JP6841196B2 - Heat exchanger and its manufacturing method - Google Patents

Description

The present invention relates to a heat exchanger and a method for manufacturing the same.

Patent Document 1 discloses a heat exchanger in which a heat exchange core and a tank main body are caulked and fixed. In this heat exchanger, the heat exchange core has a caulking plate that is caulked and fixed to the tank body. At the time of caulking fixing, a pressing portion is formed by deforming a part of the caulking plate. The formed pressing portion and the other part of the caulking plate sandwich and hold the held portion of the tank main body portion in the first direction. As a result, the heat exchange core and the tank body are caulked and fixed.

The caulking plate is formed with an opening for forming a pressing portion. A holding portion is formed by deforming a portion of the caulking plate adjacent to the opening in the first direction toward the tank body portion. This opening extends in a second direction that intersects the first direction.

U.S. Patent Application Publication No. 4331201

By the way, the present inventor has analyzed the strength of the caulking plate in a state where the heat exchange core and the tank main body are caulked and fixed. As a result, depending on the positional relationship between the starting point of deformation of the pressing portion and the end portion of the opening portion in the second direction, it is found that the strength of the caulking plate is significantly reduced in the peripheral portion of the end portion of the opening portion. It was issued.

In view of the above points, it is an object of the present invention to provide a heat exchanger capable of suppressing a decrease in strength of a caulking plate and a method for manufacturing the same.

In order to achieve the above object, the invention according to claim 1 is
A heat exchanger that exchanges heat between the first fluid and the second fluid.
A heat exchange core (12) forming a first flow path (24b) through which the first fluid flows and a second flow path (24a) through which the second fluid flows,
It is provided with a tank body (14) that forms a tank space (14a) connected to the first flow path.
The heat exchange core has a caulking plate (16) that is caulked and fixed to the tank body.
The caulking plate has a first wall portion (164) extending in the first direction (D1) and covering the outside of the tank body portion, and a second wall portion (166) connected to one side of the first wall portion in the first direction. And have
The first wall portion has a pressing portion (30) provided on the other side of the first wall portion in the first direction to press the held portion (142) of the tank main body portion.
The holding portion and the second wall portion hold the held portion of the tank main body by sandwiching it in the first direction.
The tank main body has a recess (32) in which the holding portion is located inside, in a portion different from the held portion.
The recess has two recess start portions (34, 36) aligned in a second direction (D2) intersecting the first direction and a bottom portion (38) located between the two recess start portions.
An opening (40) is formed next to one side of the first wall portion in the first direction of the pressing portion.
The holding portion is a portion of the first wall portion adjacent to the opening in the first direction, and the bottom portion of the recess is defined as two starting points (302, 304) at positions in contact with each of the two recess start portions. It is the part that bends toward
The length (L1) of the opening in the second direction is longer than the distance (L2) between the two recess start portions.
One starting point (302) of the two starting points is from one end (44) located on the same side as the starting point of one of the two ends of the opening in the second direction. Separated in the second direction.

Here, when the length of the opening in the second direction is the same as the distance between the two recess start portions, one starting point of the pressing portion and one end of the opening are at the same position in the second direction. Become. In this case, when stress is applied to the caulking plate, stress concentration occurs in the peripheral portion of the caulking plate at the end of the opening. As described above, it has been found by the present inventor that the strength of the peripheral portion of the caulking plate at the end of the opening is significantly reduced.

Therefore, in the heat exchanger of the invention according to claim 1, the length of the opening in the second direction is longer than the distance between the two recess start portions. Then, one starting point of the pressing portion is separated from one end of the opening in the second direction. According to this, when stress is applied to the caulking plate, it is possible to suppress the stress concentration that occurs in the peripheral portion of the caulking plate at the end of the opening. Therefore, it is possible to suppress a decrease in the strength of the caulking plate.

