JP7493319B2 - Heat exchanger and method for manufacturing the same - Google Patents

Description

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

Some heat exchangers have heat transfer tubes oriented vertically to facilitate the flow of refrigerant.

For example, Patent Document 1 discloses a heat exchanger in which multiple heat transfer tubes are oriented vertically or tilted from the vertical. In this heat exchanger, cylindrical distributors that extend linearly in the horizontal direction are provided at the upper and lower ends of the heat transfer tubes to distribute or collect the refrigerant.

JP 2013-57502 A

Such a distributor is used, for example, housed in a housing provided in the outdoor unit of an air conditioner.

However, the housing may have four side sections, and two or more adjacent side sections may have vents. In such cases, the heat exchanger described in Patent Document 1 can only be placed along one side section of the housing, since the distributor extends linearly in the horizontal direction. In such cases, the heat exchange efficiency is reduced.

The present invention has been made to solve the above problems, and aims to provide a heat exchanger that can be placed along two adjacent side portions of a housing and has high heat exchange efficiency, and a method for manufacturing the heat exchanger.

In order to achieve the above object, a heat exchanger according to the present invention includes a plurality of heat transfer tubes, a straight portion in which the heat transfer tubes are arranged, and a distributor formed integrally with the straight portion and having a bent portion in which the heat transfer tubes are arranged. The distributor distributes a refrigerant to each of the heat transfer tubes or collects a refrigerant from each of the heat transfer tubes. The heat transfer tubes arranged in the bent portion are fixed to the bent portion and positioned biased toward the end face that is closer to the center of the bend than the heat transfer tubes arranged in the straight portion.

According to the configuration of the present invention, the distributor has a bent portion, so it can be placed along two adjacent side portions of the housing. In addition, the heat transfer tubes are arranged at the bent portion, so the heat exchange efficiency is high.

FIG. 1 is a perspective view of a heat exchanger according to a first embodiment of the present invention; FIG. 1 is an enlarged cross-sectional view of a portion of a housing of an outdoor unit in which a heat exchanger according to a first embodiment of the present invention is housed; FIG. 1 is a top view of a distributor provided in a heat exchanger according to a first embodiment of the present invention. FIG. 1 is a top view of a fin provided in a heat exchanger according to a first embodiment of the present invention. FIG. 1 is an enlarged top view of a bent portion of a distributor included in a heat exchanger according to a first embodiment of the present invention; FIG. 1 is an enlarged top view of a fin bend portion of a fin provided in a heat exchanger according to a first embodiment of the present invention; FIG. 1 is an enlarged perspective view of a bellows portion formed in a fin bend portion of a fin included in a heat exchanger according to a first embodiment of the present invention; FIG. 1 is a conceptual diagram of a connection step included in a method for manufacturing a heat exchanger according to a first embodiment of the present invention. FIG. 1 is a perspective view of a straight fin used in a connecting step included in the method for manufacturing a heat exchanger according to the first embodiment of the present invention; FIG. 1 is a conceptual diagram of a bending step included in a method for manufacturing a heat exchanger according to a first embodiment of the present invention. FIG. 11 is an enlarged top view of a bent portion of a distributor included in a heat exchanger according to a second embodiment of the present invention. FIG. 13 is an enlarged perspective view of a leaf spring portion formed at a fin bend portion of a fin included in a heat exchanger according to a third embodiment of the present invention; FIG. 13 is an enlarged perspective view of a modified example of the heat exchanger according to the first embodiment of the present invention. FIG. 11 is an enlarged perspective view of another modified example of the heat exchanger according to the first embodiment of the present invention. FIG. 13 is an enlarged perspective view of a modified example of a fin bend portion of the fin included in the heat exchanger according to the first embodiment of the present invention;

Hereinafter, a heat exchanger and a manufacturing method for a heat exchanger according to an embodiment of the present invention will be described in detail with reference to the drawings. In the drawings, the same or equivalent parts are given the same reference numerals. In the Cartesian coordinate system XYZ shown in the drawings, when a curved portion is placed to the right of a straight portion formed in a distributor equipped with a heat exchanger, the left-right direction is the X-axis, the up-down direction is the Z-axis, and the direction perpendicular to the X-axis and Z-axis is the Y-axis. Below, this coordinate system will be referred to as appropriate in the explanation.

