけられており、上壁形成部、および上壁形成部の左右両側縁に垂下状に一体成形された左右両側壁形成部を有する板状上構成部材と、下壁形成部、下壁形成部の左右両側縁に立上り状に一体成形された左右両側壁形成部、および左右両側壁形成部間において長さ方向にのびかつ相互に所定間隔をおくように下壁形成部に立上り状に一体成形された複数の補強壁形成部を有する板状下構成部材とよりなり、下構成部材の全ての補強壁形成部の高さ、および左右両側壁形成部と補強壁形成部の高さがそれぞれ等しくなされ、下構成部材の左右両側壁形成部および全ての補強壁形成部の上縁にそれぞれ長さ方向に間隔をおいて複数の切欠きが形成され、上構成部材が下構成部材に被せられてその左右両側壁形成部が下構成部材の左右両側壁形成部の外側に重なり合った状態で両構成部材が相互にろう付されている偏平状熱交換管を製造する方法であって、圧延機の一方のワークロールの周面に、左右両側壁形成部成形用環状溝および複数の補強壁形成部成形用環状溝を、両環状溝の幅および深さが等しくなるように形成するとともに、両環状溝の底面にそれぞれ周方向に間隔をおいて複数の切欠き形成用凸部を設けておき、この圧延機に金属素板を通すことにより下構成部材をつくり、これとは別個に上構成部材をつくり、その後上構成部材の左右両側壁形成部が下構成部材の左右両側壁形成部の外側に重なり合うように上構成部材を下構成部材に被せて両構成部材を組合せ、この状態で両構成部材を相互にろう付することを特徴とするものである。
【００２２】
請求項９の発明の偏平状熱交換管の製造方法によれば、圧延機の一方のワークロールの周面に、左右両側壁形成部成形用環状溝および複数の補強壁形成部成形用環状溝を、両環状溝の幅および深さが等しくなるように形成するとともに、両環状溝の底面にそれぞれ周方向に間隔をおいて複数の切欠き形成用凸部を設けているので、このワークロールの周面に形成される全ての環状溝の容積が等しくなっており、この圧延機に金属素板を通すことにより下構成部材をつくると、金属素板から流れた金属材料は左右両側壁形成部成形用環状溝と左右両端の補強壁形成部成形用環状溝とに均等に流れ込み、その結果成形された下構成部材の左右両端の補強壁形成部の高さが、他の補強壁形成部の高さと等しくなる。したがって、上述したように、下構成部材の全ての補強壁形成部と上構成部材の上壁形成部との間でのろう付不良が発生することが防止され、偏平状熱交換管の耐圧性が向上する。しかも、下構成部材の全ての補強壁形成部と上構成部材の上壁形成部との間でのろう付不良の発生が防止されるので、ろう付不良が発生した部分を起点とする上下両構成部材の剥がれを防止することができる。
【００２３】
請求項１０の発明による偏平状熱交換管の製造方法は、請求項９の発明による偏平状熱交換管の製造方法において、上構成部材を下構成部材に被せる前に、上構成部材および下構成部材にフラックスを塗布することを含むものである。
【００２４】
請求項１１の発明による偏平状熱交換管の製造方法は、請求項９または１０の発明による偏平状熱交換管の製造方法において、上構成部材の左右両側壁形成部の垂下長さを、下構成部材の左右両側壁構成部の立上り長さに、下壁形成部の厚さを加えたものよりも長くしておくとともに、下構成部材の下壁形成部下面の左右両側縁部に左右方向外方に向かって上方に傾斜した傾斜面を形成しておき、上構成部材を下構成部材に嵌め被せた後、上構成部材の左右両側壁形成部の下端部を左右方向内方に折り曲げて下構成部材の傾斜面に密着させて係合させ、これにより両構成部材を仮止めすることを含むものである。
【００２５】
【発明の実施の形態】
以下、この発明の実施の形態を、図面を参照して説明する。以下の説明において、「アルミニウム」という語には、純アルミニウムの他にアルミニウム合金を含むものとする。
【００２６】
図１はこの発明の偏平状熱交換管の全体構成を示し、図２および図３はその要部を拡大して示し、図４〜図７はその製造方法を示す。
【００２７】
図１〜図３において、偏平状熱交換管(A)は、平らな上下壁(1)(2)と、上下壁(1)(2)の左右両側縁にまたがる２重構造の左右両側壁(3)(4)と、左右両側壁(3)(4)間において上下壁(1)(2)にまたがるとともに長さ方向にのびかつ相互に所定間隔をおいて設けられた複数の補強壁(5)とを備え、内部に並列状の流体通路(6)を有するものであり、下壁(2)、左右両側壁(3)(4)および補強壁(5)を構成するアルミニウム製下構成部材(10)と、上壁(1)および左右両側壁(3)(4)を構成する板状のアルミニウム製上構成部材(20)とにより形成されたものである。
【００２８】
下壁(2)内面における隣接する補強壁(5)どうしの間の部分および左右両側壁(3)(4)と左右両端の補強壁(5)との間の部分には、それぞれ伝熱面積を増大させる目的で、長さ方向に間隔をおいて複数の突起(7)が上方隆起状に一体に形成されている。
【００２９】
左右両側壁(3)(4)は、上壁(1)の左右両側縁に垂下状に一体成形された左右両側壁形成部(22)と、下壁(2)の左右両側縁に立上り状に一体成形された左右両側壁形成部(12)とが、垂下状左右両側壁形成部(22)が外側にくるように重なり合った状態で相互に接合されて形成されたものである。上構成部材(20)の左右両側壁形成部(22)の下端部は下壁(2)よりも下方に伸ばされるとともに、下構成部材(10)下面の左右両側縁部に形成されかつ左右方向外方に向かって上方に傾斜した傾斜面(15)に係合させられてろう付されている。また、下構成部材(10)の左右両側壁形成部(12)の上縁に、長さ方向に所定間隔をおいて複数の台形状切欠き(16)が形成されている。
【００３０】
補強壁(5)は、下壁(2)に一体に形成された補強壁形成部(13)が上壁(1)内面に接合されて形成されたものである。補強壁(5)には、並列状の流体通路(6)どうしを通じさせる複数の連通孔(8)があけられている。連通孔(8)は、平面から見て千鳥配置となっている。連通孔(8)があけられていると、並列状の流体通路(6)をそれぞれ流通する流体は、連通孔(8)を通じて偏平状熱交換管(A)の幅方向に流れ、すべての流体通路(6)に行き渡って混合され、流体通路(6)間で流体に温度差が生じることはなくなる。したがって、熱交換効率が向上する。各補強壁(5)におけるすべての連通孔(8)の占める割合である開口率は、１０〜４０％、特に１０〜３０％の範囲内であることが好ましく、２０％程度であることが望ましい。この場合に、連通孔(8)を形成することによる熱交換効率向上効果が顕著なものとなる。連通孔(8)は、補強壁形成部(13)の上縁に所定間隔おきに形成された台形状の切欠き(14)が、上壁(1)によりその開放部が塞がれることによって形成されたものである。この場合、複数の補強壁(5)にあけられた連通孔(8)が平面から見て千鳥配置となっているので、偏平状熱交換管(A)の幅方向において、両構成部材(10)(20)どうしの接合部が存在することになり、十分な接合強度が確保される。
【００３１】
偏平状熱交換管(A)は、次のようにして製造される。
【００３２】
まず、図４〜図６に示す装置を用いて、図７に示すような板状のアルミニウム製下構成部材(10)を形成する。また、ロールフォーミングにより図７に示すような板状のアルミニウム製上構成部材(20)を形成する。
【００３３】
図７において、下構成部材(10)は、平らな下壁形成部(11)と、下壁形成部(11)の左右両側縁に立上り状に一体成形された左右両側壁形成部(12)と、下壁形成部(11)の両左右両側壁形成部(12)間に相互に所定間隔をおいて立上り状に一体成形された長さ方向にのびる複数の補強壁形成部(13)とよりなり、左右両側壁形成部(12)および補強壁形成部(13)の上縁にそれぞれその長さ方向に所定間隔をおいて台形状の切欠き(16)(14)が、平面から見て千鳥配置となるように形成されている。また、下構成部材(10)の全ての補強壁形成部(13)の高さ、および左右両側壁形成部(12)と補強壁形成部(13)の高さがそれぞれ等しくなっている。さらに、下壁形成部(11)の上面に突起(7)が一体に形成されているとともに、下壁形成部(11)の下面の左右両側縁部に傾斜面(15)が形成されている。
