US20050006079A1 - Heat exchanger and manufacturing method for the same - Google Patents
Heat exchanger and manufacturing method for the same Download PDFInfo
- Publication number
- US20050006079A1 US20050006079A1 US10/857,697 US85769704A US2005006079A1 US 20050006079 A1 US20050006079 A1 US 20050006079A1 US 85769704 A US85769704 A US 85769704A US 2005006079 A1 US2005006079 A1 US 2005006079A1
- Authority
- US
- United States
- Prior art keywords
- tube
- header plate
- heat exchanger
- plate
- header
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
- B21D53/08—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of both metal tubes and sheet metal
- B21D53/085—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of both metal tubes and sheet metal with fins places on zig-zag tubes or parallel tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
- F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
- F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
- F28D1/053—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
- F28D1/0535—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight the conduits having a non-circular cross-section
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F1/00—Tubular elements; Assemblies of tubular elements
- F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
- F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
- F28F1/24—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element and extending transversely
- F28F1/32—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element and extending transversely the means having portions engaging further tubular elements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/04—Arrangements for sealing elements into header boxes or end plates
- F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/04—Arrangements for sealing elements into header boxes or end plates
- F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
- F28F9/18—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/14—Heat exchangers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2275/00—Fastening; Joining
- F28F2275/06—Fastening; Joining by welding
- F28F2275/065—Fastening; Joining by welding by ultrasonic or vibration welding
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
- Y10T29/49364—Tube joined to flat sheet longitudinally, i.e., tube sheet
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
- Y10T29/49373—Tube joint and tube plate structure
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
- Y10T29/49377—Tube with heat transfer means
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
- Y10T29/49377—Tube with heat transfer means
- Y10T29/49378—Finned tube
- Y10T29/4938—Common fin traverses plurality of tubes
Definitions
- the present invention relates to a heat exchanger having a core portion in which plate fins are mechanically connected to a tube by expanding the tube, and a method for manufacturing the same.
- the present invention is suitably used for a heater core for a heating apparatus and a radiator for cooing an engine.
- plate fins are mechanically connected to a tube by expanding the tube.
- a flat tube having a flat cross section is used, and a radius of curvature on an inner wall side at an end in a direction of long diameter of the cross section is at least 1 ⁇ 2 of a size in a direction of short diameter on the inner wall side nearly at the center in the direction of long diameter.
- an object of the present invention is to enable the bonding of an end portion in a longitudinal direction of a tube to a header plate without a furnace of high temperature, in a heat exchanger in which plate fins are mechanically bonded to the tube and in a method for manufacturing the same.
- a heat exchanger has a core portion ( 110 ) including a plurality of plate fins ( 111 ) each shaped like a flat plate, and a tube ( 112 ) in which fluid flows and which is inserted into the plate fins ( 111 ) to be mechanically connected thereto.
- An end portion of the tube ( 112 ) in the longitudinal direction of the tube ( 112 ) is bonded to a header plate ( 113 ) which constructs a part of a header tank ( 120 ).
- the tube ( 112 ) and the header plate ( 113 ) are bonded to each other by a solid bonding. This can provide a heat exchanger for eliminating the need for providing a furnace of high temperature.
- the tube ( 112 ) has a flange portion ( 112 b ) expanded and bent to the surface of the header plate ( 113 ) along the whole periphery on the tip side of an insertion portion ( 112 a ) inserted into a tube hole portion ( 113 a ) provided in the header plate ( 113 ).
- a portion where the tube ( 112 ) and the header plate ( 113 ) are bonded to each other has an abutting portion ( 114 ) where the flange portion ( 112 b ) abuts on the header plate ( 113 ). This can facilitate the solid bonding and can stably bond the tube ( 112 ) to the header plate ( 113 ).
- the flange portion ( 112 b ) is formed in such a way as to be expanded and bent nearly 90 degrees along the surface of the header plate ( 113 ). This can prevent the end portion of the tube ( 112 ) in the longitudinal direction of the tube ( 112 ) from protruding into the header tank ( 120 ) and hence can reduce a flowing resistance of the fluid flowing in the header tank ( 120 ).
- a tapered portion ( 113 b ) is formed on a side of the flange ( 112 b ) in the tube hole portion ( 113 a ).
- the tube ( 112 ) is formed along the tapered portion ( 113 b ) and is bonded to the header plate ( 113 ) also in a portion where the tube ( 112 ) abuts on the tapered portion ( 113 b ). This can increase the bonding area of the tube ( 112 ) and the header plate ( 113 ) to provide a heat exchanger ( 100 ) with the further stabilized bonding.
- a stress relieving portion ( 112 d ) is formed at a predetermined position of an outer peripheral portion of the flange portion ( 112 b ).
- the stress relieving portion ( 112 d ) is for relieving a tensile stress generated in a peripheral direction when the flange portion ( 112 b ) is formed. This can prevent the flange portion ( 112 b ) from being cracked when the flange portion ( 112 b ) is formed and secure the sufficient area of the flange portion ( 112 b ).
- the tube ( 112 ) can be bonded to the header plate ( 113 ) while absorbing a clearance ( ⁇ ) between the tube ( 112 ) and the tube hole portion ( 113 a ).
- the stress relieving portion ( 112 d ) can be formed as a cut-out portion ( 112 d ) in which the outer peripheral portion of the flange portion ( 112 b ) is cut out in a circumferential shape.
- a protruding portion ( 113 f ) for reducing a contact area with the tube ( 112 ) side is formed on a side of the header plate ( 113 ) in a bonding portion where the tube ( 112 ) is bonded to the header plate ( 113 ).
