JP4398383B2 - Resin heat exchanger and manufacturing method thereof - Google Patents

Description

  The present invention relates to a resin heat exchanger mainly used as a radiator, an intercooler, a heater core, an evaporator, a condenser and the like for automobiles and a method for manufacturing the same.

  In recent years, fuel saving needs by reducing the weight of automobiles are increasing from the viewpoint of reducing global environmental pollution. For example, in automobile cooling systems, heat exchangers such as radiators, intercoolers, heater cores, evaporators and condensers have been reduced in size and weight by replacing materials and optimizing shapes.

  Specifically, many all-resin heat exchangers in which all components are made into resin have been studied. In this case, if the component parts are made of resin, the degree of freedom of the shape is expanded, and if the tube cross-sectional area (that is, the cross-sectional area of the flow path) through which the cooling water as the heat exchange medium is circulated can be secured, It is said that there is a great merit that the entire device can be reduced in size and weight while maintaining the same performance as the heat exchanger.

  As an example of a case where a heat exchanger is formed of resin, for example, in Patent Document 1, a plurality of resin tubes having a single refrigerant flow hole are individually set in a mold so as to penetrate the cavity, and the state Discloses a technique for connecting a resin tube and a seat plate (device) by injection molding.

Patent Document 2 discloses a technique in which a tube having a refrigerant passage is formed by facing a resin grooved sheet face-to-face, and tanks are formed at both ends.
Japanese Patent No. 3488470 JP 2004-108644 A

  However, in the technique described in Patent Document 1, since it is necessary to individually set a large number of resin tubes having a single refrigerant flow hole in a mold, preparation work prior to molding has been difficult. In addition, when the seat plate is injection-molded, the resin tube is crushed by the molding pressure, and a defective product may be produced. Further, since the resin to be molded later is integrated with the resin tube that has been molded first, there is a risk that the reliability of bonding between the resin tube and the seat plate will be lowered.

  Further, in the technique described in Patent Document 2, since a tube is formed by laminating sheets, bonding reliability is low and there is a possibility of weakening to internal pressure.

  In consideration of the above circumstances, the present invention is suitable for mass production because the preparatory work prior to molding can be performed easily, and has high bonding reliability and resistance to internal pressure. Moreover, there is a concern that defective products such as tube crushing may occur. An object of the present invention is to provide a high-quality resin heat exchanger and a method for manufacturing the same.

According to the first aspect of the present invention, a plurality of metal cores for forming each refrigerant flow hole of the flat perforated tube are prepared, and both ends of the metal cores are fixed with a metal core fixing jig. Forming a core for injection molding in which a cored bar is held at a position where a flow hole can be formed; a cavity for integrally molding the flat porous tube and the seat plate; and molding the seat plate Preparing a split mold having a jig holding part for setting the cored bar fixing jig outside the cavity part in the longitudinal direction of the cored bar, and fixing the cored bar to the jig holding part The step of setting the core in the split mold while setting the jig and closing the mold, and injecting the molten resin material into the cavity of the split mold, the flat porous tube and the seat The process of injection-molding the plate and the injection-molded molded product And having a step of removing the al the core metal fixture, and a step of removing the said all of the core metal from the molded article.

Invention of Claim 2 is a manufacturing method of the resin heat exchanger of Claim 1 , Comprising: The said metal core fixing jig defines at least one part of the cavity part which shape | molds the said seat plate. Thus, the seat plate is formed using the outer surface of the cored bar fixing jig as a part of the seat plate forming surface.

The invention of claim 3 provides a plurality of metal cores for forming the refrigerant flow holes of the flat perforated tube, and fixes both ends of the metal cores with a metal core fixing member. Forming a core for injection molding in which a core metal is held at a position where a hole for molding can be formed, a cavity for integrally molding the flat porous tube and the seat plate, and molding the seat plate Preparing a split die having a jig holding portion for setting a core metal fixing member constituting a part of the seat plate in the cavity portion; and the core metal fixing member on the jig holding portion. While setting, the step of setting the core in the split mold and closing the mold, and injecting the molten resin material into the cavity of the split mold, the flat perforated tube and the seat plate A process of injection molding integrally, an injection molded molded product and And a step of pulling the entire core metal from Kishinkin fixing member, characterized in that to leave the core metal fixing member as a part of the seat plate.