【００３４】
図７において、上構成部材(20)は、平らな上壁形成部(21)と、上壁形成部(21)の両側縁に垂下状に一体に形成されかつ下構成部材(10)の両立上り状左右両側壁形成部(12)の外側に重なる左右両側壁形成部(22)とよりなる。上構成部材(20)の上壁形成部(21)の幅は下構成部材(10)の幅よりも若干広く、下構成部材(10)に被せられるようになっている。また、上構成部材(20)の左右両側壁形成部(22)の垂下長さは、下構成部材(10)の左右両側壁構成部(12)の立上り長さに、下壁形成部(11)の厚さを加えたものよりも若干長くなっている。上構成部材(20)は、下面、すなわち上壁形成部(21)の下面、および両左右両側壁形成部(22)の内面にろう材層を有するアルミニウムブレージングシートからなる。
【００３５】
図４において、下構成部材(10)を製造する装置は、アルミニウムシート(30)が巻き取られているアンコイラ(31)、予備圧延機(32)、仕上げ圧延機(33)および複数の送りロール(34)を備えている。そして、アンコイラ(31)に巻き取られているアルミニウムシート(30)がアンコイラ(31)から繰り出されて予備圧延機(32)に送られ、予備圧延機(32)を通過した後、仕上げ圧延機(33)に送られて仕上げ圧延が行われることにより下構成部材(10)が成形される。
【００３６】
予備圧延機(32)は、アルミニウムシート(30)の両側縁部に厚肉部を形成するためのものである。
【００３７】
仕上げ圧延機(33)は、中心ワークロール(35)と、中心ワークロール(35)の周囲にその周方向に等間隔をおいて配置された複数の衛星ワークロール(36)とを備えている。中心ワークロール(35)は、図示しない駆動手段により回転させられるようになっている。各衛星ワークロール(36)は、図示しない歯車装置により中心ワークロール(35)に連結されており、中心ワークロール(35)が回転することにより、すべての衛星ワークロール(36)が中心ワークロール(35)と等周速で回転するようになっている。なお、各衛星ワークロール(36)が駆動手段を備えており、これにより中心ワークロール(35)と等周速で回転させられるようになっていてもよい。また、仕上げ圧延機(33)は、隣接する衛星ワークロール(36)間に台形状のガイドシュー(37)およびガイドシュー(37)を中心ワークロール(35)に向かって付勢するばね(38)を備えている。ガイドシュー(37)の両側縁部は中心ワークロール(35)と衛星ワークロール(36)との間に入り込んでおり、衛星ワークロール(36)と摺接するようになっている。ガイドシュー(37)は、アルミニウムシート(30)が仕上げ圧延機(33)を通過する間に、アルミニウムシート(30)の長さ方向の伸びを抑制するとともに、隣接する衛星ワークロール(36)間からの膨れ出しを抑制する。アルミニウムシート(30)の長さ方向の伸びの抑制は、すべての衛星ワークロール(36)が中心ワークロール(35)と等周速で回転することによっても行なわれる。その結果、中心ワークロール(35)に形成された後述する各溝(39)(40)、凹所(42)および凸部(43)(44)、ならびに衛星ワークロール(36)に形成された後述する傾斜面(45)がアルミニウムシート(30)に完全に転写され、所望の形状を備えた下構成部材(10)が得られる。また、アルミニウムシート(30)の長さ方向の伸びが抑制されるので、素板であるアルミニウムシート(30)として、従来法で素板として使用される板材に比べて薄肉のものを用いることができ、材料費が安くなる。しかも、圧下率も従来法に比べて小さくてすむ。
【００３８】
図５および図６に示すように、仕上げ圧延機(33)の中心ワークロール(35)の周面に、左右両側壁形成部成形用環状溝(39)および補強壁形成部成形用環状溝(40)を全周にわたって形成しておく。このとき、すべての補強壁形成部成形用環状溝(40)の幅および深さを等しくしておくとともに、左右両側壁形成部成形用環状溝(39)と補強壁形成部成形用環状溝(40)の幅および深さを等しくしておく。また、中心ワークロール(35)の周面における左右両側壁形成部成形用環状溝(39)とこれに隣接する補強壁形成部成形用環状溝(40)との間、および隣接する補強壁形成部成形用環状溝(40)どうしの間に、それぞれ複数の突起成形用凹所(42)を周方向に間隔をおいて設けておく。さらに、左右両側壁形成部成形用環状溝(39)および補強壁形成部成形用環状溝(40)の底面にそれぞれ切欠き部成形用凸部(43)(44)を設けておく。
【００３９】
また、図５に示すように、仕上げ圧延機(33)の衛星ワークロール(36)の周面における左右両端部に、左右方向外方に向かって径方向外方に傾斜した傾斜面(45)を形成しておく。
【００４０】
したがって、アルミニウムシート(30)をこのような中心ワークロール(35)とすべての衛星ワークロール(36)との間に連続的に通過させると、図７に示すような下構成部材(10)が成形される。
【００４１】
ついで、上下構成部材(20)(10)に脱脂処理を施した後、これらにろう付用フラックスを塗布する。
【００４２】
ついで、上構成部材(20)を下構成部材(10)に嵌め被せた後、上構成部材(20)の左右両側壁形成部(22)の下端部を左右方向内方に折り曲げて下構成部材(10)の傾斜面(15)に密着させて係合させ、これにより両構成部材(10)(20)を仮止めする。
【００４３】
ついで、両構成部材(20)(10)を仮止めしたものをろう付温度に加熱する。すると、下構成部材(10)の左右両側壁形成部(12)外面と上構成部材(20)の左右両側壁形成部(22)内面、下構成部材(10)の左右両側壁形成部(12)の上端および補強壁形成部(13)の上端と上構成部材(20)の上壁形成部(21)の下面とがそれぞれろう付される。こうして、偏平状熱交換管(A)が製造される。
【００４４】
上記実施形態においては、上構成部材(20)の左右両側壁形成部(22)の下端部が左右方向内方に折り曲げられ、下構成部材(10)の傾斜面(15)に密着させられて係合させられているが、これに代えて、下構成部材の下壁形成部の下面全体を平坦にしておき、上構成部材の左右両側壁形成部の下端面を下構成部材の下壁形成部の下面と面一となるようにしておいてもよい。また、上構成部材の左右両側壁形成部により下構成部材の左右両側壁形成部の上縁に形成された切欠きを覆いうるのであれば、上構成部材の左右両側壁形成部の下端が、下構成部材の左右両側壁形成部の高さの中間部に位置していてもよい。
【図面の簡単な説明】
【図１】この発明の偏平状熱交換管の実施形態を示す横断面図である。
【図２】図１の部分拡大図である。
【図３】図２のIII-III 線断面図である。
【図４】図１の偏平状熱交換管の下構成部材を製造する装置の概略を示す図である。
【図５】図４のＶ−Ｖ線拡大断面図である。
【図６】図４の装置の中心ワークロールの周面を展開して示す部分拡大斜視図である。
【図７】図１の偏平状熱交換管を製造する過程において上下両構成部材を組合わせる状態を示す部分拡大斜視図である。
【図８】偏平状冷媒流通管を備えたカーエアコン用コンデンサの正面図である。
【符号の説明】
(1) 上壁
(2) 下壁
(3) 左側壁
(4) 右側壁
(5) 補強壁
(6) 流体通路
(8) 連通孔
(10) 下構成部材
