JP5712786B2 - Manufacturing method of corrugated fin laminated heat exchanger - Google Patents

Description

  The present invention relates to a method for manufacturing a corrugated fin laminated heat exchanger.

  Conventionally, there exists a corrugated fin lamination | stacking heat exchanger as shown to patent document 1 (Unexamined-Japanese-Patent No. 2010-2138). This corrugated fin laminated heat exchanger has a flat tube, a corrugated fin, and a header tank. A flat tube is a tube | pipe arrange | positioned in the state in which a wide plane part faces an up-down direction. The corrugated fin is a fin having a shape bent into a corrugated shape. The corrugated fin laminated heat exchanger is configured by laminating flat tubes and corrugated fins alternately in a plurality of stages in the vertical direction, and inserting longitudinal end portions of the plurality of flat tubes into the header tank. Yes.

  In the conventional corrugated fin laminated heat exchanger, flat tubes and corrugated fins are alternately laminated to form a fin-tube laminate, and then the longitudinal ends of a plurality of flat tubes are inserted into a header tank. Thus, a heat exchanger core temporary assembly is formed and brazed and joined.

  However, in such a manufacturing method, when the number of stacked layers increases, the dimensional tolerance in the stacking direction of the corrugated fins accumulates, and a flat tube that cannot be inserted into the header tank is generated, thereby forming a heat exchanger core temporary assembly. There is a risk that it will not be possible. For example, assuming that the dimensional tolerance in the laminating direction of the corrugated fins is 0.03 mm and the layers are laminated up to about 100 stages, the dimensional tolerance is accumulated up to about 3 mm, which may hinder the formation of the heat exchanger core temporary assembly. There is.

  An object of the present invention is to provide a method for manufacturing a corrugated fin laminated heat exchanger that allows a plurality of flat tubes to be inserted into a header tank even when the number of laminated stages increases.

  In the corrugated fin laminated heat exchanger manufactured by the manufacturing method according to the first aspect, flat tubes and corrugated fins are alternately stacked in a plurality of stages in the vertical direction, and the longitudinal ends of the flat tubes are headers. It is configured by being inserted into the tank. A flat tube is a tube | pipe arrange | positioned in the state in which a wide plane part faces an up-down direction. The corrugated fin is a fin having a shape bent into a corrugated shape.

  And this corrugated fin lamination | stacking heat exchanger is manufactured as follows. First, flat tubes are arranged side by side with a predetermined interval in the stacking direction of the flat tubes and the corrugated fins. Next, the longitudinal ends of the plurality of flat tubes are inserted into the header tank. Next, corrugated fins are inserted between the flat tubes to form a heat exchanger core temporary assembly. Next, it joins by brazing a heat exchanger core temporary assembly.

  In this manufacturing method, since the flat tube is inserted into the header tank without the corrugated fin being disposed between the flat tubes, the flat tube is securely attached to the header tank without being affected by the dimensional tolerance of the corrugated fin. Can be inserted.

  Thereby, even if the number of stacked stages is increased, a plurality of flat tubes can be inserted into the header tank.

Here, the predetermined interval is a value obtained by adding the maximum tolerance of the laminating direction width to the laminating direction width which is a dimension in the laminating direction between the flat tube of the corrugated fin and the corrugated fin.

  In this manufacturing method, the predetermined interval between the flat tubes is set to a value obtained by adding the maximum tolerance to the width of the corrugated fins in the stacking direction. Corrugated fins can be inserted into

The manufacturing method of the corrugated fin laminated heat exchanger according to the second aspect is the manufacturing method according to the first aspect, wherein the number of laminated stages of the flat tube and the corrugated fin is 100 to 300.

  When the number of stacking stages of the flat tube and the corrugated fin is 100 or more, in the conventional manufacturing method, accumulation of dimensional tolerance in the stacking direction of the corrugated fin becomes significant.

  However, in this manufacturing method, as described above, since it is not affected by the dimensional tolerance of the corrugated fins, the flat tubes are used as header tanks even when the number of layers of the flat tubes and corrugated fins is 100 to 300. Can be inserted reliably.

The manufacturing method of the corrugated fin laminated heat exchanger according to the third aspect is the manufacturing method according to the first or second aspect, wherein brazing of the heat exchanger core temporary assembly constitutes the heat exchanger core temporary assembly. Of the flat tubes, the flat tubes and the corrugated fins are arranged so that the deformation amount in the stacking direction of the flat tubes and the corrugated fins is 1.2 mm or less with respect to the flat tubes located at the ends of the flat tubes and the corrugated fins. It is performed in a state of being pressed in the stacking direction.