The invention according to claim 3 is a heat exchange core (12) forming a first flow path (24b) through which the first fluid flows and a second flow path (24a) through which the second fluid flows, and a first. A method for manufacturing a heat exchanger, which comprises a tank body portion (14) forming a tank space (14a) connected to a flow path and exchanges heat between a first fluid and a second fluid.
It has a caulking plate (16) that is caulked and fixed to the tank body, and the caulking plate has a first wall portion (164) extending in the first direction (D1) and one side of the first wall portion in the first direction. To prepare a heat exchange core having a second wall portion (166) connected to the first wall portion and having an opening (40) for forming a holding portion formed in the first wall portion.
It has recesses (32) for forming a pressing portion, and the recesses are two recess start portions (34, 36) arranged in a second direction (D2) intersecting with the first direction, and two recess start portions. To prepare a tank body having a bottom (38) located between them,
By arranging the first wall portion at a position where the first wall portion of the caulking plate covers the outside of the tank body portion, and assembling the heat exchange core and the tank body portion,
The part of the first wall of the caulking plate that is adjacent to the opening in the first direction is pushed toward the bottom of the recess of the tank body, and the positions where the two recesses start are in contact with each of the two starting points ( As 302, 304), the portion adjacent to the opening is bent toward the bottom to form the holding portion (30), and the holding portion (142) of the tank main body portion is formed by the pressing portion and the second wall portion. Including crimping and fixing the heat exchange core and the tank body by sandwiching and holding in one direction.
In preparing the heat exchange core, prepare a heat exchange core in which the length (L1) of the opening in the second direction is longer than the distance (L2) between the two recess start portions.
In caulking, at least one of the two origins (302) is located on the same side in the second direction as the origin of one of the two ends of the opening in the second direction. The portion adjacent to the opening is bent so that it is located away from one end (402) in the second direction.

Here, when the length of the opening in the second direction is the same as the distance between the two recess start portions, one starting point of the pressing portion and one end of the opening are at the same position in the second direction. Become. In this case, when stress is applied to the caulking plate, stress concentration occurs in the peripheral portion of the caulking plate at the end of the opening. As described above, it has been found by the present inventor that the strength of the peripheral portion of the caulking plate at the end of the opening is significantly reduced.

Therefore, in the method for manufacturing a heat exchanger according to the third aspect of the present invention, a heat exchange core in which the length of the opening in the second direction is longer than the distance between the two recess start portions is used. Then, the portion adjacent to the opening is bent so that one starting point of the pressing portion is located at a position separated from one end of the opening in the second direction. According to this, when stress is applied to the caulking plate, it is possible to suppress the stress concentration that occurs in the peripheral portion of the caulking plate at the end of the opening. Therefore, it is possible to suppress a decrease in the strength of the caulking plate.

In addition, the reference numerals in parentheses of each means described in this column and the scope of claims are an example showing the correspondence with the specific means described in the embodiment described later.

It is a top view of the heat exchanger in 1st Embodiment. FIG. 2 is a cross-sectional view taken along the line II-II of FIG. It is a perspective view of a part of a heat exchanger seen in the direction of arrow III of FIG. It is a top view of a part of the heat exchanger seen in the direction of the IV arrow of FIG. It is an enlarged view of the V part of FIG. FIG. 6 is a plan view of the tank main body in FIG. 4 as viewed from the other side in the first direction. It is a figure for demonstrating the manufacturing method of the heat exchanger in 1st Embodiment, and is the sectional view of the heat exchanger in the state before being caulked and fixed. It is a figure for demonstrating the manufacturing method of the heat exchanger in 1st Embodiment, and is the perspective view of a part of the heat exchanger in the state before caulking and fixing. It is a perspective view which shows a part of the heat exchanger of the comparative example 1. FIG. 9 is a perspective view of the caulking plate in FIG. 9 as viewed in the direction of the X arrow. It is a figure which shows the stress distribution of the XI part in FIG. It is a perspective view which looked at the caulking plate in FIG. 3 in the direction of the XII arrow. It is a figure which shows the stress distribution of part XIII in FIG.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In each of the following embodiments, parts that are the same or equal to each other will be described with the same reference numerals.

(First Embodiment)
The heat exchanger 10 of the present embodiment shown in FIG. 1 is an intercooler that cools the intake air by exchanging heat between the intake air that has been pressurized by a supercharger and becomes hot and the cooling water.

As shown in FIG. 1, the heat exchanger 10 includes a heat exchange core 12 and a tank body 14. The heat exchange core 12 exchanges heat between the intake air and the cooling water. The heat exchange core 12 is made of a metal having high thermal conductivity such as aluminum.

In the tank main body 14, the intake air flowing into the heat exchange core 12 or the intake air flowing out from the heat exchange core 12 flows. The tank body 14 is made of synthetic resin. The tank body 14 may be made of metal. The heat exchange core side of the tank body 14 is joined to the heat exchange core 12 via the caulking plate 16. The opposite side of the tank body 14 on the heat exchange core side is connected to a supercharger (not shown) or an intake port of an engine (not shown) via a hose or the like.