(Embodiment 1)
The heat exchanger according to the first embodiment is a heat exchanger in which the distributor has a bent portion. In this heat exchanger, in order to increase the heat exchange efficiency, heat transfer tubes and fins are also provided at the bent portion of the distributor. First, the configuration of the heat exchanger will be described with reference to Figs. 1 to 4, and then the configuration of the bent portion of the distributor will be described with reference to Figs. 5 to 7. Next, a manufacturing method of the heat exchanger will be described with reference to Figs. 8 to 10.

Figure 1 is a perspective view of a heat exchanger 1A according to the first embodiment. Figure 2 is an enlarged cross-sectional view of a portion of an outdoor unit housing 100 in which the heat exchanger 1A is housed. Figure 3 is a top view of a distributor 10U provided in the heat exchanger 1A. Figure 4 is a top view of a fin 30 provided in the heat exchanger 1A. Note that in Figure 1, for ease of understanding, the shape of each fin 30 is not shown, and only the overall outline of the fin 30 provided in the heat exchanger 1A is shown. Also, in Figure 3, the shape and size of the through hole 14 formed in the distributor 10U are emphasized.

As shown in FIG. 1, the heat exchanger 1A includes distributors 10U and 10L through which the refrigerant flows in and out, a number of heat transfer tubes 20 connected to the distributors 10U and 10L and through which the refrigerant flows, and a number of fins 30 that exchange heat between the heat transfer tubes 20 and air.

The distributors 10U and 10L are formed in a rectangular tubular shape. The distributors 10U and 10L are bent. In detail, the distributors 10U and 10L have a first straight portion 11 that extends in the left-right direction, i.e., in the X-axis direction, a bent portion 12 that bends from the first straight portion 11 in the Y-direction, and a second straight portion 13 that extends from the bent portion 12 in the Y-direction.

The distributors 10U, 10L are formed in the above shape so that they are disposed adjacent to the vent V of the outdoor unit housing 100 shown in FIG. 2. In detail, the outdoor unit housing 100 has the vent V formed across the adjacent side sections S1, S2. The distributors 10U, 10L have a first straight section 11, a bent section 12, and a second straight section 13 so that they are disposed along the side sections S1, S2 where the vent V is located. The outdoor unit is a machine that is installed outdoors and is equipped with an air conditioner.

The first straight portion 11 is shorter than the length of the inner wall of the housing 100 in the left-right direction of FIG. 2, i.e., the X direction, and the second straight portion 13 is shorter than the length of the inner wall of the housing 100 in the Y direction. The bent portion 12 is bent only by the angle of the corner portion C of the side portions S1 and S2 of the housing 100, i.e., the angle formed by the side portions S1 and S2. The angle is 90°. This makes it possible for the distributors 10U and 10L to be housed in the housing 100 with the first straight portion 11 and the second straight portion 13 arranged along the side portions S1 and S2 of the housing 100 and the first straight portion 11, the bent portion 12, and the second straight portion 13 oriented horizontally. The first straight portion 11 and the second straight portion 13 are examples of straight portions as defined in this specification.

In addition, a flow path for flowing the refrigerant is formed inside the distributors 10U and 10L, although this is not shown. The distributors 10U and 10L are provided with joints, which are not shown, and are connected to the refrigerant pipes of the external device via these joints. As a result, the distributors 10U and 10L receive a supply of refrigerant from the external device and flow the refrigerant through the internal flow path. Alternatively, the distributors 10U and 10L discharge the refrigerant that has flowed through the flow path to the external device.

As shown in FIG. 1, distributors 10U and 10L have their top and bottom surfaces oriented horizontally. This makes distributors 10U and 10L less likely to cause uneven distribution of refrigerant in the internal flow paths. Conventionally, there are heat exchangers in which the axis of the distributor is oriented vertically, but in such heat exchangers, the refrigerant can become unevenly distributed in the flow paths within the distributor due to gravity. By arranging the top and bottom surfaces of distributors 10U and 10L horizontally, distributors 10U and 10L prevent uneven distribution of refrigerant in the flow paths. As a result, uneven distribution and concentration of refrigerant, which will be described later, is prevented.