  When brazing the heat exchanger core temporary assembly, it is performed in a state where the heat exchanger core temporary assembly is pressed in the stacking direction in order to improve the bonding state between the flat tube and the corrugated fins. Here, in the manufacturing method for forming the heat exchanger core temporary assembly by inserting the corrugated fins between the flat tubes after inserting the longitudinal ends of the plurality of flat tubes into the header tank, as described above, Due to the predetermined interval, a gap is likely to be generated between the flat tube and the corrugated fin constituting the heat exchange core temporary assembly. For this reason, the heat exchanger manufactured in this way has a shape in which the center portion in the longitudinal direction of the flat tube is recessed closer to the center in the stacking direction than the end portion in the longitudinal direction.

  However, when brazing the heat exchanger core temporary assembly, if the pressure in the stacking direction of the heat exchanger core temporary assembly becomes excessive, the degree of the depression in the central portion in the longitudinal direction of the flat tube increases, Later, peeling between the corrugated fin and the flat tube may occur.

  Therefore, in this manufacturing method, as described above, among the flat tubes constituting the heat exchanger core temporary assembly, the flat tube positioned at the end in the stacking direction has a deformation amount of 1.2 mm or less. In addition, the heat exchange core temporary assembly is brazed while being pressed in the stacking direction.

  Thereby, peeling with the corrugated fin after brazing and a flat tube can be made hard to produce.

  As described above, according to the present invention, the following effects can be obtained.

In the manufacturing method of the corrugated fin laminated heat exchanger according to the first or second aspect , a plurality of flat tubes can be inserted into the header tank even if the number of laminated stages is increased. In addition, after inserting a plurality of flat tubes into the header tank, the corrugated fins can be reliably inserted between the flat tubes.

In the manufacturing method of the corrugated fin laminated heat exchanger according to the third aspect , peeling between the corrugated fin and the flat tube after brazing can be made difficult to occur.

It is a perspective view showing the outline internal structure of the outdoor unit which has the outdoor heat exchanger by which the manufacturing method of the corrugated fin laminated heat exchanger concerning one embodiment of the present invention was adopted. It is a figure which shows the external appearance of the outdoor heat exchanger before bending in a planar view substantially L shape. It is an expansion perspective view of the D section of FIG. It is the schematic which looked at FIG. 3 from the arrow E side. It is an expanded view of the corrugated fin before being bent by the corrugation. It is a figure which shows the insertion hole vicinity of a header tank. It is a figure which shows the manufacturing process of an outdoor heat exchanger (flat tube arrangement process). It is a figure which shows the manufacturing process of an outdoor heat exchanger (insertion process of a header tank). It is a figure which shows the manufacturing process of an outdoor heat exchanger (insertion process of a corrugated fin). It is a schematic enlarged view of the G section of FIG. It is a figure which shows the manufacturing process of an outdoor heat exchanger (the brazing process of a heat exchanger core temporary assembly). It is a figure which shows the relationship between the deformation | transformation amount to the lamination direction of a flat tube by the pressure at the time of brazing, and the joining state of the flat tube and corrugated fin after brazing.

  Hereinafter, an embodiment of a manufacturing method of a corrugated fin lamination heat exchanger concerning the present invention is described based on a drawing.

<Outline configuration of outdoor unit>
FIG. 1 is a perspective view showing a schematic internal structure of an outdoor unit 1 having an outdoor heat exchanger 7 in which a method for manufacturing a corrugated fin laminated heat exchanger according to an embodiment of the present invention is employed. The outdoor unit 1 constitutes an air conditioner that performs air conditioning by a vapor compression refrigeration cycle. The outdoor unit 1 is connected to an indoor unit (not shown) via the refrigerant communication pipes 2 and 3. In the following description, the front side in FIG. 1 is referred to as “front surface”, the back side in FIG. 1 is referred to as “rear surface”, the left side in FIG. 1 is referred to as “left side”, and the right side in FIG. 1 is the “top surface”, and the lower side of FIG. 1 is the “bottom surface”.

  The indoor unit 2 mainly includes a substantially rectangular parallelepiped box-shaped unit casing 4, a compressor 6, an outdoor heat exchanger 7, and an outdoor fan 8. In addition to the above, the indoor unit 2 accommodates various devices, valves, refrigerant pipes, etc., but the description thereof is omitted here.

  The unit casing 4 mainly includes a bottom plate 41, a top plate 42 (illustrated by a two-dot chain line), a front plate 43 (illustrated by a two-dot chain line), a side plate 44 (illustrated by a two-dot chain line), a partition plate 45, have.

  The bottom plate 41 is a horizontally long, substantially rectangular plate-like member that constitutes the bottom surface portion of the unit casing 4. The peripheral edge of the bottom plate 41 is bent upward. On the outer surface of the bottom plate 41, two fixed legs 5 fixed to the field installation surface are provided. The fixed leg 5 extends from the front side of the unit casing 4 toward the rear side.