The heat exchange core 12 has a caulking plate 16. The caulking plate 16 is a component of the heat exchange core 12. The caulking plate 16 is caulked and fixed to the tank body 14. Caulking fixing is the joining of a plurality of parts by plastic working a part of the plurality of parts. Therefore, the caulking plate 16 is a joining plate that joins the heat exchange core 12 and the tank body 14.

The heat exchange core 12 has an inlet pipe 18 and an outlet pipe 20. The inlet pipe 18 constitutes the inlet of the cooling water of the heat exchange core 12. The inlet pipe 18 is connected to a pipe (not shown) in which cooling water flows toward the heat exchange core 12. The outlet pipe 20 constitutes an outlet for the cooling water of the heat exchange core 12. The outlet pipe 20 is connected to a pipe (not shown) through which the cooling water flowing out of the heat exchange core 12 flows.

As shown in FIG. 2, the heat exchange core 12 has a housing 22, a plurality of tubes 24, and a plurality of fins 26. The housing 22 forms the outer shell of the heat exchange core 12. The housing 22 contains a laminated body in which a plurality of tubes 24 and a plurality of fins 26 are laminated. Each of the plurality of tubes 24 forms a tube inner space 24a inside. Each of the plurality of tubes 24 is laminated with a gap from each other. Each of the plurality of fins 26 is arranged between adjacent tubes 24 among the plurality of tubes 24. Each of the plurality of fins 26 is brazed to each of the plurality of tubes 24.

The tube outer space 24b on the outer side of the plurality of tubes 24 in the inside of the housing 22 is an intake flow path through which intake air flows. Each tube inner space 24a of the plurality of tubes 24 is a cooling water flow path through which cooling water flows. The plurality of fins 26 promote heat exchange between the intake air and the cooling water by increasing the heat transfer area on the intake side. In this embodiment, the intake air corresponds to the first fluid. The intake flow path corresponds to the first flow path through which the first fluid flows. The cooling water corresponds to the second fluid. The cooling water flow path corresponds to the second flow path through which the second fluid flows.

The tank body 14 forms a tank space 14a inside. The tank space 14a is connected to the tube outer space 24b.

The caulking plate 16 is joined to the housing 22 by brazing. The caulking plate 16 has an inner wall portion 162, an outer wall portion 164, and a bottom wall portion 166. The outer wall portion 164 is located outside the tank main body portion 14 with respect to the inner wall portion 162. The outer wall portion 164 faces the inner wall portion 162 with a gap. The bottom wall portion 166 extends in a direction intersecting the inner wall portion 162 and the outer wall portion 164. The bottom wall portion 166 connects the inner wall portion 162 and the outer wall portion 164. The inner wall portion 162, the outer wall portion 164, and the bottom wall portion 166 form a groove portion having a U-shaped cross section.

The inner wall portion 162 of the caulking plate 16 is brazed to the flat plate-shaped end portion 222 of the housing 22. Alternatively, the bottom wall portion 166 of the caulking plate 16 is brazed to the end portion 224 having an L-shaped cross section of the housing 22.

The inner wall portion 162 and the outer wall portion 164 extend from the bottom wall portion 166 in the first direction D1. The bottom wall portion 166 is connected to one end of the inner wall portion 162 and the outer wall portion 164 in the first direction D1. The first direction D1 is the stretching direction of each of the plurality of tubes 24. In other words, the first direction D1 is the alignment direction of the heat exchange core 12 and the tank main body 14. As shown in FIG. 2, one side of the first direction D1 is the heat exchange core side. The other side, which is the opposite side of the first direction D1, is the tank body side. In the present embodiment, the outer wall portion 164 corresponds to the first wall portion extending in the first direction. The bottom wall portion 166 corresponds to a second wall portion connected to one side in the first direction of the first wall portion.

Further, the heat exchanger 10 includes packing 28. The packing 28 is a sealing member that seals the joint portion between the heat exchange core 12 and the tank main body portion 14. The packing 28 is made of an elastic member such as synthetic rubber.

The packing 28 and the end portion 142 of the tank main body portion 14 are arranged between the inner wall portion 162 and the outer wall portion 164. In this state, the outer wall portion 146 covers the outside of the tank main body portion 14.

The outer wall portion 164 has a plurality of caulking portions 30. Each caulking portion 30 is provided on the other side of the outer wall portion 164 in the first direction D1. The caulking portion 30 is a portion of the outer wall portion 164 that is plastically deformed in order to caulk and fix the caulking plate 16 to the tank main body portion 14. Each of the caulked portion 30 and the bottom wall portion 166 holds the end portion 142 of the tank main body portion 14 sandwiched in the first direction D1. Therefore, the end portion 142 of the tank main body portion 14 is a held portion. Further, each crimped portion 30 presses the end portion 142 of the tank main body portion 14 in a state where the packing 28 is compressed in the first direction D1. Therefore, each caulking portion 30 is a pressing portion that presses the end portion 142 of the tank main body portion 14.