The distributors 10U and 10L are spaced apart from each other in the vertical direction. As shown in FIG. 3, the bottom surface of the distributor 10U has a through hole 14 into which a heat transfer tube 20 is inserted to allow the refrigerant to flow between the distributors 10U and 10L. Although not shown, a through hole 14 of the same shape and size is also formed in the top surface of the distributor 10L.

Each through hole 14 is formed in the same shape as the cross section of the heat transfer tube 20 so that the heat transfer tube 20 can be inserted. Each through hole 14 also penetrates to the internal flow path of the distributors 10U and 10L. The number of through holes 14 in each of the distributors 10U and 10L is the same as the number of heat transfer tubes 20. The through holes 14 are arranged in the direction in which the cylindrical axis A of the distributors 10U and 10L extends. Although not shown, each through hole 14 formed in the distributor 10U is located directly above each through hole 14 formed in the distributor 10L, that is, in the +Z direction shown in FIG. 1.

Although not shown, the upper end of each heat transfer tube 20 is inserted into each through hole 14 on the distributor 10U side. Also, the lower end of each heat transfer tube 20 is inserted into each through hole 14 on the distributor 10L side. The inner wall of each through hole 14 and each heat transfer tube 20 are joined with brazing material. This connects distributors 10U and 10L with multiple heat transfer tubes 20. As a result, refrigerant flows between distributors 10U and 10L.

As mentioned above, distributors 10U and 10L are components that distribute or aggregate refrigerant. However, in this specification, they will be referred to simply as distributors, focusing on their function of distributing refrigerant. Distributors 10U and 10L have the same configuration, except that they are symmetrical from top to bottom. For this reason, hereinafter, reference numerals 10U and 10L will be used only when describing the positional relationship between distributors 10U and 10L, and reference numeral 10 will be used in other cases.

The heat transfer tube 20 is formed in a flat plate shape, in other words, in a flat shape, in order to improve heat transfer. Inside the tube, a continuous flow path is formed in the tube axial direction, although not shown. The heat transfer tube 20 is connected to the distributor 10 as described above. As a result, the refrigerant in the distributor 10 flows through the heat transfer tube 20, and the heat of the refrigerant is transferred. As shown in FIG. 1, a number of fins 30 are attached to the heat transfer tube 20 in order to release the transferred heat into the air or to absorb the heat of the air.

The heat transfer tube 20 has its tube axis oriented vertically. As a result, even if foreign matter adheres to the heat transfer tube 20, it falls off easily and is easy to remove. This improves the maintainability of the heat transfer tube 20.

Although not shown, the fins 30 are formed in the shape of long, thin plates. As shown in FIG. 4, the fins 30 are bent in the same shape as the distributor 10. In detail, the fins 30 extend from left to right, then bend 90 degrees toward the rear side, and then extend further toward the rear side. As a result, the fins 30 have fin bends 32.

Fin 30 has cutouts 31 arranged in extension direction D into which heat transfer tubes 20 can be fitted. The number of cutouts 31 is the same as the number of heat transfer tubes 20. The arrangement pitch of cutouts 31 is the same as the pitch of heat transfer tubes 20. Although not shown, fin 30 has a plate surface oriented horizontally, and cutouts 31 are fitted into heat transfer tubes 20. In this way, fin 30 is assembled to heat transfer tube 20. Fin 30 is joined to heat transfer tube 20 by brazing material. As a result, heat from heat transfer tube 20 is transferred to fin 30.

The fins 30 are also arranged at a constant pitch in the vertical direction (not shown). This leaves gaps between the fins 30. The fins 30 exchange heat with the air in the gaps.

As described above, the distributor 10 has a bent portion 12. The fins 30 also have fin bent portions 32. When manufacturing the heat exchanger 1A, if the distributor that extends linearly and the fins that extend linearly are bent, the bent portion 12 and the fins 30 may be damaged because the heat transfer tubes 20 are brazed. The heat transfer tubes 20 may also be damaged.

Therefore, in the bent portion 12, the arrangement of the through holes 14 is different from that of the first straight portion 11 and the second straight portion 13. In addition, the fin bent portion 32 is provided with a bellows portion 33. Next, the bent portion 12 provided in the distributor 10 and the fin bent portion 32 provided in the fin 30 will be described with reference to Figures 5 to 7.

Figure 5 is an enlarged top view of the bent portion 12 of the distributor 10. Figure 6 is an enlarged top view of the fin bent portion 32. Figure 7 is an enlarged perspective view of the bellows portion 33 formed in the fin bent portion 32.