  The top plate 42 is a horizontally long and substantially rectangular plate-like member that constitutes the top surface portion of the unit casing 4.

  The front plate 43 is a plate-like member that mainly forms the front portion of the unit casing 4 and the front portion of the right side surface. The lower part of the front plate 43 is fixed to the bottom plate 41 with screws or the like. The front plate 43 is formed with an air outlet 43a. The blower outlet 43a is an opening for blowing outdoor air taken into the unit casing 4 through suction ports (not shown) formed on the back surface and the left side surface of the unit casing 4 (arrows A to A indicating airflow). See C).

  The side plate 44 is a plate-like member that mainly constitutes the rear portion and the right back portion of the right side surface of the unit casing 4. The lower part of the side plate 44 is fixed to the bottom plate 42 with screws or the like.

  The partition plate 45 is a plate-like member disposed on the bottom plate 41. The partition plate 45 extends vertically. The partition plate 45 is disposed so as to partition the internal space of the unit casing 4 into two left and right spaces (that is, the fan chamber S1 and the machine chamber S2). The lower part of the partition plate 45 is fixed to the bottom plate 41 with screws or the like.

  Thus, the internal space of the unit casing 4 is divided into the blower chamber S1 and the machine chamber S2 by the partition plate 45. The blower chamber S <b> 1 is a space surrounded by the bottom plate 41, the top plate 42, the front plate 43, and the partition plate 45. The machine room S <b> 2 is a space surrounded by the bottom plate 41, the top plate 42, the front plate 43, the side plate 44, and the partition plate 45. In the blower room S1, an outdoor heat exchanger 7 and an outdoor fan 8 are mainly disposed. A compressor 6 is mainly disposed in the machine room S2.

  The compressor 6 is a compressor for compressing a low-pressure refrigerant in the refrigeration cycle until it becomes a high-pressure refrigerant. The compressor 6 is an approximately vertical cylindrical hermetic compressor. The compressor 6 is disposed at the approximate center in plan view in the machine room S2.

  The outdoor heat exchanger 7 functions as a refrigerant radiator that uses outdoor air as a heat source during cooling, and functions as a refrigerant evaporator that uses outdoor air as a heat source during heating. The outdoor heat exchanger 7 has a corrugated fin laminated structure in which flat tubes and corrugated fins are alternately laminated in a plurality of stages in the vertical direction, and longitudinal ends of the plural flat tubes are inserted into a header tank. It is a heat exchanger. The outdoor heat exchanger 7 is bent so as to form a substantially L shape in plan view. The outdoor heat exchanger 7 is disposed in the blower chamber S <b> 2 so as to follow the left side surface and the back surface of the unit casing 4 and to surround the left side surface and the back surface side of the blower fan 8. The detailed configuration and manufacturing method of the outdoor heat exchanger 7 will be described later.

  The outdoor fan 8 takes air into the blower chamber S <b> 1 through suction ports (not shown) formed on the left side surface and the back surface of the unit casing 4, passes the outdoor heat exchanger 7, and then the front surface of the unit casing 4. It is a ventilation fan which functions so that it may blow off from the blower outlet 43a formed in this. Here, the outdoor fan 8 is a propeller fan, and is disposed downstream of the outdoor heat exchanger 7 in the blower chamber S1.

<Detailed configuration of outdoor heat exchanger>
Next, the detailed structure of the outdoor heat exchanger 7 which consists of a corrugated fin laminated heat exchanger is demonstrated using FIGS. Here, FIG. 2 is a diagram showing an appearance of the outdoor heat exchanger 7 before being bent into a substantially L shape in plan view. FIG. 3 is an enlarged perspective view of a portion D in FIG. FIG. 4 is a schematic view of FIG. 3 viewed from the arrow E side. FIG. 5 is a development view of the corrugated fin 21 before being bent into a corrugated shape. FIG. 6 is a view showing the vicinity of the insertion holes 42 and 52 of the header tanks 41 and 51.

  In the outdoor heat exchanger 7, the flat tubes 11 and the corrugated fins 21 are alternately stacked in a plurality of stages in the vertical direction, and the longitudinal ends of the plurality of flat tubes 11 are inserted into the header tanks 41 and 51. It is the comprised corrugated fin laminated heat exchanger. Here, the number of stacked layers of the flat tube 11 and the corrugated fins 21 is very large, 100 to 300.

  The flat tube 11 is composed of a tube having a wide flat surface portion 12 in a direction orthogonal to the longitudinal direction. The flat tube 11 has a width direction of the plane portion 12 between the up and down directions in a state where the plane portion 12 faces in the up and down direction (in FIG. 1, the directions of arrows A and B, in FIG. 2 and FIG. In FIG. 3, a plurality of stages are arranged with a ventilation space through which outdoor air flows in the direction of arrow E).