FIG. 3 is a perspective view of the tank body 14 and the caulking plate 16 in a crimped and fixed state. FIG. 4 is a side view of the tank body 14 and the caulking plate 16 in a crimped state. In FIGS. 3 and 4, the heat exchange core 12 is not shown. As shown in FIG. 3, the tank main body portion 14 has a plurality of recesses 32 in a portion covered by the outer wall portion 164 of the caulking plate 16. The plurality of recesses 32 are formed in a portion of the tank body 14 that is different from the end 142 of the tank body 14 in the first direction D1. Each of the plurality of caulking portions 30 is located inside each of the plurality of recesses 32.

As shown in FIGS. 3 and 4, a plurality of slits 40 are formed in the caulking plate 16. Each slit 40 is an opening formed on one side of the outer wall portion 164 in the first direction D1 of each caulking portion 30, that is, adjacent to the bottom wall portion 166 side. Each slit 40 is formed to define the position of each crimped portion 30 in the first direction D1.

As shown in FIG. 4, each slit 40 has a shape extending in the second direction D2 on the outer surface 164a of the outer wall portion 164. The second direction D2 is a direction that intersects the first direction D1. The second direction D2 is a direction along the periphery of the wall portion of the tank main body portion 14 connected to the heat exchange core 12. On the outer surface 164a of the outer wall portion 164, the ends 44 and 46 of the slit 40 in the second direction D2 have a rounded shape. The ends 44 and 46 of the slit 40 in the second direction D2 face each other in the second direction D2.

The slit 40 will be described in detail. As shown in FIG. 5, the slit 40 has a slit space 401 and a slit forming surface 402 forming the slit space 401. The slit forming surface 402 surrounds the slit space 401. The main surface 403 located on the other side of the first direction D1 of the slit forming surface 402 forms a straight side 42 on the outer surface 164a of the outer wall portion 164. The end surfaces 404 and 405 of the slit forming surface 402 located at both ends of the second direction D2 form curved sides 44 and 46 on the outer surface 164a of the outer wall portion 164. On the outer surface 164a of the outer wall portion 164, the portions having curved sides forming the outer shape of the slit 40 are the ends 44 and 46 of the slit 40 in the second direction D2.

Of the plurality of caulking portions 30, the caulking portion 30 shown in the V portion of FIG. 3 will be described with reference to FIG. The caulking portion 30 is located outside the outer wall portion 164 of the tank main body portion 14 in the circumferential direction.

As shown in FIG. 5, the recess 32 has two recess start portions 34, 36 and a bottom portion 38 located between the two recess start portions 34, 36. The two recess start portions 34 and 36 are aligned in the second direction D2. Each of the dent start portions 34 and 36 is a portion of the wall surface 144 of the tank main body portion 14 where the dent is started. The portion where the dent is started is the portion where the dent starts to bend from a flat surface.

FIG. 6 is a view when the recess 32 is viewed from the other side of the first direction D1, that is, from the upper side of FIG. FIG. 6 illustrates a virtual surface V1 that covers the recess 32. The virtual surface V1 is a surface of the wall surface 144 of the tank main body 14 in which the portion where the recess 32 is not formed is extended toward the recess 32. The portions where the virtual surface V1 and the recess 32 are in contact with each other are the two recess start portions 34 and 36.

As shown in FIG. 5, the caulking portion 30 is a portion of the outer wall portion 164 adjacent to the slit 40 in the first direction D1. The caulking portion 30 is a portion of the outer wall portion 164 that is bent toward the bottom 38 of the recess 32, with the positions of the recess 32 in contact with the two recess start portions 34 and 36 as the two starting points 302 and 304. is there. In other words, the crimped portion 30 is a portion between the two starting points 302 and 304, and is a portion protruding toward the recess 32 of the tank main body portion 14.

Here, one of the two recess start portions 34 and 36 is the first recess start portion 34, and the other of the two recess start portions 34 and 36 is the second recess start portion 36. One of the two ends 44, 46 in the second direction D2 of the slit 40 is the first end 44, and the other of the two ends 44, 46 is the second end 46. One of the two starting points 302 and 304 is the first starting point 302, and the other of the two starting points 302 and 304 is the second starting point 304.