(11) 下壁形成部
(12) 左右両側壁形成部
(13) 補強壁形成部
(14)(16) 切欠き
(20) 上構成部材
(21) 上壁形成部
(22) 左右両側壁形成部
(35) 中心ワークロール
(39) 左右両側壁形成部成形用環状溝
(40) 補強壁形成部成形用環状溝
(43)(44) 切欠き形成用凸部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a heat exchanger for an automobile such as a condenser for a car air conditioner, an evaporator for a car air conditioner, and an oil cooler for an automobile, a heat exchanger for an electric device such as a condenser for a room air conditioner, and a heat exchange for an industrial machine such as an oil cooler. The present invention relates to a flat heat exchange tube used in a vessel.
[0002]
In this specification, the top, bottom, left and right in FIGS. 1, 2, and 5 to 7 are referred to as top and bottom and left and right, respectively. However, in the description related to FIG. 8, the upper and lower sides and the left and right sides in FIG.
[0003]
[Prior art and problems to be solved by the invention]
Recently, as a capacitor for a car air conditioner, for example, as shown in FIG. 8, a pair of headers (51) and (52) arranged in parallel to the left and right at intervals, and both headers (51) and (52) ) Connected in parallel between the flat refrigerant flow pipe (53) (heat exchange pipe) and the adjacent refrigerant flow pipe (53), and both refrigerant flow pipes (53) Brazed corrugated fin (54), inlet pipe (55) connected to the upper end of the peripheral wall of the left header (51), and outlet pipe (56) connected to the lower end of the peripheral wall of the right header (52) ), A left partition plate (57) provided in the upper position from the middle of the left header (51), and a right partition plate (58) installed in the lower position from the middle of the right header (52). ), The number of refrigerant flow pipes (53) between the inlet pipe (55) and the left partition plate (57), and the refrigerant flow pipe (53 between the left partition plate (57) and the right partition plate (58)). ), Between right partition (58) and outlet pipe (56) The number of refrigerant circulation pipes (53) is sequentially reduced from above to form a passage group, and the gas-phase refrigerant flowing from the inlet pipe (55) flows out from the outlet pipe (56) as a liquid phase. By the way, a so-called multiflow type capacitor (refer to Japanese Patent Publication No. 3-45300), which is configured to flow in a meandering manner in each path group unit, is replaced with a conventional serpentine type capacitor. It has been widely used as one that can realize performance, low pressure loss, and ultra-compact.
[0004]
Since the high-pressure gas refrigerant is introduced into the flat refrigerant circulation pipe used for the capacitor, pressure resistance is required. In order to meet this requirement and increase the heat exchange efficiency, the refrigerant distribution pipe is made of an aluminum hollow extruded shape that has flat upper and lower walls and a reinforcing wall that extends across the upper and lower walls and extends in the length direction. It was done. By the way, in view of improving heat exchange efficiency and downsizing of the condenser, it is desirable that the flat refrigerant flow pipe is thin and has a height as low as possible. However, in the case of an extruded profile, there is a limit to reducing the tube height and reducing the wall thickness due to restrictions on extrusion technology.