  The planar portion 12 is formed with a plurality of flow passage holes 13 arranged in the width direction so as to penetrate the planar portion 12 in the longitudinal direction. The refrigerant flows through each flow path hole 13. The flat tube 11 is made of a metal material such as aluminum and is manufactured by extrusion molding or the like. Thus, here, as the flat tube 11, a flat multi-hole tube in which a plurality of flow passage holes 13 are formed is adopted, and the heat transfer coefficient on the refrigerant side is improved.

  The corrugated fin 21 is a fin configured by bending a plate-like material P having a width dimension larger than the width dimension of the flat portion 12 of the flat tube 11 into a corrugated shape along the longitudinal direction of the flat tube 11. Here, when the width direction dimension of the plane part 12 is W1 and the width direction dimension of the corrugated fin 21 is W2, the relation of the width direction dimension W1 of the plane part 12 <the width direction dimension W2 of the corrugated fin 21 is established. The corrugated fin 21 is made of a metal material such as aluminum. The corrugated fin 21 has a fin body portion 22 and a fin edge portion 23.

  The fin main body portion 22 is a portion disposed in the ventilation space between the upper and lower directions of the flat portion 12, and the upper fin wave crest portion 24 and the lower fin portion 22 are bent by bending the plate-like material P into a waveform along the longitudinal direction of the flat tube 11. Side fin crests 25 are formed. The upper fin wave crest portion 24 is disposed within the width of the planar portion 12 among the bent portions of the plate material P, and is joined to the lower surface of the planar portion 12 by brazing. The lower fin wave crest portion 25 is disposed within the width of the planar portion 12 among the bent portions of the plate material P, and is joined to the upper surface of the planar portion 12 by brazing. Here, the upper fin wave crest 24 and the lower fin crest 25 are formed by bending the plate-like material P into a rectangular shape at the positions of the fold line X1 and the fold line X2. As a result, the upper fin wave crest portion 24 and the lower fin wave crest portion 25 are formed with flat surfaces facing the flat surface portion 12. In addition, in order to improve heat exchange efficiency, the fin main body portion 22 is formed with a plurality of main body side cut-up portions 26 by cutting up the central portion of the fin main body portion 22 in the vertical direction. Here, the main body side cut and raised portion 26 is cut and raised in a louver shape. And the main body side cut-and-raised part 26 is formed so that the inclination direction with respect to the outdoor air flow is reversed between the upstream portion and the downstream portion of the outdoor air flow.

  The fin edge portion 23 is a portion in which a part of the corrugated fin 21 protrudes in a direction orthogonal to the longitudinal direction of the flat tube 11. More specifically, the fin edge part 23 is a part which protrudes toward the width direction outward (here both width direction outer sides) of the flat tube 11 from each ventilation space. An upper fin bridge portion 27 and a lower fin bridge portion 28 are formed on the fin edge portion 23. When the upper fin bridge portion 27 and the lower fin bridge portion 28 are bent into a waveform along the longitudinal direction of the flat tube 11 to form the upper fin crest portion 24 and the lower fin crest portion 25, It is a part cut and raised in the vertical direction. The upper fin bridge portion 27 is arranged so as to protrude outward in the width direction of the plane portion 12 in the bent portion of the plate-shaped material P, and is cut and raised so as to protrude upward from the upper fin wave crest portion 24. It is a part. The lower fin bridge portion 28 is disposed so as to protrude outward in the width direction of the plane portion 12 in the bent portion of the plate-like material P, and is cut and raised so as to protrude downward from the lower fin crest portion 25. It is a part that has been. Here, the upper fin bridge portion 27 and the lower fin bridge portion 28 are formed by cuts Y1 and Y2 provided in the plate-like material P. The cut Y1 is a cut perpendicular to the folding lines X1 and X2 for forming the upper fin crest 24 and the lower fin crest 25. The cut Y2 is a cut extending obliquely from the cut Y1 outward in the width direction of the plate material P with respect to the folding lines X1 and X2 (that is, with respect to the width direction of the flat tube 11). Further, the upper fin bridge portion 27 and the lower fin bridge portion 28 are provided on the downstream side of the outdoor air flow in the fin edge portions 23 formed on both sides in the width direction of the flat tube 11 (in FIG. 1, the outdoor fan 8 side, 2 and FIG. 4, it is formed only on the fin edge portion 23 located on the front side of the paper surface and on the arrow E side in FIG. For this reason, the fin edge parts 23 adjacent to each other in the vertical direction are close to each other via the upper fin bridge part 27 and the lower fin bridge part 28. Further, in order to improve the heat exchange efficiency, the fin edge portion 23 is formed with a plurality of edge side raised portions 29a and 29b by cutting the central portion of the fin edge portion 23 in the vertical direction. The edge cut-and-raised portion 29 a located on the upstream side of the outdoor air flow is formed to have the same vertical width as that of the main body-side cut and raised portion 26. On the other hand, the edge cut-and-raised portion 29b located on the downstream side of the outdoor air flow is formed to have a shorter vertical width than the body-side cut and raised portion 26. Here, the edge cut and raised portions 29a and 29b are cut and raised in a louver shape. The edge cut-and-raised portions 29a and 29b are formed so that the inclination direction with respect to the outdoor air flow is reversed between the upstream portion and the downstream portion of the outdoor air flow. Thus, since the vertical width of the edge cut-and-raised part 29b is shorter than the body-side cut-and-raised part 26 in this case, the fin edge on which the upper fin bridge part 27 and the lower fin bridge part 28 are formed. A decrease in strength of the portion 23 is suppressed.