In the bent portion 12, as shown in FIG. 5, the through holes 14 are arranged at a pitch P2 that is larger than the pitch P1 of the through holes 14 in the first straight portion 11 and the second straight portion 13. Heat transfer tubes 20 are inserted into and connected to these through holes 14. As a result, the heat transfer tubes 20 are arranged at pitch P1 in the first straight portion 11 and the second straight portion 13, and the heat transfer tubes 20 are arranged at pitch P2 in the bent portion 12.

In addition, the bent portion 12 has the through holes 14 arranged at a pitch P2 larger than the pitch P1 of the first straight portion 11 and the second straight portion 13, thereby preventing the through holes 14 and the heat transfer tubes 20 from being damaged by tensile forces during the bending process in the manufacture of the heat exchanger 1A. In detail, when the distributor 10, which extends linearly, is bent during the bending process, compressive and tensile forces are applied to the bent portion 12. However, by increasing the pitch P2 of the through holes 14 in the bent portion 12, the bent portion 12 prevents cracks from occurring in the through holes 14 and gaps from occurring between the through holes 14 and the heat transfer tubes 20 due to tensile forces.

The pitch P2 at the bend 12 is the distance from the end of the through hole 14 on the side of the bending center BC to the end of the adjacent through hole 14 on the side of the bending center BC when the through hole 14 is flat and its longitudinal direction faces the bending center BC of the bend 12. The pitch P1 is an example of the first pitch as referred to in this specification. The pitch P2 is an example of the second pitch as referred to in this specification.

In contrast, the fin bend 32 is provided with a bellows portion 33, as shown in Figures 6 and 7.

As shown in FIG. 7, in the bellows portion 33, a plurality of mountain folds 34 are formed in which the plate is bent upward and then folded back downward. As a result, between the mountain folds 34, valley folds 35 are formed in which the plate extending downward is bent upward. Note that up and down are examples of directions perpendicular to the bending radius direction D1 and bending direction D2 as used in this specification.

The bellows portion 33 has mountain folds 34 and valley folds 35, which prevents the fins 30 themselves from being damaged during the bending process. In detail, when the fins extending in a straight line are bent during the bending process, the bending angles of the mountain folds 34 and valley folds 35 are deformed, which prevents the fins 30 from being damaged or falling off the heat transfer tube 20 due to compressive and tensile forces.

Next, a method for manufacturing the heat exchanger 1A will be described with reference to Figures 8 and 9.

Figure 8 is a conceptual diagram of the connection step included in the manufacturing method of heat exchanger 1A. Figure 9 is a perspective view of the straight fins 36 used in the connection step. Figure 10 is a conceptual diagram of the bending step included in the same manufacturing method. Note that in Figure 8, for ease of understanding, the shape of each straight fin 36 is not shown, and only the overall outline of the straight fins 36 is shown.

First, prepare a linear distributor 16 and heat transfer tube 20 having a linear extending shape as shown in FIG. 8, and a linear fin 36 having a linear extending shape as shown in FIG. 9.

In detail, two linear distributors 16 are prepared, each having the same length as the overall cylindrical axial length including the first linear portion 11, the second linear portion 13, and the bent portion 12. In one linear distributor 16, the through holes 14 are arranged at the pitch P1 described above on the underside of the regions A1 and A3 that form the first linear portion 11 and the second linear portion 13, and the through holes 14 are arranged at the pitch P2 on the underside of the region A2 that forms the bent portion 12. Furthermore, the other linear distributor 16 has through holes 14 arranged at the same pitch on the upper surface. Then, the same number of heat transfer tubes 20 as the arranged through holes 14 are prepared.

In addition, multiple linear fins 36 that have the same length as the longitudinal direction of the above-mentioned fins 30 and extend linearly are prepared. Here, the linear fins 36 have bellows portions 33 in the area A2 that becomes the fin bends 32, as shown in FIG. 9.

Next, although not shown, of the multiple heat transfer tubes 20 prepared, the same number of heat transfer tubes 20 as the through holes 14 formed in region A1 of the linear distributor 16 are arranged at pitch P1. The same number of heat transfer tubes 20 as the through holes 14 formed in region A2 are arranged at pitch P2. Furthermore, the same number of heat transfer tubes 20 as the through holes 14 formed in region A3 are arranged at pitch P1. Then, linear fins 36 are attached to these heat transfer tubes 20. Next, the heat transfer tubes 20 and the linear fins 36 are joined by brazing.