[0005]
Therefore, in order to solve this problem, the present applicant firstly has an upper and lower wall, left and right side walls straddling the left and right edges of the upper and lower walls, and straddles the upper and lower walls and extends in the length direction and is spaced from each other. And a plurality of communication holes that have parallel fluid passages in the interior and that allow the parallel fluid passages to pass through the reinforcement walls at intervals in the lengthwise direction. A flat heat exchange tube formed by rolling a plate material, and formed between the lower wall forming portion, the left and right side wall forming portions integrally formed in a rising manner on the lower wall forming portion, and the left and right side wall forming portions A plate-like lower constituent member having a plurality of reinforcing wall forming portions integrally formed in a standing manner on the lower wall forming portion so as to extend in the length direction and have a predetermined interval therebetween, and left and right side wall forming portions of the lower constituent member Flat with upper wall forming part straddling The thickness of the left and right side wall forming portions of the lower component member is made larger than the thickness of the reinforcing wall forming portion, and the upper ends of the left and right side wall forming portions are interposed via the stepped portion. A thin wall portion projecting upward from the reinforcing wall forming portion is formed, and a plurality of communication hole forming notches are formed on the upper edge of the reinforcing wall forming portion at intervals in the length direction thereof. Flat heat in which both side edges are placed on the step portions of the left and right side wall forming portions and the thin wall portion is bent inward and engaged with the upper component member, and in this state, both component members are brazed to each other An exchange pipe was proposed (see Japanese Patent Laid-Open No. 9-26278).
[0006]
The above-described conventional flat heat exchange tube is manufactured as follows. That is, on the peripheral surface of one work roll of the rolling mill, left and right side wall forming portion forming annular grooves and a plurality of reinforcing wall forming portion forming annular grooves are formed so that the depths of both annular grooves are equal. The width and depth of all the reinforcing wall forming portion forming annular grooves are made equal, and the width of the left and right side wall forming portion forming annular grooves is made larger than the width of the reinforcing wall forming portion forming annular grooves, A narrow annular groove for forming a thin wall portion is formed on the bottom surface of the annular groove for forming both side wall forming portions, and a plurality of notch forming convex portions are spaced circumferentially on the bottom surface of the annular groove for forming the reinforcing wall forming portion. The lower component is made by passing a metal base plate through the rolling mill. Separately from this, the upper component is made. Thereafter, the left and right side edges of the upper component member are placed on the step portions of the left and right side wall forming portions, the thin portion is bent inward and engaged with the upper component member, and the two component members are brazed to each other in this state. It is manufactured by.
[0007]
However, in the conventional method for manufacturing a flat heat exchange tube, the width of the annular groove for forming the left and right side wall forming portions is larger than the width of the annular groove for forming the reinforcing wall forming portion, and the width for forming the thin wall portion is narrow. The depth of the annular groove for forming the left and right side wall forming portions including the annular groove is larger than the depth of the annular groove for forming the reinforcing wall forming portion, and the bottom surface of the annular groove for forming the reinforcing wall forming portion is notched. Since the forming convex portion is provided, the volume of the annular groove for forming the left and right side wall forming portions is larger than the volume of the annular groove for forming the reinforcing wall forming portion, and as a result, the metal flowing from the metal base plate during rolling In the annular groove for forming the left and right side wall forming parts, rather than the annular groove for forming the reinforcing wall forming part at the left and right ends, that is, the annular groove for forming the reinforcing wall forming part located next to the annular groove for forming the left and right side wall forming parts. It becomes easy to flow into. Therefore, the molded lower component member has a problem that the height of the reinforcing wall forming portions at both ends is lower than the other reinforcing wall forming portions.
[0008]
Moreover, in the molded lower constituent member, the height of the reinforcing wall forming portions at both ends is lower than the other reinforcing wall forming portions, so that the upper end of the reinforcing wall forming portions at both ends and the upper wall of the upper constituent member A large gap occurs between the forming part, and in the manufactured flat heat exchange pipe, a brazing defect occurs between the reinforcing wall forming part at both ends and the upper wall forming part of the upper component member, There was a problem that the required pressure resistance could not be obtained. Moreover, there is a possibility that both constituent members may be peeled off starting from the portion where the brazing defect has occurred.
[0009]
An object of the present invention is to provide a flat heat exchange tube having improved pressure resistance and a method for manufacturing the same without solving the above-described problems and causing no brazing failure between the reinforcing wall and the upper wall forming portion. It is in.
[0010]
[Means for Solving the Problems and Effects of the Invention]
The flat heat exchange pipe according to the first aspect of the present invention includes an upper and lower wall, left and right side walls straddling the left and right side edges of the upper and lower walls, and spans the upper and lower walls between the left and right side walls and extends in the length direction and has a predetermined distance from each other. A flat heat exchange pipe having a plurality of reinforcing walls provided in parallel and having a parallel fluid passage inside, and a plurality of communication holes through which the parallel fluid passages are formed in the reinforcing wall. An upper wall forming portion, and a plate-like upper component member having left and right side wall forming portions integrally formed in a hanging manner on both left and right side edges of the upper wall forming portion, a lower wall forming portion, and a lower wall forming portion. The left and right side wall forming portions are integrally formed in a rising manner on the left and right side edges, and the bottom wall forming portion is integrally formed in a rising shape so as to extend in the length direction between the left and right side wall forming portions and to be spaced apart from each other. Plate having a plurality of reinforcing wall forming portions The heights of all the reinforcing wall forming portions of the lower constituent member, and the heights of the left and right side wall forming portions and the reinforcing wall forming portion are equal to each other. A plurality of notches are formed on the upper edge of the reinforcing wall forming portion at intervals in the length direction, the upper component member is covered with the lower component member, and the left and right side wall forming portions are on the left and right sides of the lower component member. Both components are in mutual contact with each other over the outside of the wall forming part. The lower end portions of the left and right side wall forming portions of the upper component member are brazed and extended below the lower wall, and are formed at the left and right side edge portions of the lower component member lower surface and upward in the left and right direction outward. Engaged with an inclined inclined surface It is brazed.