  The header tanks 41 and 51 have a function of supporting the flat tube 11, a function of flowing the refrigerant into the flat tube 11 (here, a plurality of flow path holes 13), and a flat tube 11 (here, a plurality of flow paths). And has a function of causing the refrigerant to flow out of the hole 13). The header tanks 41 and 51 are cylindrical members extending in the vertical direction, and the longitudinal ends of the flat tubes 11 arranged in the vertical direction are joined by brazing. Here, the header tank on the right side in FIG. 2 is a first header tank 41, and the header tank on the left side in FIG. 2 is a second header tank 51. The header tanks 41 and 51 are made of a metal material such as aluminum. The header tanks 41 and 51 are connected to other devices in the outdoor unit 1 such as the compressor 6 through a refrigerant pipe, but the description thereof is omitted here.

  The first header tank 41 has a plurality of insertion holes 42 for inserting the end portion 14 on the right side in the longitudinal direction of the flat tube 11 in FIG. 2 (ie, the stacking direction of the flat tube 11 and the corrugated fins 21). Are formed side by side. Further, the second header tank 51 has a plurality of insertion holes 52 for inserting the end 15 on the left side in the longitudinal direction of the flat tube 11 in FIG. 2 (ie, the lamination of the flat tube 11 and the corrugated fins 21). Direction). The longitudinal ends 14 and 15 of the flat tube 11 are joined to the header tanks 41 and 51 while being inserted into the insertion holes 42 and 52. Here, the hole pitch P of the insertion holes 42 and 52 is set so that the vertical interval between the longitudinal ends 14 and 15 of the two flat tubes 11 adjacent to each other with the corrugated fin 21 interposed therebetween is a predetermined interval Q. Is set. The predetermined interval Q is set to a value obtained by adding the maximum tolerance ΔHx of the design stacking direction width Ho to the design stacking direction width Ho which is the vertical dimension of the corrugated fin 21 determined in design. Here, the vertical dimension of the corrugated fin 21, that is, the width in the stacking direction of the corrugated fin 21 refers to the distance in the vertical direction between the upper fin wave crest 24 and the lower fin wave crest 25. Therefore, the hole pitch P is set to a value obtained by adding the stacking direction width h which is the vertical dimension of the flat tube 11 to the predetermined interval Q.

  In the outdoor heat exchanger 7 having the above configuration, when functioning as a refrigerant radiator during cooling, the refrigerant flowing in the flat tube 11 and the outdoor air as a cooling source flowing in the ventilation space so as to cross the flat tube 11 Performs heat exchange via the corrugated fins 21 and the flat tubes 11. Thereby, heat dissipation of the refrigerant is performed. When the outdoor heat exchanger 7 functions as a refrigerant evaporator, the refrigerant flowing in the flat tube 11 and the outdoor air as a heating source flowing in the ventilation space so as to cross the flat tube 11 are corrugated fins 21 and Heat exchange is performed through the flat tube 11. Thereby, the refrigerant is evaporated. At this time, dew condensation water is generated on the surface of the corrugated fin 21, but the dew condensation is formed via the fin edge portion 23 because the fin edge portion 23 is formed to protrude downstream of the outdoor air flow of the outdoor heat exchanger 7. Water can flow down. In particular, here, as described above, the fin edge portion 23 has the fin bridge portions 27 and 28 that are cut and raised so as to protrude in the vertical direction from the fin wave crest portions 24 and 25, and is adjacent to the vertical direction. The matching fin bridge portions 27 and 28 are close to each other. For this reason, the drainage performance of the corrugated fin 21 is improved.