The first recess start portion 34, the first end portion 44, and the first start point portion 302 are located on the same side in the second direction. That is, the side where the first starting point 302 of the two starting points 301 and 302 is located in the second direction and the side where the first end 44 of the two endings 44 and 46 are located in the second direction are two. The dent start portions 34, 36 are the same as the side where the first dent start portion 34 is located in the second direction. In the present embodiment, the first starting point 302 corresponds to one starting point of the two starting points. The first end 44 corresponds to one of the two ends of the opening in the second direction that is located on the same side as the starting point of one in the second direction.

In the present embodiment, the length L1 of the slit 40 in the second direction D2 is longer than the distance L2 between the two recess start portions 34 and 36 of the recess 32. Further, the first recess start portion 34 of the recess 32 is separated from the first end portion 44 of the slit 40 in the second direction D2. Therefore, the first starting point 302 of the caulking portion 30 corresponding to the first recessing start portion 34 of the recess 32 is separated from the first end 44 of the slit 40 in the second direction D2.

The first starting point 302 of the caulking portion 30 is located outside the second starting point 304 of the outer wall portion 164 shown in FIG. 5 in the circumferential direction of the tank main body 14. In other words, the first starting point 302 of the caulking portion 30 is located closer to the corner of the tank body 14 than the second starting point 304.

Further, the second recess start portion 36 of the recess 32 is at the same position in the second direction D2 with respect to the second end portion 46 of the slit 40. Therefore, the second starting point 304 of the caulking portion 30 corresponding to the second recessing start portion 36 of the recess 32 is at the same position in the second direction D2 with respect to the second end portion 46 of the slit 40.

Next, a method of manufacturing the heat exchanger 10 of the present embodiment will be described with reference to FIGS. 7 and 8. FIG. 7 corresponds to FIG. FIG. 8 corresponds to FIG. In FIG. 8, the heat exchange core 12 is not shown.

First, the heat exchange core 12 shown in FIG. 7 is prepared. At this time, the heat exchange core 12 has a caulking plate 16 that is caulked and fixed to the tank body 14. The caulking plate 16 has an inner wall portion 162, an outer wall portion 164, and a bottom wall portion 166. The outer wall portion 164 is formed with a slit 40 for forming the caulking portion 30. As shown in FIGS. 7 and 8, the caulking portion 30 is not formed on the outer wall portion 164.

Further, the tank main body 14 shown in FIGS. 7 and 8 is prepared. At this time, the tank main body portion 14 has a recess 32 for forming the caulking portion 30. The recess 32 has two recess start portions 34 and 36 and a bottom portion 38.

Subsequently, the heat exchange core 12 and the tank body 14 are assembled. At this time, as shown in FIGS. 7 and 8, the outer wall portion 164 is arranged at a position where the outer wall portion 164 of the caulking plate 16 covers the outside of the tank main body portion 14. More specifically, as shown in FIG. 7, the packing 28 and the end portion 142 of the tank main body portion 14 are arranged in the space surrounded by the inner wall portion 162, the outer wall portion 164, and the bottom wall portion 166 of the caulking plate 16. To do.

Subsequently, the heat exchange core 12 and the tank body 14 are caulked and fixed. At this time, as shown in FIG. 7, a load is applied to the tank main body 14 on one side of the first direction D1. It is assumed that the packing 28 is compressed in the first direction D1. In this state, the portion 31 of the outer wall portion 164 of the caulking plate 16 adjacent to the slit 40 is pushed toward the bottom portion 38 of the recess 32. As a result, as shown in FIG. 5, the positions in contact with the two recess start portions 34 and 36 are set as the two starting points 302 and 304, and the adjacent portion 31 is directed toward the bottom 38 in the first direction D1 of the slit 40. And bend. As a result, the crimped portion 30 is formed. The caulking portion 30 and the bottom wall portion 166 sandwich and hold the end portion 142 of the tank main body portion 14 in the first direction D1.

Of the slit forming surfaces 402 shown in FIG. 5, the forming surface on the other side of the first direction D1 is the end surface of the caulking portion 30 in contact with the end portion 142 of the tank main body portion 14. That is, the slit 40 defines the position of the end face of the crimped portion 30.

Then, in preparing the above heat exchange core, as described above, the length L1 of the slit 40 in the second direction D2 is longer than the distance L2 between the two recess start portions 34 and 36. The replacement core 12 is prepared. As a result, when the caulking portion is fixed, the first starting point portion 302 of the caulking portion 30 is located at a position separated from the first end portion 44 of the slit 40 in the second direction D2, so that the first direction D1 of the slit 40 is located. The adjacent portion 31 at can be bent. In this way, the heat exchanger 10 of the present embodiment can be manufactured.