After joining the heat transfer tubes 20 and the linear fins 36, as shown in FIG. 8, each of the heat transfer tubes 20 with the brazed linear fins 36 is inserted into the through holes 14 of the linear distributor 16 to attach the heat transfer tubes 20 to the linear distributor 16. Next, the heat transfer tubes 20 and the linear fins 36 are brazed and joined to each other. This process is an example of the connection process referred to in this specification.

Next, as shown in FIG. 10, a punch 200 is pressed against the center of the region A2 that will become the bent portion 12 of the linear distributor 16 in the extension direction of the cylinder axis A. The punch 200 has a semi-cylindrical portion 210 with a radius equal to the bending radius R. In this pressing, the cylindrical axis of the semi-cylindrical portion 210 is oriented perpendicular to the cylinder axis A, and the semi-cylindrical portion 210 is pressed against the back side of the region A2 of the linear distributor 16, and the semi-cylindrical portion 210 further presses the region A2. Then, the linear distributor 16 is aligned with the semi-cylindrical portion 210. As a result, the linear distributor 16 is bent to form the bent portion 12. As a result, the distributor 10 having the above-mentioned shape is formed. Also, the bellows portion 33 is deformed to form the fin bent portion 32. As a result, the fin 30 having the above-mentioned shape is formed.

At this time, the pitch of the through holes 14 is larger in the bent portion 12 of the distributor 10 than in the first straight portion 11 and the second straight portion 13, so the compressive force and tensile force caused by the pressing of the punch 200 are less likely to concentrate on the through holes 14. As a result, cracks will not occur in the through holes 14 due to the tensile force. Furthermore, no gaps will occur between the through holes 14 and the heat transfer tubes 20. As a result, damage to the distributor 10 and the heat transfer tubes 20 is prevented.

In addition, in the fin bend section 32, the bellows section 33 expands and contracts and deforms in response to the above-mentioned compressive and tensile forces. This prevents cracks from occurring in the fin 30 due to compressive and tensile forces, and prevents the joint between the fin 30 and the heat transfer tube 20 from breaking and causing the fin 30 to fall off the heat transfer tube 20. As a result, damage to the fin 30 is prevented.

The process of bending the linear distributor 16 using the punch 200 is an example of the bending process as defined in this specification. The area A2 of the linear distributor 16 is an example of another linear portion as defined in this specification.

The heat exchanger 1A is completed by using the punch 200 to shape the distributor 10 and fins 30 on the punch 200 side as described above.

As described above, the heat exchanger 1A according to embodiment 1 has a distributor 10 with a bent portion 12, so that it can be positioned along two adjacent side portions S1 and S2 of the housing 100.

In addition, the heat transfer tubes 20 are arranged in the bent portion 12, so the heat exchange efficiency is high.

In the bent portion 12, the through holes 14 are arranged at a pitch P2 that is larger than the pitch P1 of the through holes 14 in the first straight portion 11 and the second straight portion 13. Therefore, the bent portion 12 is less likely to be damaged when it is formed. As a result, there is no need for repairs, and the heat exchanger 1A is easy to manufacture.

In addition, when the heat transfer tube 20 is inserted into the through hole 14 and then joined to the inner wall of the through hole 14, when the bent portion 12 is formed, not only the bent portion 12 but also the heat transfer tube 20 is less likely to be damaged.

Since the heat transfer tube 20 is joined to the bent portion 12, the heat exchanger 1A can also exchange heat at the bent portion 12. Conventionally, it has been difficult to join the heat transfer tube 20 to the bent portion 12, and there have been heat exchangers that do not have the heat transfer tube 20 at the bent portion 12, but compared to such heat exchangers, the heat exchanger 1A has a higher heat exchange efficiency.

In addition, because the heat exchanger 1A is equipped with fins 30 provided with bellows portions 33, the fins 30 are less likely to be damaged during the manufacture of the heat exchanger 1A. There is no need to repair the fins 30, so manufacturing efficiency is high. In addition, because the fins 30 are present at the bent portions 12, heat exchange efficiency is high.