  Further, in the outdoor heat exchanger 7 having the above-described configuration, the vertical interval at the longitudinal ends 14 and 15 of the two flat tubes 11 adjacent to each other with the corrugated fin 21 interposed therebetween is the predetermined interval Q. The hole pitch P of the insertion holes 42 and 52 of the header tanks 41 and 51 is set. On the other hand, the stacking direction width H of the actually manufactured corrugated fins 21 varies within a predetermined dimensional tolerance (maximum tolerance ΔHx) with respect to the design stacking direction width Ho. The predetermined interval Q is a value obtained by adding the maximum tolerance ΔHx of the designed stacking direction width Ho to the designed stacking direction width Ho, and thus is larger than the stacking direction width H of the corrugated fins 21. However, as will be described later, the outdoor heat exchanger 7 is manufactured by brazing in a state where a gap between the flat tubes 11 and the corrugated fins 21 is pressed from the stacking direction. That is, in the outdoor heat exchanger 7, a gap corresponding to the difference between the actual dimensional tolerance of the corrugated fin 21 and the maximum tolerance ΔHx is generated between the flat tube 11 and the corrugated fin 21 before brazing. However, after brazing, there is no such gap. For this reason, the outdoor heat exchanger 7 has a shape in which the center portion in the longitudinal direction of the flat tube 11 is recessed closer to the center in the stacking direction (that is, the vertical direction) than the end portions 14 and 15 in the longitudinal direction ( (See FIG. 2).

<Manufacturing method of outdoor heat exchanger>
Next, the manufacturing method of the outdoor heat exchanger 7 which consists of a corrugated fin laminated heat exchanger is demonstrated using FIG.1, FIG.2, FIG.4 and FIG. Here, FIG. 7 is a diagram illustrating a manufacturing process of the outdoor heat exchanger 7 (an arrangement process of the flat tube 11). FIG. 8 is a diagram showing a manufacturing process of the outdoor heat exchanger 7 (insertion process of the header tanks 41 and 51). FIG. 9 is a diagram illustrating a manufacturing process of the outdoor heat exchanger 7 (an insertion process of the corrugated fins 21). FIG. 10 is a schematic enlarged view of a portion G in FIG. FIG. 11 is a diagram illustrating a manufacturing process of the outdoor heat exchanger 7 (a brazing process of the heat exchanger core temporary assembly 7a). FIG. 12 is a diagram showing the relationship between the deformation amount in the stacking direction of the flat tubes 11 due to pressing during brazing and the bonding state between the flat tubes 11 and the corrugated fins 21 after brazing.

  First, as many straight pipes 11 as necessary for a predetermined number of stacked stages (100 to 300 stages) are prepared. A plurality of flat tubes 11 are arranged side by side with a predetermined interval Q between the vertical directions (that is, the stacking direction of the flat tubes 11 and the corrugated fins 21) with the flat portion 12 facing the vertical direction (see FIG. 7). Specifically, the longitudinal ends 14 and 15 of the plurality of flat tubes 11 are arranged to match the hole pitch P of the insertion holes 42 and 52 of the header tanks 41 and 51.

  Next, the longitudinal ends 14 and 15 of the plurality of flat tubes 11 are inserted into the header tanks 41 and 51 (see FIG. 8). Specifically, the longitudinal ends 14 and 15 of the plurality of flat tubes 11 are brought closer to the longitudinal ends 14 and 15 of the plurality of flat tubes 11 from the direction of the arrow F in FIG. Is inserted into the insertion holes 42 and 52 of the header tanks 41 and 51.

  At this time, the plurality of flat tubes 11 are inserted into the header tanks 41 and 51 in a state where the corrugated fins 21 are not disposed between the flat tubes 11. Therefore, unlike the conventional manufacturing method in which a plurality of flat tubes and corrugated fins are stacked in a header tank, the header tanks 41 and 51 are all at the same time without being affected by the dimensional tolerance of the corrugated fins 21. And it can insert reliably. Moreover, since the longitudinal ends 14 and 15 of the plurality of flat tubes 11 are arranged so as to match the hole pitch P of the insertion holes 42 and 52 of the header tanks 41 and 51, the lengths of the plurality of flat tubes 11 are The operation | work which inserts the direction edge parts 14 and 15 into the header tanks 41 and 51 simultaneously can be performed smoothly. Thereby, even if the number of stacked stages is increased, a plurality of flat tubes 11 can be inserted into the header tanks 41 and 51. In particular, here, the number of stacking stages is 100 or more, and in the conventional manufacturing method, accumulation of dimensional tolerances in the stacking direction of the corrugated fins 21 becomes remarkable. 11 can be securely inserted into the header tanks 41 and 51.

  Next, the corrugated fins 21 are inserted between the flat tubes 11 to form the heat exchanger core temporary assembly 7a. Specifically, the corrugated fins 21 are inserted between the flat tubes 11 from the front side of the drawing in FIG. 9 toward the back side of the drawing.