Next, the heat exchanger 10 of the present embodiment and the heat exchanger J10 of Comparative Example 1 shown in FIG. 9 are compared. In FIG. 9, the heat exchange core 12 is not shown. In the heat exchanger J10 of Comparative Example 1, the length L1 of the slit 40 in the second direction D2 is the same as the distance L2 between the two recess start portions 34 and 36 of the recess 32. The first starting point 302 of the caulking portion 30 is at the same position as the first end 44 of the slit 40 in the second direction D2. Other configurations of the heat exchanger J10 of Comparative Example 1 are the same as those of the heat exchanger 10 of the present embodiment.

When the heat exchanger J10 of Comparative Example 1 vibrates, stress is applied to the caulking plate 16. The stress analysis results at this time are shown in FIGS. 10 and 11. FIG. 10 is a view of the caulking plate 16 of FIG. 9 viewed in the direction of the X arrow. In FIG. 10, the inner surface 164b of the outer wall portion 164 is shown. FIG. 11 is an enlarged view of the XI portion of FIG. "The first starting point 302 of the caulking portion 30 is at the same position as the first end 44 of the slit 40 in the second direction D2," says the second slit 40 in the second direction D2, as shown in FIG. It means that the first starting point 302 of the caulking portion 30 is located within the range R44 where the one end 44 is located. The range R44 is a range in which the outer surface of the slit 40 is curved on the inner surface 164b and the outer surface 164a of the outer wall portion 164.

In the heat exchanger J10 of Comparative Example 1, similarly to the heat exchanger 10 of the present embodiment, the ends 44 and 46 of the slit 40 in the second direction D2 are rounded on the outer surface 164a and the inner surface 164b of the outer wall portion 164. It has a tinged shape. Therefore, when the caulking plate 16 is stressed, the periphery of the ends 44, 46 is compared with the case where the ends 44, 46 are not rounded and the ends 44, 46 have corners. The stress concentration of the part is suppressed.

However, as shown in FIG. 11, in the heat exchanger J10 of Comparative Example 1, the stress applied to the peripheral portion B1 of the first end portion 44 of the slit 40 is particularly large. It is considered that this is because the peripheral portion B1 of the first end portion 44 of the slit 40 of the outer wall portion 164 was deformed when the crimped portion 30 was formed. Therefore, when the heat exchanger J10 of Comparative Example 1 vibrates, a crack may occur from the peripheral portion B1 of the first end portion 44 of the slit 40.

On the other hand, in the heat exchanger 10 of the present embodiment, the first starting point 302 of the caulking portion 30 is separated from the first end 44 of the slit 40 in the second direction D2. Therefore, as shown in FIGS. 12 and 13, in the heat exchanger 10 of the present embodiment, the stress applied to the peripheral portion B1 of the first end portion 44 of the slit 40 is compared with the heat exchanger J10 of Comparative Example 1. Becomes smaller.

12 and 13 are the analysis results of the stress applied to the caulking plate 16 of the heat exchanger 10 of the present embodiment. 12 and 13 are the analysis results under the same conditions as the heat exchanger J10 of Comparative Example 1. FIG. 12 is a view of the caulking plate 16 of FIG. 3 viewed in the direction of the arrow of XII. In FIG. 12, the inner surface 164b of the outer wall portion 164 is shown. FIG. 13 is a diagram showing the stress distribution of the XIII portion of FIG. As shown in FIG. 13, in the heat exchanger 10 of the present embodiment, the first starting point 302 of the caulking portion 30 is separated from the range R44 in the second direction D2. When the magnitude of stress at the maximum stress portion of the peripheral portion B1 of FIG. 11 was set to 100, the magnitude of stress at the maximum stress portion of the peripheral portion B1 of FIG. 13 was 78.

As described above, according to the heat exchanger 10 of the present embodiment, it is possible to suppress a decrease in the strength of the caulking plate 16.

(Other embodiments)
(1) In the above embodiment, the first end portion 44 of the slit 40 has a rounded shape. That is, the first end portion 44 of the slit 40 had a curved shape on the outer surface 164a and the inner surface 164b of the outer wall portion 164. However, the first end portion 44 of the slit 40 may have a linear shape on the outer surface 164a and the inner surface 164b of the outer wall portion 164. In this case as well, as in the first embodiment, the first starting point 302 of the caulking portion 30 may be separated from the first end 44 of the slit 40 in the second direction D2. As a result, the same effect as that of the first embodiment can be obtained.