According to the first aspect of the present invention, a flat porous tube having a large number of refrigerant flow holes and a seat plate are simultaneously and integrally formed by using a core having a core for forming the refrigerant flow holes. It is possible to manufacture a resin heat exchanger with high bonding reliability. Moreover, since a plurality of core bars are held as a group by using the core bar fixing jig, handling as a core becomes easy.

According to the invention of claim 2 , since the seat plate is formed using the outer surface of the core metal fixing jig as a part of the seat plate molding surface, the molding surface of the seat plate after removing the core metal fixing jig Can be flattened. That is, the allowance for the flat porous tube to protrude from the seat plate can be eliminated.

According to invention of Claim 3 , since a core metal fixing member is left as a part of seat plate, the effort which removes a metal core fixing member can be saved. However, since the core metal fixing member is only left as a part of the seat plate formed by injection molding, the bonding reliability between the seat plate and the flat porous tube can be maintained without change.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

“First Embodiment”
FIG. 1 is a perspective view of a resin heat exchanger 10 according to the first embodiment. This resin heat exchanger 10 includes a plurality of flat perforated tubes 11 arranged in parallel with each other with wide outer surfaces 11a facing each other with a space therebetween, and the longitudinal direction of these flat perforated tubes 11 (FIG. 1). It has seat plates 13 and 13 which are located at both ends of the tube longitudinal direction (shown by the middle arrow B) and hold and connect each flat porous tube 11 at a fixed position. It is molded at the same time. Each flat porous tube 11 is provided with a plurality of coolant circulation holes 12 arranged in the width direction (tube width direction indicated by arrow A in FIG. 1). Further, the end of each flat porous tube 11 slightly protrudes from the seat plate 13.

  Although FIG. 1 shows a case where only four refrigerant circulation holes 12 having a circular cross section are provided, the number and cross sectional shape may be changed as appropriate. In practice, in order to sufficiently secure the heat exchange efficiency, many holes having a smaller cross-sectional area are often provided.

  Next, a method for manufacturing such a resin heat exchanger 10 will be described.

  First, as shown in FIGS. 2 (a) and 2 (b), a plurality of metal cores 22 are prepared for forming each refrigerant flow hole 12 of the flat porous tube 11 of FIG. It is desirable to apply a release agent to the cored bar 22 so that the cored bar 22 can be easily pulled out from a molded product (an integrally molded product of a tube and a seat plate) in a later-described cored bar drawing process. The cross section and the number of the core bars 22 are matched with the cross section and the number of the coolant circulation holes 12. These core bars 22 are arranged in parallel with each other in a fixed arrangement, and in this state, both ends thereof are fixed with a rectangular parallelepiped block-shaped core bar fixing jig 23. Thereby, the core 20 for injection molding which hold | maintained the metal core 22 in the position which can shape | mold each refrigerant | coolant circulation hole 12 is completed. Here, the cored bar fixing jig 23 has a halved structure, and a groove 24 sandwiching the cored bar 22 is formed on the mating surface of each half body 23a.

  Further, a split mold 50 including a pair of molds 50A and 50B as shown in FIGS. 3 and 4 is prepared. The split mold 50 is formed with a cavity 30 for integrally molding the flat perforated tube 11 and the seat plate 13, and the cavity 30 opens on the mating surface 51 of the molds 50A and 50B that can be contacted and separated. ing. The cavity 30 in this case includes a cavity portion 31 for forming the flat porous tube 11 and a cavity portion 33 for forming the seat plate 13. Further, a jig holding part for setting the cored bar fixing jig 23 in each mold 50A, 50B is positioned outside the cavity part 33 for molding the seat plate 13 in the longitudinal direction of the cored bar 22. 40 is provided.

  Thus, after preparing the split die 50 and the necessary number of cores 20, as shown in FIGS. 4 and 5, while inserting the metal core fixing jig 23 into the jig holding portion 40, The core 20 is set in the split mold 50. Here, a release material is applied in advance on the surface of the core 20, particularly the surface of the cored bar 22. When the core 20 is set in this way, as shown in FIG. 6, each cored bar 22 is held in a floating state in the cavity part 31 for cored bar molding.

  After all the cores 20 are set, the molds 50A and 50B are closed together, and then the molten resin material is injected into the cavity 30 of the split mold 50, so that the flat porous tube 11 and The seat plate 13 is integrally formed by injection molding.