  At this time, the predetermined interval Q between the flat tubes 11 is set to a value obtained by adding the maximum tolerance ΔHx of the design stacking direction width Ho to the design stacking direction width Ho, so that the corrugated fins 21 are stacked between the flat tubes 11. The predetermined interval Q equal to or greater than the direction width H is vacant. For this reason, the corrugated fins 21 can be reliably inserted despite the fact that the plurality of flat tubes 11 have been inserted into the header tanks 41 and 51. Thereby, the heat exchanger core temporary assembly 7a in a state in which the longitudinal ends 14 and 15 of the plurality of flat tubes 11 are inserted into the header tanks 41 and 51 and the corrugated fins 21 are inserted between the flat tubes 11 is obtained. can get. Note that, in the state of the heat exchanger core temporary assembly 7a, the plurality of flat tubes 11 are different from those after the manufacture of the outdoor heat exchanger 7 in FIG. It is not in a shape recessed toward the center in the stacking direction (that is, the vertical direction).

  Next, the heat exchanger core temporary assembly 7a is joined by brazing. Specifically, the heat exchanger core temporary assembly 7a is put into a brazing furnace, and brazing is performed between the flat tube 11 and the corrugated fins 21 or between the flat tube 11 and the header tanks 41 and 51. The flat tube 11 and the corrugated fin 21 are joined by brazing between the flat surface portion 12 and the wave crest portions 45 and 25. Further, the flat tube 11 and the header tanks 41 and 51 are joined by brazing the longitudinal end portions 14 and 15 and the peripheral portions of the insertion holes 42 and 52.

  At this time, the brazing of the heat exchanger core temporary assembly 7a is a state in which the heat exchanger core temporary assembly 7a is pressed in the stacking direction in order to improve the bonding state between the flat tube 11 and the corrugated fins 21 (FIG. 11). (See arrow K). Here, as described above, after inserting the longitudinal ends 14 and 15 of the plurality of flat tubes 11 into the header tanks 41 and 51, the corrugated fins 21 are inserted between the flat tubes 11 and the heat exchanger core temporary assembly 7a. The manufacturing method which forms is adopted. For this reason, a gap is easily generated between the flat tube 11 and the corrugated fins 21 constituting the heat exchanger core temporary assembly 7a due to the predetermined interval Q between the flat tubes 11 (see FIG. 10). ). For this reason, the space | interval between the flat tubes 11 becomes small from the predetermined space | interval Q to the lamination direction width | variety H of the waveform fin 21 by the press at the time of brazing (refer FIG.4 and FIG.10). The flat plate-shaped outdoor heat exchanger 7 manufactured in this way has a shape in which the center portion in the longitudinal direction of the flat tube 11 is recessed closer to the center in the stacking direction than the end portions 14 and 15 in the longitudinal direction (see FIG. 2).

  However, when the heat exchanger core temporary assembly 7a is brazed, if the pressure in the stacking direction of the heat exchanger core temporary assembly 7a becomes excessive, the degree of the depression in the central portion of the flat tube 11 in the longitudinal direction becomes large. After the brazing, the corrugated fin 21 and the flat tube 11 may be peeled off.

  Therefore, here, the flat tube 11 positioned at the ends in the stacking direction (that is, the upper end and the lower end of the heat exchanger core temporary assembly 7a) of the flat tubes 11 constituting the heat exchanger core temporary assembly 7a is stacked in the stacking direction. The heat exchanger core temporary assembly 7a is brazed so as to be pressed in the stacking direction so that the deformation amount L of the heat flux is 1.2 mm or less. Here, the deformation amount L is the distance in the vertical direction (that is, the stacking direction) from the longitudinal ends 14 and 15 of the flat tube 11 to the central portion in the longitudinal direction of the flat tube 11. Thereby, peeling with the flat tube 11 and the corrugated fin 21 after brazing can be made hard to produce. Note that the deformation amount L in the laminating direction of the flat tube 11 due to pressing during brazing is limited to 1.2 mm or less because the flat tube 11 due to pressing during brazing shown in FIG. This is based on the relationship between the deformation amount L and the joined state of the flattened tube 11 and the corrugated fin 21 after brazing. This relationship is obtained from the experimental results of investigating the joining state of the flat tube and the corrugated fin when brazing is performed by changing the deformation amount L by pressing of the heat exchanger core temporary assembly from 0.4 to 3 mm. It is a thing. According to this experimental result, it can be seen that if brazing is performed with the deformation amount L limited to 1.2 mm or less, brazing can be performed satisfactorily without causing separation between the flat tube and the corrugated fins.

  Next, the outdoor heat exchanger 7 is completed by bending the flat plate-shaped outdoor heat exchanger 7 into a substantially L shape in plan view using a bending apparatus.

  In the above manufacturing method, the flat tube 11 is inserted into the header tanks 41 and 51 in a state where the corrugated fins 21 are not disposed between the flat tubes 11. For this reason, the flat tube 11 can be reliably inserted into the header tanks 41 and 51 without being affected by the dimensional tolerance of the corrugated fins 21. Thereby, even if the number of stacked stages is increased (here, 100 to 300 stages), a plurality of flat tubes 11 can be inserted into the header tanks 41 and 51.