(2) In the above embodiment, only the first starting point 302 of the first starting point 302 and the second starting point 304 of the caulking portion 30 is separated from the end portion of the slit 40. However, not only the first starting point 302 but also the second starting point 304 may be separated from the second end 46 of the slit 40 in the second direction D2.

(3) In the above embodiment, the heat exchanger is a water-cooled intercooler, but it may be an air-cooled intercooler. In this case, the cooling air corresponds to the second fluid. Further, the heat exchanger may be a heat exchanger for other purposes. Examples of heat exchangers for other purposes include radiators for dissipating cooling water such as engine cooling water, and heater cores for heating using cooling water such as engine cooling water as a heat source. In both the radiator and the heater core, one of the cooling water and the air corresponds to the first fluid, and the other of the cooling water and the air corresponds to the second fluid.

(4) The present invention is not limited to the above-described embodiment, and can be appropriately modified within the scope of claims, and includes various modifications and modifications within an equal range. Further, the above-described embodiments are not unrelated to each other, and can be appropriately combined unless the combination is clearly impossible. Further, in each of the above embodiments, it goes without saying that the elements constituting the embodiment are not necessarily essential except when it is clearly stated that they are essential and when they are clearly considered to be essential in principle. No. Further, in each of the above embodiments, when numerical values such as the number, numerical values, amounts, and ranges of the constituent elements of the embodiment are mentioned, when it is clearly stated that they are particularly essential, and in principle, the number is clearly limited to a specific number. It is not limited to the specific number except when it is done. Further, in each of the above embodiments, when referring to the material, shape, positional relationship, etc. of the constituent elements, etc., except when specifically specified or when the material, shape, positional relationship, etc. are limited in principle. , The material, shape, positional relationship, etc. are not limited.

(Summary)
According to the first aspect shown in part or all of each of the above embodiments, the heat exchanger includes a heat exchange core and a tank body. The heat exchange core has a caulking plate that is caulked and fixed to the tank body. The caulking plate has a first wall portion and a second wall portion. The first wall portion has a pressing portion that presses the held portion of the tank main body portion. The holding portion and the second wall portion sandwich and hold the held portion of the tank main body portion in the first direction. The tank main body has a recess in which the holding portion is located inside. The recess has two recess start portions aligned in a second direction and a bottom portion located between the two recess start portions. An opening is formed next to one side of the first wall portion in the first direction of the pressing portion. The holding portion is a portion of the first wall portion adjacent to the opening in the first direction, and bends toward the bottom of the recess with the positions in contact with each of the two recess start portions as the two starting points. This is the part that is. The length of the opening in the second direction is longer than the distance between the two recess start portions. One starting point of the two starting points is separated from one of the two ends of the opening in the second direction in the second direction.

Further, according to the second aspect, one end of the opening on the outer surface and the inner surface of the first wall portion has a rounded shape. When the end portion has a rounded shape, stress concentration in the peripheral portion of the end portion of the opening is suppressed as compared with the case where the end portion does not have a rounded shape. In this case, by applying the first aspect, it is possible to further suppress the stress concentration in the peripheral portion of the end portion of the opening. Therefore, it is possible to further suppress a decrease in the strength of the caulking plate.

Further, according to the third viewpoint, one end of the opening on the outer surface and the inner surface of the first wall portion has a linear shape. The shape of the end of the opening can be such a shape.

Further, according to the fourth viewpoint, the method of manufacturing the heat exchanger is to prepare a heat exchange core, prepare a tank main body, assemble the heat exchange core and the tank main body, and heat. Includes caulking and fixing the replacement core and the tank body. In preparing the heat exchange core, the heat exchange core is prepared in which the length of the opening in the second direction is longer than the distance between the two recess start portions. In caulking, so that at least one of the two origins is located in the second direction away from one of the two ends of the opening in the second direction. , Bend the part next to the opening.

Further, according to the fifth aspect, in preparing the heat exchange core, the heat exchange core having a rounded shape at one end of the opening on the outer surface and the inner surface of the first wall portion is prepared. .. When the end portion has a rounded shape, stress concentration in the peripheral portion of the end portion of the opening is suppressed as compared with the case where the end portion does not have a rounded shape. In this case, by applying the fourth aspect, the stress concentration in the peripheral portion of the end portion of the opening can be further suppressed. Therefore, it is possible to further suppress a decrease in the strength of the caulking plate.

Further, according to the sixth aspect, in preparing the heat exchange core, the heat exchange core in which one end of the opening on the outer surface and the inner surface of the first wall portion has a linear shape is prepared. The shape of the end of the opening can be such a shape.