(Embodiment 2)
In the heat exchanger 1A according to the first embodiment, the pitch P2 of the through holes 14 in the bent portion 12 of the distributor 10 is larger than the pitch P1 of the through holes 14 in the first straight portion 11 and the second straight portion 13. However, the shape of the bent portion 12 is not limited to this. The bent portion 12 may have any shape as long as the tensile force applied to the through holes 14 when bent is small. In the heat exchanger 1A according to the second embodiment, in order to reduce the tensile force when bending, the positions of the through holes 14 formed in the bent portion 12 are shifted toward the bending side from the positions of the through holes 14 formed in the first straight portion 11 and the second straight portion 13.

Below, the heat exchanger 1A according to the second embodiment will be described with reference to FIG. 11. In the second embodiment, a configuration different from the first embodiment will be described.

Figure 11 is an enlarged top view of the bent portion 42 of the distributor 40 included in the heat exchanger 1A according to embodiment 2. Note that the distributor 40 shown in Figure 11 is a distributor located on the upper side, similar to the distributor 10U described in embodiment 1.

As shown in FIG. 11 , the bent portion 42 has through holes 44 arranged at the same pitch P<b>1 as the pitch P<b>1 at which the through holes 14 are arranged in the first straight portion 41 and the second straight portion 43 .
As in the first embodiment, the pitch of the through holes 44 in the bent portion 42 is desirably larger than the pitch P1 of the through holes 14 in the first straight portion 41 and the second straight portion 43 .

The through holes 44 are arranged biased toward the bending center BC side relative to the through holes 14 formed in the first straight portion 41 and the second straight portion 43. In other words, the through holes 44 are arranged biased toward the end face on the back side. Note that the end face on the back side is an example of the end face and lateral end face on the bending center BC side as referred to in this specification.

As explained in the first embodiment, a tensile force is applied to the through hole 44 during the bending process. The tensile force is applied to the front side, not the back side. The closer to the front side, the stronger the tensile force becomes.

As described above, the through hole 44 is biased toward the end face on the back side relative to the through holes 14 of the first straight portion 41 and the second straight portion 43, so it is less susceptible to the tensile force applied during the bending process. Alternatively, no tensile force is applied. As a result, cracks will not occur in the through hole 44 due to the tensile force, and no gaps will occur between the through hole 44 and the heat transfer tube 20. As a result, damage to the through hole 44 is prevented.

The manufacturing method of the heat exchanger 1A according to the second embodiment is the same as the first embodiment, except that the through holes 44 of the bent portion 42 are formed offset toward the rear side relative to the through holes 14 of the first straight portion 41 and the second straight portion 43. Therefore, in the second embodiment, the description of the manufacturing method of the heat exchanger 1A is omitted.

As described above, the heat exchanger 1A according to the second embodiment includes a distributor 40 having a bent portion 42 in which the through holes 44 are biased toward the bending center BC side relative to the through holes 14 of the first straight portion 41 and the second straight portion 43, so that the bent portion 42 is less likely to be damaged when the bent portion 42 is formed. In addition, because the bent portion 42 is less likely to be damaged, the heat transfer tube 20 joined to the bent portion 42 is also less likely to be damaged.

(Embodiment 3)
In the heat exchanger 1A according to the first embodiment, the fin 30 has a bellows portion 33. However, the shape of the fin 30 is not limited to this. The fin 30 may have any shape as long as it is deformable when the bending portion 12 is bent. In the heat exchanger 1A according to the third embodiment, the fin 50 has a leaf spring portion 53.

Below, a heat exchanger 1A according to embodiment 3 will be described with reference to FIG. 12. In embodiment 3, a configuration different from embodiments 1 and 2 will be described.

Figure 12 is an enlarged perspective view of a leaf spring portion 53 formed in a fin bend portion 52 of a fin 50 provided in a heat exchanger 1A according to embodiment 3.

As shown in FIG. 12, the leaf spring portion 53 is a plate that extends horizontally, bends upward, then extends horizontally again, and then bends downward. The leaf spring portion 53 then extends horizontally. The bending angles of the upward bent portion 54 and the downward bent portion 55 change when a load is applied to the fin bending portion 52 during the bending process. In other words, the leaf spring portion 53 functions as a leaf spring component. This causes the leaf spring portion 53 to deform, preventing damage to the fin 50.