  In the above manufacturing method, the predetermined interval Q between the flat tubes 11 is set to a value obtained by adding the maximum tolerance ΔHx to the design stacking direction width Ho of the corrugated fins 21. For this reason, the corrugated fin 21 can be reliably inserted between the flat tubes 11 after the plurality of flat tubes 11 are inserted into the header tanks 41 and 51.

  Furthermore, in the above manufacturing method, the deformation L in the stacking direction is 1.2 mm or less for the flat tube 11 positioned at the end in the stacking direction among the flat tubes 11 constituting the heat exchanger core temporary assembly 7a. In addition, the heat-exchange core temporary assembly 7a is brazed while being pressed in the stacking direction. For this reason, peeling between the corrugated fin 21 and the flat tube 11 after brazing can be made difficult to occur.

<Other embodiments>
As mentioned above, although embodiment of this invention was described based on drawing, a specific structure is not restricted to these embodiment, It can change in the range which does not deviate from the summary of invention.

(A)
In the outdoor heat exchanger 7 as the corrugated fin laminated heat exchanger of the above embodiment, the shape of the fin bridge portions 27 and 28 is a substantially triangular cut and raised formed by the oblique notch Y2 with respect to the folding lines X1 and X2. However, it is not limited to this. For example, it may be a cut-and-raised shape of another shape such as a substantially rectangular cut-and-raised shape formed by a cut parallel to the folding lines X1 and X2 or a step-like cut.

(B)
In the outdoor heat exchanger 7 as the corrugated fin laminated heat exchanger of the above embodiment, the fin bridge portions 27 and 28 are formed. However, the present invention is not limited to this, and the fin bridge portions 27 and 28 are not limited thereto. It may not have.

(C)
In the outdoor heat exchanger 7 as the corrugated fin laminated heat exchanger of the above embodiment, the fin wave crests 24 and 25 of the corrugated fin 21 have a flat surface facing the flat portion 12 of the flat tube 11. However, the present invention is not limited to this. For example, other surface shapes, such as what has the curved surface which protrudes in the plane part 12 side of the flat tube 11, may be sufficient.

(D)
The outdoor unit 1 in which the outdoor heat exchanger 7 as the corrugated fin laminated heat exchanger of the above embodiment is employed was of a horizontal blowing type in which outdoor air flows in from the side surface and the back surface and blows out from the front surface. It is not limited to. For example, other forms such as a top blowing type in which outdoor air flows in from the side surface or the back surface and blows out from the top surface may be used.

  The present invention is widely applicable to a method for manufacturing a corrugated fin laminated heat exchanger.

7 Outdoor heat exchanger (corrugated fin laminated heat exchanger)
7a Heat exchanger core temporary assembly 11 Flat tube 12 Flat portion 14, 15 Longitudinal end portion of flat tube 21 Corrugated fin 41, 51 Header tank Ho Lamination direction width L Deformation Q Predetermined interval ΔHx Maximum tolerance

JP 2010-2138 A

Claims (3)

A flat tube (11) arranged in a state where the wide flat surface portion (12) faces in the up-down direction and a corrugated fin (21) bent into a corrugated shape are alternately stacked in a plurality of stages in the vertical direction, A method for manufacturing a corrugated fin laminated heat exchanger (7) configured by inserting longitudinal ends (14, 15) of the plurality of flat tubes into a header tank (41, 51),
A maximum tolerance of the width in the stacking direction in the stacking direction width (Ho) which is a dimension in the stacking direction of the flat tube and the corrugated fin of the corrugated fin in the stacking direction of the flat tube and the corrugated fin. (ΔHx) plus a predetermined interval (Q) arranged side by side,
Inserting the longitudinal ends of the plurality of flat tubes into the header tank;
Inserting the corrugated fin between the flat tubes to form a heat exchanger core temporary assembly (7a);
Bonding by brazing the heat exchanger core temporary assembly,
Manufacturing method of corrugated fin laminated heat exchanger. The number of stacked layers of the flat tube (11) and the corrugated fin (21) is 100 to 300.
The manufacturing method of the corrugated fin lamination | stacking heat exchanger of Claim 1 . The brazing of the heat exchanger core temporary assembly (7a) is performed at the end in the stacking direction of the flat tube and the corrugated fin (21) of the flat tube (11) constituting the heat exchanger core temporary assembly. About the flat tube located in the state where the flat tube and the corrugated fin are pressed in the stacking direction of the flat tube and the corrugated fin so that the deformation (L) in the stacking direction of the flat tube and the corrugated fin is 1.2 mm or less Done in
The manufacturing method of the corrugated fin lamination | stacking heat exchanger of Claim 1 or 2 .

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