[0011]
According to the flat heat exchange pipe of the first aspect of the present invention, the heights of all the reinforcing wall forming portions of the lower component member and the heights of the left and right side wall forming portions and the reinforcing wall forming portion are equal to each other. In the state where the upper constituent member is covered with the lower constituent member, the upper ends of the left and right side wall forming portions and all the reinforcing wall forming portions abut against the lower surface of the upper wall forming portion of the upper constituent member. In this state, since the two structural members are brazed to each other, it is possible to prevent the occurrence of poor brazing between all the reinforcing wall forming portions of the lower structural member and the upper wall forming portion of the upper structural member. The Therefore, the pressure resistance of the flat heat exchange tube is improved. In addition, since the occurrence of brazing failure between all the reinforcing wall forming portions of the lower component member and the upper wall forming portion of the upper component member is prevented, both the upper and lower sides starting from the portion where the brazing failure has occurred are prevented. It is possible to prevent the component members from peeling off.
[0012]
According to the flat heat exchange pipe of the invention of claim 1, the heights of the left and right side wall forming portions and the reinforcing wall forming portion are equal to each other and the upper edges of the left and right side wall forming portions and the reinforcing wall forming portion are respectively Since the plurality of notches are formed at intervals in the length direction, the heights of all the reinforcing wall forming portions can be made equal. That is, this flat heat exchange tube is manufactured by the method according to claim 10. In this case, the volume of all the annular grooves formed on the peripheral surface of one work roll can be made equal. Accordingly, the metal material flowing from the metal base plate flows equally into the left and right side wall forming portion forming annular grooves and the left and right end reinforcing wall forming portion forming annular grooves, and the left and right ends of the formed lower component member are reinforced. The height of the wall forming portion is equal to the height of the other reinforcing wall forming portions. As a result, the effects as described above are derived.
[0013]
According to the flat heat exchange pipe of the first aspect of the present invention, the two constituent members are mutually connected in a state where the left and right side wall forming portions of the upper constituent member overlap the outside of the left and right side wall forming portions of the lower constituent member. Therefore, fluid leakage from the notches in the left and right side wall forming portions is prevented.
[0014]
The flat heat exchange pipe according to the invention of claim 2 is replaced with the flat heat exchange pipe according to the invention of claim 1. Leave The opening ratio, which is the ratio of all the communication holes in each reinforcing wall, is 10 to 40%.
[0015]
Claim 3 The flat heat exchange pipe according to the invention of Claim 1 or 2 In the flat heat exchange pipe according to the invention, the opening ratio, which is the ratio of all the communication holes in each reinforcing wall, is 10 to 30%.
[0016]
Claim 4 The flat heat exchange pipe according to the invention of Claims 1-3 In the flat heat exchange pipe according to any one of the inventions, the communication holes formed in the plurality of reinforcing walls are arranged in a staggered manner as viewed from above.
[0017]
Claim 5 The automotive heat exchanger according to the invention of Claims 1-4 The flat heat exchange tube according to any one of the inventions is used.
[0018]
Claim 6 The automobile according to the invention of Claim 5 The vehicle air conditioner using the automobile heat exchanger according to the present invention is mounted.
[0019]
Claim 7 The heat exchanger for electrical equipment according to the invention of Claims 1-4 The flat heat exchange tube according to any one of the inventions is used.
[0020]
Claim 8 The heat exchanger for industrial machinery according to the invention of Claims 1-4 The flat heat exchange tube according to any one of the inventions is used.
[0021]
Claim 9 The manufacturing method of the flat heat exchange tube according to the invention of Upper and lower walls, left and right side walls straddling the left and right side edges of the upper and lower walls, and a plurality of reinforcing walls that extend between the left and right side walls and extend in the length direction and spaced apart from each other by a predetermined distance In addition to having parallel fluid passages in the interior, a plurality of communication holes are formed in the reinforcing wall to allow the parallel fluid passages to pass through. The upper wall forming portion and the left and right edges of the upper wall forming portion are suspended. A plate-like upper component member having left and right side wall forming portions integrally formed with the lower wall forming portion, a left and right side wall forming portion integrally formed in a rising manner on both left and right edges of the lower wall forming portion, and left and right side walls The lower component member comprises a plate-like lower component member having a plurality of reinforcing wall forming portions integrally formed in a rising manner on the lower wall forming portion so as to extend in the length direction between the forming portions and to be spaced apart from each other. The height of all reinforcing wall forming parts, The heights of the left and right side wall forming portions and the reinforcing wall forming portions are equal to each other, and a plurality of left and right side wall forming portions and upper edges of all the reinforcing wall forming portions of the lower component member are spaced apart in the longitudinal direction. A notch is formed, the upper component member is covered with the lower component member, and both the component members are brazed to each other with the left and right side wall forming portions overlapping the outer sides of the left and right side wall forming portions of the lower component member. Have A method of manufacturing a flat heat exchange pipe, comprising: an annular groove for forming left and right side wall forming portions and a plurality of annular grooves for forming reinforcing wall forming portions on a circumferential surface of one work roll of a rolling mill. Are formed to have the same width and depth, and a plurality of notch forming projections are provided on the bottom surfaces of both annular grooves at intervals in the circumferential direction, and the metal base plate is passed through the rolling mill. The lower component is made separately, and then the upper component is formed separately. Thereafter, the upper component is lowered so that the left and right side wall forming portions of the upper component overlap the outside of the left and right side wall forming portions of the lower component. Both constituent members are combined on the constituent members, and both constituent members are brazed to each other in this state.
[0022]
Claim 9 According to the method for manufacturing a flat heat exchange tube of the invention, the circumferential grooves of one work roll of the rolling mill are provided with both the left and right side wall forming portion forming annular grooves and the plurality of reinforcing wall forming portion forming annular grooves. Since the annular grooves are formed to have the same width and depth, and a plurality of notch forming projections are provided on the bottom surfaces of both annular grooves at intervals in the circumferential direction, the circumferential surface of this work roll The volume of all the annular grooves formed on the metal plate is equal, and when the lower component is made by passing the metal base plate through this rolling mill, the metal material flowing from the metal base plate is used for forming the left and right side wall forming portions. It flows evenly into the annular groove and the annular grooves for forming the reinforcing wall forming portions at the left and right ends, and as a result, the height of the reinforcing wall forming portions at the left and right ends of the formed lower structural member is the same as the height of the other reinforcing wall forming portions. Will be equal. Therefore, as described above, it is possible to prevent the occurrence of brazing failure between all the reinforcing wall forming portions of the lower constituent member and the upper wall forming portion of the upper constituent member, and the pressure resistance of the flat heat exchange tube. Will improve. In addition, since the occurrence of brazing failure between all the reinforcing wall forming portions of the lower component member and the upper wall forming portion of the upper component member is prevented, both the upper and lower sides starting from the portion where the brazing failure has occurred are prevented. It is possible to prevent the component members from peeling off.