The manufacturing method for the heat exchanger 1A according to the third embodiment is the same as the first embodiment, except that the leaf spring portion 53 having the above-mentioned shape is formed in the fin bend portion 52. Therefore, in the third embodiment, the description of the manufacturing method for the heat exchanger 1A is omitted.

As described above, in the heat exchanger 1A according to embodiment 3, the leaf spring portion 53 is formed in the fin bend portion 52, so that when the fin bend portion 52 is formed, the leaf spring portion 53 deforms, preventing damage to the fin 50.

The above describes the heat exchanger 1A and the manufacturing method of the heat exchanger 1A according to the embodiment of the present invention, but the heat exchanger 1A and the manufacturing method of the heat exchanger 1A are not limited to this. For example, in the embodiments 1-3, the fins 30, 50 are connected to the heat transfer tube 20 provided at the bent portions 12, 42 of the distributor 10. However, in the heat exchanger 1A, the fins 30, 50 are optional members. For example, in order to increase the heat exchange efficiency, it is desirable that the fins 30, 50 are connected to the heat transfer tube 20, but the fins 30, 50 do not have to have the fin bent portions 32, 52.

Figure 13 is an enlarged perspective view of a modified example of heat exchanger 1B according to embodiment 1. Note that, in order to facilitate understanding, Figure 13 does not show the shape of each fin 60, as in Figure 1, but shows only the overall outline of the fins 60 provided in heat exchanger 1B.

As shown in FIG. 13, the fin 60 may not have the fin bends 32, 52, and may only have the fins 61, 62 that extend linearly. That is, the fin 60 may not be connected to the heat transfer tube 20 provided in the bend 12 of the distributor 10, and the fins 61, 62 may be provided only on the heat transfer tube 20 provided in the first straight section 11 and the second straight section 13 of the distributor 10. Even in this form, since the heat transfer tube 20 is provided in the bend 12 of the distributor 10, heat exchange can be performed in the bend 12. Therefore, the heat exchange efficiency can be improved compared to a heat exchanger that does not have a heat transfer tube 20 provided in the bend 12.

In addition, in the first to third embodiments, the fins 30 and 50 are connected to all the heat transfer tubes 20 provided in the distributor 10, but a separate fin 63 may be connected only to the heat transfer tubes 20 provided in the bent portions 12 and 42.

Figure 14 is an enlarged perspective view of another modified example of the heat exchanger 1C according to embodiment 1. Note that in Figure 14, as in Figure 13, only the overall outline of the fin 63 is shown to facilitate understanding.

As shown in FIG. 14, fins 63 may be provided on each of the heat transfer tubes 20 at the bend 12. In this case, in order to prevent damage during the bending process described in the first embodiment, each of the fins 63 should have a gap G2 between adjacent fins 63 that is shorter than the gap G1 between the heat transfer tubes 20 in the direction in which the heat transfer tubes 20 are arranged.

In the first to third embodiments, the fins 30 and 50 have a bellows portion 33 and a leaf spring portion 53 provided at the fin bends 32 and 52, but the fins 30 and 50 are not limited to this. The fins 30 and 50 may be connected to the heat transfer tubes 20 arranged at the bends 12, and may be formed in the shape of a plate that undulates in a direction perpendicular to the bending radius direction of the bends 12 and the bending direction of the bends 12.

Figure 15 is an enlarged perspective view of a modified example of the fin bend portion 32 of the fin 30 provided in the heat exchanger 1A according to embodiment 1.

As shown in FIG. 15, the fin may have a wave-shaped fin bend 72. In FIG. 15, the fin bend 72 has a wave-shaped portion 73 that protrudes upward and a wave-shaped portion 74 that is recessed downward between them, but it may have only the wave-shaped portion 73 that protrudes upward, or only the wave-shaped portion 74 that is recessed downward. Even in this form, the fin can be deformed during the bending process described in embodiment 1, preventing damage to the fin. As a result, the heat exchanger 1A can be easily manufactured.

The upwardly protruding corrugated portion 73 and the downwardly recessed corrugated portion 74 may be thinner than the other fin portions in order to facilitate deformation during the bending process. This also applies to the thicknesses of the mountain fold portion 34 and the valley fold portion 35 described in embodiment 1, and the thicknesses of the upwardly folded portion 54 and the downwardly folded portion 55 described in embodiment 3. In other words, the thicknesses of the mountain fold portion 34 and the valley fold portion 35 and the thicknesses of the upwardly folded portion 54 and the downwardly folded portion 55 may be thinner than the other fin portions.