10 Heat exchanger 12 Heat exchange core 14 Tank body 16 Caulking plate 164 Outer wall 166 Bottom wall 30 Holding 32 Recess 40 Slit

Claims (6)

A heat exchanger that exchanges heat between the first fluid and the second fluid.
A heat exchange core (12) forming a first flow path (24b) through which the first fluid flows and a second flow path (24a) through which the second fluid flows,
A tank main body portion (14) forming a tank space (14a) connected to the first flow path is provided.
The heat exchange core has a caulking plate (16) that is caulked and fixed to the tank body portion.
The caulking plate has a first wall portion (164) extending in the first direction (D1) and covering the outside of the tank main body portion, and a second wall portion of the first wall portion connected to one side in the first direction. Has a part (166) and
The first wall portion has a pressing portion (30) provided on the other side of the first wall portion in the first direction to press the held portion (142) of the tank main body portion.
The holding portion and the second wall portion hold the held portion of the tank main body portion by sandwiching it in the first direction.
The tank main body portion has a recess (32) in which the holding portion is located inside at a portion different from the held portion.
The recess has two recess start portions (34, 36) aligned in a second direction (D2) intersecting the first direction and a bottom portion (38) located between the two recess start portions. ,
An opening (40) is formed next to the one side of the first wall portion in the first direction of the holding portion.
The holding portion is a portion of the first wall portion adjacent to the opening in the first direction, and the two starting points (302, 304) are positioned in contact with each of the two recess start portions. It is a part that is bent toward the bottom of the recess.
The length (L1) of the opening in the second direction is longer than the distance (L2) between the two recess start portions.
The one starting point (302) of the two starting points is one of the two ends of the opening in the second direction, which is located on the same side as the one starting point in the second direction. A heat exchanger that is separated from the portion (44) in the second direction. The heat exchanger according to claim 1, wherein the one end of the opening on the outer surface (164a) and the inner surface (164b) of the first wall portion has a rounded shape. The heat exchanger according to claim 1, wherein the one end of the opening on the outer surface (164a) and the inner surface (164b) of the first wall portion has a linear shape. A heat exchange core (12) forming a first flow path (24b) through which the first fluid flows and a second flow path (24a) through which the second fluid flows, and a tank space (14a) connected to the first flow path. A method for manufacturing a heat exchanger having a tank body (14) to be formed and exchanging heat between a first fluid and a second fluid.
The caulking plate (16) is crimped and fixed to the tank body portion, and the caulking plate has a first wall portion (164) extending in the first direction (D1) and the first direction of the first wall portion. To prepare the heat exchange core having a second wall portion (166) connected to one side of the above surface and having an opening (40) for forming a holding portion formed in the first wall portion. ,
Two recess start portions (34, 36) having recesses (32) for forming the holding portion, and the recesses lining up in a second direction (D2) intersecting the first direction, and the two recesses. To prepare the tank main body portion having a bottom portion (38) located between the dent start portions, and to prepare the tank main body portion.
The first wall portion of the caulking plate is arranged at a position where the first wall portion covers the outside of the tank main body portion, and the heat exchange core and the tank main body portion are assembled.
The portion of the first wall portion of the caulking plate adjacent to the opening in the first direction is pushed toward the bottom of the recess of the tank body, and is combined with each of the two recess start portions. The contacting positions are set as two starting points (302, 304), and the portion adjacent to the opening is bent toward the bottom to form a pressing portion (30), and the pressing portion and the second wall portion form a pressing portion. By sandwiching and holding the held portion (142) of the tank main body portion in the first direction, the heat exchange core and the tank main body portion are crimped and fixed.
In preparing the heat exchange core, the heat exchange core is prepared in which the length (L1) of the opening in the second direction is longer than the distance (L2) between the two recess start portions. And
In performing the caulking fixing, at least one starting point (302) of the two starting points is the starting point of the one of the two ends of the opening in the second direction and the second starting point. A method of manufacturing a heat exchanger that bends a portion adjacent to the opening so that it is located away from one end (402) located on the same side in the direction in the second direction. In preparing the heat exchange core, the heat exchange core having a rounded shape at one end of the opening on the outer surface (164a) and the inner surface (164b) of the first wall portion is prepared. The method for manufacturing a heat exchanger according to claim 4. In preparing the heat exchange core, it is claimed to prepare the heat exchange core in which one end of the opening on the outer surface (164a) and the inner surface (164b) of the first wall portion has a linear shape. 4. The method for manufacturing a heat exchanger according to 4.

Images