[0023]
Claim 10 The manufacturing method of the flat heat exchange tube according to the invention of Claim 9 In the method for manufacturing a flat heat exchange tube according to the present invention, before the upper constituent member is put on the lower constituent member, a flux is applied to the upper constituent member and the lower constituent member.
[0024]
Claim 11 The manufacturing method of the flat heat exchange tube according to the invention of Claim 9 or 10 In the method of manufacturing a flat heat exchange tube according to the invention, the hanging length of the left and right side wall forming portions of the upper component member is set to the rising length of the left and right side wall forming portions of the lower component member, and the thickness of the lower wall forming portion is set. In addition, an inclined surface inclined upward outward in the left-right direction is formed on the left and right side edges of the lower surface of the lower wall forming portion of the lower component member, and the upper component member is After fitting the lower component member, the lower end portions of the left and right side wall forming portions of the upper component member are bent inward in the left-right direction and brought into close contact with the inclined surface of the lower component member. Including stopping.
[0025]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings. In the following description, the term “aluminum” includes an aluminum alloy in addition to pure aluminum.
[0026]
FIG. 1 shows the overall configuration of a flat heat exchange tube according to the present invention, FIGS. 2 and 3 show an enlarged main part thereof, and FIGS. 4 to 7 show a manufacturing method thereof.
[0027]
1 to 3, the flat heat exchange pipe (A) is composed of flat upper and lower walls (1) (2) and left and right side walls of a double structure straddling the left and right edges of the upper and lower walls (1) (2). (3) A plurality of reinforcing walls that extend between the upper and lower walls (1) and (2) between the left and right side walls (3) and (4), extend in the length direction, and are spaced apart from each other by a predetermined distance. (5) and has a parallel fluid passage (6) inside, and is made of an aluminum bottom that constitutes the lower wall (2), the left and right side walls (3) and (4), and the reinforcing wall (5). The component member (10) is formed by a plate-shaped aluminum upper component member (20) constituting the upper wall (1) and the left and right side walls (3) and (4).
[0028]
The area between the adjacent reinforcing walls (5) on the inner surface of the lower wall (2) and the part between the left and right side walls (3) (4) and the reinforcing walls (5) at both left and right ends respectively In order to increase the number of protrusions, a plurality of protrusions (7) are integrally formed in an upwardly protruding shape with a gap in the length direction.
[0029]
The left and right side walls (3) and (4) are formed on the left and right side edges of the upper wall (1) so as to hang down from the left and right side wall forming portions (22), and the left and right side edges of the lower wall (2) are raised. The left and right side wall forming portions (12) formed integrally with each other are joined to each other in a state of overlapping so that the hanging left and right side wall forming portions (22) come to the outside. The lower end portions of the left and right side wall forming portions (22) of the upper component member (20) extend downward from the lower wall (2) and are formed at the left and right side edges of the lower surface of the lower component member (10) and in the left-right direction. It is engaged and brazed to an inclined surface (15) inclined upward toward the outside. In addition, a plurality of trapezoidal notches (16) are formed on the upper edges of the left and right side wall forming portions (12) of the lower component member (10) at predetermined intervals in the length direction.
[0030]
The reinforcing wall (5) is formed by joining a reinforcing wall forming portion (13) formed integrally with the lower wall (2) to the inner surface of the upper wall (1). The reinforcing wall (5) has a plurality of communication holes (8) through which the parallel fluid passages (6) pass. The communication holes (8) are staggered when viewed from above. When the communication holes (8) are opened, the fluid flowing through the parallel fluid passages (6) flows in the width direction of the flat heat exchange pipe (A) through the communication holes (8). The fluid is mixed in the passage (6), and there is no temperature difference between the fluid passages (6). Therefore, the heat exchange efficiency is improved. The opening ratio, which is the ratio of all the communication holes (8) in each reinforcing wall (5), is preferably in the range of 10 to 40%, particularly 10 to 30%, and preferably about 20%. . In this case, the effect of improving the heat exchange efficiency by forming the communication hole (8) becomes remarkable. The communication hole (8) is formed by the trapezoidal notches (14) formed at predetermined intervals on the upper edge of the reinforcing wall forming part (13), and the open part is blocked by the upper wall (1). It is formed. In this case, since the communication holes (8) opened in the plurality of reinforcing walls (5) are arranged in a staggered manner as viewed from the plane, both constituent members (10 ) (20) There will be joints between each other, and sufficient joint strength will be ensured.
[0031]
The flat heat exchange tube (A) is manufactured as follows.
[0032]
First, by using the apparatus shown in FIGS. 4 to 6, a plate-like aluminum lower component member (10) as shown in FIG. 7 is formed. Further, a plate-like aluminum upper component member (20) as shown in FIG. 7 is formed by roll forming.
[0033]
In FIG. 7, the lower component member (10) includes a flat lower wall forming portion (11) and left and right side wall forming portions (12) integrally formed in a rising manner on the left and right side edges of the lower wall forming portion (11). A plurality of reinforcing wall forming portions (13) extending in the length direction and integrally formed in a rising manner with a predetermined interval between the left and right side wall forming portions (12) of the lower wall forming portion (11). A trapezoidal notch (16) (14) is formed on the upper edges of the left and right side wall forming parts (12) and the reinforcing wall forming part (13) at predetermined intervals in the length direction as viewed from above. It is formed in a zigzag arrangement. The heights of all the reinforcing wall forming portions (13) of the lower component member (10) and the heights of the left and right side wall forming portions (12) and the reinforcing wall forming portion (13) are equal. Further, the protrusion (7) is integrally formed on the upper surface of the lower wall forming portion (11), and the inclined surfaces (15) are formed on the left and right side edges of the lower surface of the lower wall forming portion (11). .