In the first embodiment, it is described that the heat exchanger 1A is housed in the housing 100 of the outdoor unit of the air conditioner, but the heat exchanger 1A-1C is not limited to this. The heat exchanger 1A-1C may also be used in other devices such as an indoor unit or a hot water heating system.

1A-1C heat exchanger, 10, 10U, 10L distributor, 11 first straight portion, 12 bent portion, 13 second straight portion, 14 through hole, 16 straight distributor, 20 heat transfer tube, 30 fin, 31 cutout, 32 fin bent portion, 33 bellows portion, 34 mountain fold portion, 35 valley fold portion, 36 straight fin, 40 distributor, 41 first straight portion, 42 bent portion, 43 second straight portion, 44 through hole, 50 fin, 52 fin bent portion, 53 leaf spring portion, 54 upward bent portion, 55 downward bent portion, 60-63 fin, 72 fin bent portion, 73, 74 corrugated portion, 100 housing, 200 punch, 210 semi-cylindrical portion, A cylinder shaft, A1-A3 area, BC Bending center, C corner part, D extension direction, D1 bending radius direction, D2 bending direction, G1, G2 gap, P1, P2 pitch, R bending radius, S1, S2 side part, V ventilation hole.

Claims (11)

A plurality of heat transfer tubes;
a distributor having a straight section in which the heat transfer tubes are arranged and a bent section formed integrally with the straight section and in which the heat transfer tubes are arranged, the distributor distributing a refrigerant to each of the heat transfer tubes or collecting the refrigerant from each of the heat transfer tubes,
The heat transfer tubes arranged in the bent portion are arranged biased toward an end face located on a bent center side relative to the heat transfer tubes arranged in the straight portion and are fixed to the bent portion.
Heat exchanger. In the straight portion, the heat transfer tubes are arranged at a first pitch,
In the bent portion, the heat transfer tubes are arranged at a second pitch that is larger than the first pitch.
2. The heat exchanger of claim 1. a fin connected to the heat transfer tubes arranged in the bent portion and formed in a plate shape undulating in a direction perpendicular to a bending radius direction of the bent portion and a bending direction of the bent portion;
3. A heat exchanger according to claim 1 or 2. The fin has a bellows shape that is bent in one of the perpendicular directions and then folded back in the other perpendicular direction different from the one of the perpendicular directions.
4. The heat exchanger of claim 3. The fin has a rectangular shape that is bent in one of the perpendicular directions, extends in a direction parallel to the bending radius direction and the bending direction, and is further folded back in the other direction different from the one of the perpendicular directions.
4. The heat exchanger of claim 3. fins that connect only the heat transfer tubes arranged in the straight portion;
3. A heat exchanger according to claim 1 or 2. a plurality of fins provided on each of the heat transfer tubes arranged in the bent portion, the fins having a gap between adjacent heat transfer tubes;
3. A heat exchanger according to claim 1 or 2. a connecting step of connecting a plurality of heat transfer tubes to a straight portion and another straight portion of a distributor that is integrally formed with the straight portion;
and a bending step of bending the other straight portion,
In the connecting step, the heat transfer tubes are arranged and connected to the other straight portion while being biased toward the side end face of the other straight portion with respect to a distance from a side end face of the straight portion to the heat transfer tubes arranged on the straight portion ,
In the bending step, the other straight portion is bent toward the side of the side end face, so that the side of the side end face is a bending center side .
A method for manufacturing a heat exchanger. In the connecting step, a plurality of heat transfer tubes are arranged and connected to the straight portion at a first pitch, and a plurality of heat transfer tubes are arranged and connected to the other straight portion at a second pitch larger than the first pitch.
A method for manufacturing the heat exchanger according to claim 8 . In the bending step, the side of the lateral end face is compressed and the opposite end face side is pulled, thereby bending the other straight portion.
A method for manufacturing the heat exchanger according to claim 8 . The bending step is performed after the plurality of heat transfer tubes are connected in the connecting step.
A method for manufacturing a heat exchanger according to any one of claims 8 to 10 .

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