  Then, when the injection molding is completed, the cored bar fixing jig 23 is removed from the removed molded product, and then all the cored bar 22 is extracted from the molded product. Thereby, the resin heat exchanger 10 shown in FIG. 1 is completed.

  Since the resin heat exchanger 10 manufactured in the above steps is formed by simultaneously molding the flat porous tube 11 and the seat plate 13 together, the flat porous tube 11 itself, and the flat porous tube 11 and the seat plate 13 There are no joints between. Therefore, it is strong against the internal pressure and the product reliability is increased. In addition, since there are a large number of refrigerant circulation holes 12 in one flat porous tube 11, preparation work (handling of the cored bar 22) during molding is facilitated. In addition, since the flat porous tube 11 and the seat plate 13 are integrally formed at the same time, there is no fear of the tube 11 being crushed and the product quality can be improved.

  Further, in the above manufacturing method, since the plurality of core bars 22 are handled as a group by using the core bar fixing jig 23, the efficiency of the preparation work prior to molding can be improved.

“Second Embodiment”
FIG. 7 is a perspective view of a resin heat exchanger 110 according to the second embodiment of the present invention. The difference between the resin heat exchanger 110 and the resin heat exchanger 10 of the first embodiment is that the end face of the seat plate 13 is flat and the end of the flat porous tube 11 does not protrude. is there. Other configurations are the same as those of the first embodiment.

  When the resin heat exchanger 110 is manufactured, as shown in FIG. 8, the jig holding part 140 for setting the core metal fixing jig 23 is adjacent to the cavity part 33 for molding the seat plate 13. The split mold 150 provided is used. That is, the jig holding portion 140 is formed on the pair of molds 150A and 150B that can be separated from each other so as to face directly next to the cavity portion 33 for molding the seat plate 13.

  When the core 20 is set in the molds 150A and 150B while the core metal fixing jig 23 is inserted into the jig holding part 140, the outer surface 123 of the metal core fixing jig 23 is a cavity part for molding the seat plate 13 Define at least a portion of 30. Therefore, by injecting the molten resin into the cavity 30, the seat plate 13 can be formed using the outer surface 123 of the cored bar fixing jig 23 as a part of the seat plate forming surface, as shown in FIG. A resin heat exchanger 110 having a flat end face 13 can be obtained.

"Other embodiments"
In the manufacturing method of the above embodiment, the case where the cored bar fixing jig 23 is finally removed from the molded product has been described. However, the cored bar fixing jig 23 can be left as a part of the molded seat plate 13. is there. In that case, it can be said that the metal core fixing member 23 is more appropriate than the metal core fixing jig 23.

  In addition, when leaving the cored bar fixing jig 23 as a part of the seat plate 13, as shown in FIG. 8, a jig holding portion 140 may be provided adjacent to the cavity portion 33 for forming the seat plate. However, in order to have more unity, the jig holding portion 140 is formed in a form included in a part of the cavity portion 33 for forming the seat plate (in other words, a part of the core metal fixing jig 23 is seated). It is preferable that the jig holding part 140 is formed so as to enter the plate forming cavity part 33). By doing so, the cored bar fixing jig 23 can be embedded as a part of the seat plate 13 in a form close to insert molding.

  Thus, by leaving the cored bar fixing jig (core bar fixing member) 23 as a part of the seat plate 13, it is possible to save the trouble of removing the cored bar fixing jig 23. In addition, since the metal core fixing jig 23 is only left as a part of the seat plate 13 formed by injection molding, the bonding reliability between the seat plate 13 and the flat porous tube 11 can be maintained without change. .

  Moreover, in the said embodiment, although the flat porous tube 11 in which the refrigerant | coolant circulation hole 12 of circular cross section was arranged was shown as an example, as shown in FIG. Various forms are possible.

  In the flat porous tube 211 shown in FIG. 9A, both ends in the width direction have an arc shape, and elliptic refrigerant circulation holes 212 are arranged in the width direction.

  In the flat perforated tube 311 shown in FIG. 9B, both ends in the width direction have a cut shape perpendicular to the wide surface, and square-shaped refrigerant circulation holes 312 are arranged along the width direction. Yes.

  In the flat perforated tube 411 shown in FIG. 9C, both ends in the width direction have a cut shape perpendicular to the wide surface, and rectangular coolant circulation holes 412 are arranged along the width direction. Yes.