[0034]
In FIG. 7, the upper component member (20) is formed integrally with the flat upper wall forming portion (21) and the both side edges of the upper wall forming portion (21) so as to hang down and is compatible with the lower component member (10). The left and right side wall forming portions (22) overlap the outside of the upright left and right side wall forming portions (12). The width of the upper wall forming portion (21) of the upper component member (20) is slightly wider than the width of the lower component member (10), and covers the lower component member (10). Further, the hanging length of the left and right side wall forming portions (22) of the upper component member (20) is set to the rising length of the left and right side wall forming portions (12) of the lower component member (10), and the lower wall forming portion (11 ) Is slightly longer than the one with the added thickness. The upper component member (20) is made of an aluminum brazing sheet having a brazing material layer on the lower surface, that is, the lower surface of the upper wall forming portion (21) and the inner surfaces of both the left and right side wall forming portions (22).
[0035]
In FIG. 4, the apparatus for producing the lower component (10) includes an uncoiler (31) around which an aluminum sheet (30) is wound, a preliminary rolling mill (32), a finish rolling mill (33), and a plurality of feed rolls. (34). Then, the aluminum sheet (30) wound around the uncoiler (31) is unwound from the uncoiler (31) and sent to the preliminary rolling mill (32), and after passing through the preliminary rolling mill (32), the finish rolling mill The lower component (10) is formed by being sent to (33) and subjected to finish rolling.
[0036]
The pre-roller (32) is for forming thick portions on both side edges of the aluminum sheet (30).
[0037]
The finish rolling mill (33) includes a central work roll (35) and a plurality of satellite work rolls (36) arranged at equal intervals in the circumferential direction around the central work roll (35). . The central work roll (35) is rotated by a driving means (not shown). Each satellite work roll (36) is connected to the central work roll (35) by a gear device (not shown), and when the central work roll (35) rotates, all the satellite work rolls (36) are central work rolls. It rotates at the same peripheral speed as (35). Note that each satellite work roll (36) may be provided with a driving means so that it can be rotated at the same peripheral speed as the central work roll (35). Further, the finish rolling mill (33) includes a trapezoidal guide shoe (37) and a spring (38) that urges the guide shoe (37) toward the central work roll (35) between the adjacent satellite work rolls (36). ). Both side edges of the guide shoe (37) enter between the central work roll (35) and the satellite work roll (36), and are in sliding contact with the satellite work roll (36). The guide shoe (37) suppresses the elongation of the aluminum sheet (30) in the length direction while the aluminum sheet (30) passes through the finish rolling mill (33), and between adjacent satellite work rolls (36). Suppresses swelling from The suppression of the elongation in the length direction of the aluminum sheet (30) is also performed by rotating all the satellite work rolls (36) at the same peripheral speed as the central work roll (35). As a result, grooves (39) and (40) described later formed in the central work roll (35), recesses (42) and protrusions (43) and (44), and satellite work roll (36) were formed. An inclined surface (45), which will be described later, is completely transferred to the aluminum sheet (30), and a lower component member (10) having a desired shape is obtained. Further, since the elongation in the length direction of the aluminum sheet (30) is suppressed, the aluminum sheet (30) that is a base plate should be thinner than the plate material used as the base plate in the conventional method. And material costs are reduced. In addition, the rolling reduction is smaller than that of the conventional method.
[0038]
As shown in FIGS. 5 and 6, on the peripheral surface of the central work roll (35) of the finish rolling mill (33), left and right side wall forming portion forming annular grooves (39) and reinforcing wall forming portion forming annular grooves ( 40) is formed all around. At this time, the width and depth of all the reinforcing wall forming portion forming annular grooves (40) are made equal, and the left and right side wall forming portion forming annular grooves (39) and the reinforcing wall forming portion forming annular grooves ( 40) Keep the width and depth equal. Further, the left and right side wall forming portion forming annular groove (39) on the peripheral surface of the central work roll (35) and the reinforcing wall forming portion forming annular groove (40) adjacent thereto, and the adjacent reinforcing wall forming are also formed. A plurality of protrusion forming recesses (42) are provided in the circumferential direction at intervals between the partial forming annular grooves (40). Further, notched portion forming convex portions (43) and (44) are provided on the bottom surfaces of the left and right side wall forming portion forming annular grooves (39) and the reinforcing wall forming portion forming annular grooves (40), respectively.
[0039]
Further, as shown in FIG. 5, inclined surfaces (45) inclined radially outward toward the left and right ends at the left and right ends of the peripheral surface of the satellite work roll (36) of the finish rolling mill (33). Is formed.
[0040]
Therefore, when the aluminum sheet (30) is continuously passed between the central work roll (35) and all the satellite work rolls (36), the lower component member (10) as shown in FIG. Molded.
[0041]
Next, the upper and lower components (20) and (10) are subjected to a degreasing treatment, and then a brazing flux is applied thereto.
[0042]
Next, after fitting the upper component member (20) on the lower component member (10), the lower component member is bent inward in the left-right direction by bending the lower ends of the left and right side wall forming portions (22) of the upper component member (20). The inclined surfaces (15) of (10) are brought into close contact with each other, whereby both the constituent members (10) and (20) are temporarily fixed.
[0043]
Next, the temporarily fixed members (20) and (10) are heated to a brazing temperature. Then, the left and right side wall forming portions (12) of the lower component member (10), the inner surfaces of the left and right side wall forming portions (22) of the upper component member (20), and the left and right side wall forming portions (12 of the lower component member (10)). ) And the upper end of the reinforcing wall forming portion (13) and the lower surface of the upper wall forming portion (21) of the upper component member (20) are brazed. Thus, the flat heat exchange tube (A) is manufactured.
[0044]
In the above embodiment, the lower end portions of the left and right side wall forming portions (22) of the upper component member (20) are bent inward in the left-right direction, and are brought into close contact with the inclined surface (15) of the lower component member (10). Instead of this, instead of this, the entire lower surface of the lower wall forming portion of the lower component member is flattened, and the lower end surfaces of the left and right side wall forming portions of the upper component member are formed as the lower wall of the lower component member. It may be arranged so as to be flush with the lower surface of the part. Further, if the left and right side wall forming portions of the upper component member can cover the notches formed on the upper edges of the left and right side wall forming portions of the lower component member, the lower ends of the left and right side wall forming portions of the upper component member are You may be located in the intermediate part of the height of the right-and-left both-sides wall formation part of a lower structural member.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a flat heat exchange tube of the present invention.
FIG. 2 is a partially enlarged view of FIG.
3 is a cross-sectional view taken along line III-III in FIG.
4 is a diagram showing an outline of an apparatus for manufacturing a lower component member of the flat heat exchange tube of FIG. 1. FIG.
FIG. 5 is an enlarged cross-sectional view taken along line VV in FIG. 4;
6 is a partially enlarged perspective view showing a developed peripheral surface of a central work roll of the apparatus of FIG. 4;
7 is a partially enlarged perspective view showing a state in which the upper and lower constituent members are combined in the process of manufacturing the flat heat exchange tube of FIG. 1. FIG.
FIG. 8 is a front view of a condenser for a car air conditioner provided with a flat refrigerant flow pipe.
[Explanation of symbols]
(1) Upper wall
(2) Lower wall
(3) Left side wall
(4) Right side wall
(5) Reinforcement wall
(6) Fluid passage
(8) Communication hole
(10) Lower component
(11) Lower wall forming part
(12) Left and right side wall forming part
(13) Reinforcing wall forming part
(14) (16) Notch
(20) Upper component
(21) Upper wall forming part
(22) Left and right side wall forming part
(35) Central work roll
(39) Circular grooves for forming left and right side wall forming parts
(40) Reinforcing wall forming part forming annular groove
(43) (44) Convex for notch formation

Claims

Upper and lower walls, left and right side walls straddling the left and right side edges of the upper and lower walls, and a plurality of reinforcing walls that extend between the left and right side walls and extend in the length direction and spaced apart from each other by a predetermined distance A flat heat exchange pipe having a parallel fluid passage inside and a plurality of communication holes through which the parallel fluid passages are formed in the reinforcing wall,
On the left and right side edges of the lower wall forming part and the lower wall forming part, a plate-like upper constituent member having left and right side wall forming parts integrally formed on the left and right side edges of the upper wall forming part and the upper wall forming part The left and right side wall forming portions integrally formed in a rising shape, and a plurality of reinforcements integrally formed in the rising shape in the lower wall forming portion so as to extend in the length direction between the left and right side wall forming portions and to be spaced apart from each other by a predetermined distance. A lower plate-shaped constituent member having a wall forming portion, and the height of all the reinforcing wall forming portions of the lower constituent member and the heights of the left and right side wall forming portions and the reinforcing wall forming portion are made equal, respectively. A plurality of notches are formed in the upper edges of the left and right side wall forming portions and all the reinforcing wall forming portions at intervals in the length direction, and the upper component member is covered with the lower component member to form the left and right side walls. Overlaps the outside of the left and right side wall forming parts of the lower component Both components while the brazed to each other and lower end portions of the left and right side wall forming portion of the upper structure member, with stretched below the bottom wall, is formed on the left and right side edges of the lower structure member lower surface and A flat heat exchange tube engaged and brazed to an inclined surface inclined upward in the left-right direction .

The flat heat exchange pipe according to claim 1 , wherein an opening ratio, which is a ratio of all the communication holes in each reinforcing wall, is 10 to 40% .

The flat heat exchange pipe according to claim 1 or 2 , wherein an opening ratio, which is a ratio of all the communication holes in each reinforcing wall, is 10 to 30% .

The flat heat exchange pipe according to any one of claims 1 to 3 , wherein the communication holes formed in the plurality of reinforcing walls are arranged in a staggered manner when viewed from above.

The heat exchanger for motor vehicles using the flat-shaped heat exchange pipe in any one of Claims 1-4 .

An automobile equipped with a car air conditioner using the automobile heat exchanger according to claim 5 .

The heat exchanger for electric equipments using the flat heat exchange pipe according to any one of claims 1 to 4 .

The heat exchanger for industrial machines using the flat heat exchange pipe according to any one of claims 1 to 4 .

Upper and lower walls, left and right side walls straddling the left and right side edges of the upper and lower walls, and a plurality of reinforcing walls that extend between the left and right side walls and extend in the length direction and spaced apart from each other by a predetermined distance In addition to having parallel fluid passages in the interior, a plurality of communication holes are formed in the reinforcing wall to allow the parallel fluid passages to pass through. The upper wall forming portion and the left and right edges of the upper wall forming portion are suspended. A plate-like upper component member having left and right side wall forming portions integrally formed with the lower wall forming portion, a left and right side wall forming portion integrally formed in a rising manner on both left and right edges of the lower wall forming portion, and left and right side walls The lower component member comprises a plate-like lower component member having a plurality of reinforcing wall forming portions integrally formed in a rising manner on the lower wall forming portion so as to extend in the length direction between the forming portions and to be spaced apart from each other. The height of all reinforcing wall forming parts, The heights of the left and right side wall forming portions and the reinforcing wall forming portions are equal to each other, and a plurality of left and right side wall forming portions and upper edges of all the reinforcing wall forming portions of the lower component member are spaced apart in the longitudinal direction. A notch is formed, the upper component member is covered with the lower component member, and both the component members are brazed to each other with the left and right side wall forming portions overlapping the outer sides of the left and right side wall forming portions of the lower component member. A method for producing a flat heat exchange tube comprising:
On the peripheral surface of one work roll of the rolling mill, the left and right side wall forming portion forming annular grooves and the plurality of reinforcing wall forming portion forming annular grooves are formed so that the width and depth of both annular grooves are equal. , you can have a plurality of notch forming projections at each interval in the circumferential direction on the bottom surface of the two annular grooves, creating a lower structure member by passing the metal material plates into the rolling mill, separate from this Then, the upper component is covered with the lower component so that the left and right side wall forming portions of the upper component overlap the outside of the left and right side wall forming portions of the lower component, and the two components are combined. A method of manufacturing a flat heat exchange tube, wherein both constituent members are brazed to each other in a state .

The method for manufacturing a flat heat exchange tube according to claim 9, further comprising applying a flux to the upper component member and the lower component member before the upper component member is placed on the lower component member .

The hanging length of the left and right side wall forming portions of the upper structural member is set longer than the rising length of the left and right side wall forming portions of the lower structural member plus the thickness of the lower wall forming portion. An inclined surface inclined upward in the left-right direction is formed on both left and right edges of the lower surface of the lower wall forming portion of the component member, and after the upper component member is fitted over the lower component member, 11. The flat structure according to claim 9, further comprising bending the lower end portions of the left and right side wall forming portions inward in the left-right direction so as to be brought into close contact with the inclined surface of the lower component member and thereby temporarily fixing both component members. Of manufacturing a heat exchanger tube.