  In the flat perforated tube 511 shown in FIG. 9 (D), both ends in the width direction have a cut shape perpendicular to the wide surface, and the triangular coolant circulation holes 512 are alternately reversed in width. It is lined up along the direction.

It is an external appearance perspective view of the resin heat exchanger of 1st Embodiment of this invention. It is a block diagram of the core for injection molding for manufacturing the said resin-made heat exchanger, (a) is a perspective view which shows the state before an assembly and (b) after an assembly. It is a front view of the mating surface of the split mold for injection molding for manufacturing the said resin heat exchanger. It is a perspective view which shows the relationship between the said split mold and a core. It is a partial expansion perspective view which shows the state which incorporated the core in the split mold. It is the front view which looked at the state where the core was built in the split mold toward the mating surface of the mold. It is an external appearance perspective view of the resin heat exchanger of 2nd Embodiment of this invention. It is the front view which looked at the state which incorporated the core in the split mold in order to shape | mold the resin heat exchanger of FIG. It is sectional drawing which shows the other example of the flat porous tube in the said resin-made heat exchangers.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10,110 ... Resin heat exchanger 11 ... Flat porous tube 11a ... Wide outer surface 12 ... Refrigerant circulation hole 13 ... Seat plate 20 ... Core 22 ... Core metal 23 ... Core metal fixing jig (core metal fixing member) )
30 ... Cavity 31 ... Cavity part for forming flat porous tube 33 ... Cavity part for forming seat plate 40,140 ... Jig holding part 50,150 ... Split mold 50A, 50B, 150A, 150B ... Mold 51 ... Matching Surface 123 ... outer surface of the cored bar fixing jig

Claims (3)

A plurality of metal cores (22) for forming each refrigerant circulation hole (12) of the flat porous tube (11) are prepared, and both ends of the metal cores (22) are connected to a metal core fixing jig (23). A step of creating an injection molding core (20) holding the cored bar (22) at a position where each coolant circulation hole (12) can be molded,
It has a cavity (30) for integrally molding the flat perforated tube (11) and the seat plate (13), and more of the core metal (22) than the cavity portion (33) for molding the seat plate (13). A split mold (50, 50A, 50B, 150, 150A, 150B) having a jig holding part (40, 140) for setting the cored bar fixing jig (23) on the outside in the longitudinal direction is prepared. Process,
The core (20) is inserted into the split mold (50, 50A, 50B, 150, 150A, 150B) while the core metal fixing jig (23) is set on the jig holding part (40, 140). Setting and closing the mold;
By injecting the molten resin material into the cavity (30) of the split mold (50, 50A, 50B, 150, 150A, 150B), the flat porous tube (11) and the seat plate (13) are A process of injection molding integrally;
Removing the cored bar fixing jig (23) from the injection-molded molded product;
And a step of removing all the cored bars (22) from the molded article. A method for producing a resin heat exchanger (10, 110), comprising: It is a manufacturing method of the resin heat exchanger of Claim 1 , Comprising:
By defining at least a part of a cavity portion (33) for molding the seat plate (13) with the metal core fixing jig (23), an outer surface (123) of the metal core fixing jig (23). The seat plate (13) is molded using a part of the seat plate molding surface. A method for manufacturing a resin heat exchanger (110). A plurality of metal cores (22) for forming each refrigerant circulation hole (12) of the flat porous tube (11) are prepared, and both ends of the metal cores (22) are connected to the metal core fixing member (23). Creating a core (20) for injection molding that holds the cored bar (22) at a position where each coolant circulation hole (22) can be molded by fixing;
It has a cavity (30) for integrally molding the flat porous tube (11) and the seat plate (13), and the cavity plate (33) for molding the seat plate (13) includes the seat plate (13). Preparing a split mold (150, 150A, 150B) having a jig holding part (140) for setting a core metal fixing member (23) constituting a part of
Setting the core (20) in the split mold (150, 150A, 150B) and closing the mold while setting the core metal fixing member (23) in the jig holding part (140);
A step of integrally injection-molding the flat porous tube (11) and the seat plate (13) by injecting a molten resin material into the cavity (30) of the split mold (150, 150A, 150B). When,
And a step of removing all of the core metal (22) from the injection-molded molded product and the core metal fixing member (23),
The manufacturing method of the resin heat exchanger characterized by leaving the said metal core fixing member (23) as a part of said seat plate (13).

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