- This can reduce the contact area of the tube ( 112 ) side and the header plate ( 113 ) and hence can increase a bearing stress even if a load applied in the solid bonding is decreased, thereby providing reliable bonding and preventing the deformation of the tube ( 112 ) and the header plate ( 113 ).
- a first chamfered portion ( 113 c ) is formed on a side of the tube hole portion ( 113 a ) in which the tube ( 112 ) is inserted. This can improve the ease with which the tube ( 112 ) is inserted into the tube hole portion ( 113 a ).
- a second chamfered portion ( 113 g ) is formed on a side of the flange portion ( 112 b ) in the tube hole portion ( 113 a ).
- the tube ( 112 ) has a thickness that is in a range from 0.1 mm to 0.5 mm.
- a tube ( 112 ) in which a fluid flows is inserted into a plurality of plate fins ( 111 ) each shaped like a flat plate and the tube ( 112 ) is expanded to make the plate fins ( 111 ) be mechanically bonded to the tube ( 112 ) to form a core portion ( 110 ).
- the method for manufacturing the heat exchanger further includes a step of passing the tube ( 112 ) into a tube hole portion ( 113 a ) made in the header plate ( 113 ) and then bending the end portion in the longitudinal direction of the tube ( 112 ) along its whole periphery in such a way as to expand to a surface side of the header plate ( 113 ) to form a flange portion ( 112 b ) and to make the flange portion ( 112 b ) abut on the header plate ( 113 ), in a forming step of the abutting portion ( 114 ).
- This can eliminate the need for increasing the position accuracy of a vibrator ( 220 ) and the tube ( 112 ) when the supersonic vibration is applied, and can realize stable bonding necessary for hermetically holding the fluid flowing in the tube ( 112 ).
- FIG. 1 is an exploded perspective view showing a general construction of a heater core of the present invention
- FIG. 2 is a cross-sectional view showing a step of pounding a header plate in a first embodiment of the present invention
- FIG. 3A is a cross-sectional view showing a step of preliminarily expanding the tip portion of a tube in the first embodiment of the present invention
- FIG. 3B is a cross-sectional view showing a step of finally expanding the tip portion of the tube;
- FIG. 4 is a cross-sectional view showing a step of bonding the tube to the header plate in a solid bonding in the first embodiment of the present invention
- FIGS. 5A and 5B are cross-sectional views showing the tip portion of a tube and a header plate in a second embodiment of the present invention
- FIG. 6 is an enlarged cross-sectional view showing the vicinity of the bent portion of a flange portion in FIG. 5 before the solid bonding;
- FIG. 7 is an enlarged cross-sectional view showing the vicinity of the bent portion of a flange portion in FIG. 5 after the solid bonding;
- FIGS. 8A and 8B are comparative examples of the second embodiment shown in FIGS. 5A and 5B and are cross-sectional views in a case where R cut-out portions and chamfered portions are not formed;
- FIG. 9 is a comparative example of FIG. 7 and an enlarged cross-sectional view showing the vicinity of the bent portion of a flange portion after the solid bonding;
- FIGS. 10A and 10B are cross-sectional views showing the tip portion of a tube and a header plate in a third embodiment of the present invention.
- FIGS. 11A and 11B are cross-sectional views showing the tip portion of a tube and a header plate in a modified example 1 of the third embodiment.
- FIGS. 12A and 12B are cross-sectional views showing the tip portion of a tube and a header plate in a modified example 2 of the third embodiment.
- a heat exchanger of the present invention is applied to a heater core 100 for a heating apparatus that heats air for air conditioning by using a hot water (inside fluid).
- the heater core 100 includes a core portion 110 for exchanging heat and two header tanks 120 arranged on end sides in a longitudinal direction of a tube 112 .
- the material of the respective parts of the heater core 100 to be described below is aluminum or aluminum alloy.
- the core portion 110 includes plate fins 111 and tubes 112 .
- the plate fin (hereinafter referred to as fin) 111 is a band-shaped member having a thin thickness (here, assumed to be 25 ⁇ m) and the fins 111 are laminated at a predetermined pitch (fin pitch). A plurality of sets (three sets) of assemblies of the plural laminated fins 111 are used.
- Each fin 111 has plural insertion holes 111 a ( FIG. 4 ) arranged in a longitudinal direction of the fin 111 .
- the tube 112 is a flat tube having a thin thickness (for example, 0.2 mm in thickness) and a flat cross section.
- the tube 112 is inserted into the insertion hole 111 a of each fin 111 , and the direction of long diameter in a cross section of the tube 112 is pointed in the longitudinal direction of the fin 111 .
- the tube 112 is expanded and press-fitted to the fin 111 , whereby the tube 112 is mechanically bonded to the fin 111 .
- the header plate 113 is a plate-shaped member forming a part of the header tank 120 together with a tank body 121 to be described below.
- an erect edge portion 113 e is formed on the outside periphery of a rectangular plane portion 113 d that has a size larger than an outer dimension of the core portion 110 in a case where the core portion 110 is projected from the longitudinal direction of the tube 112 .
- tube holes 113 a corresponding to the tubes 112 are formed in the header plate 113 .
- the end portion in the longitudinal direction of each tube 112 is inserted into the tube hole portions 113 a, whereby the tubes 112 are bonded to the header plate 113 .
- the present invention is characterized by the bonding structure of the tube 112 and the header plate 113 and a method for manufacturing the same, which will be described later in detail.
- the tank bodies 121 are bonded to both of the header plates 113 to form the header tanks 120 .
- the tank body 121 is a box-shaped part open at the side of the header plate 113 .
- the opening side of the tank body 121 is inserted inside the erect edge portion 113 e of the header plate 113 and is welded to the header plate 113 along the entire periphery of the tank body 121 .
- An inlet pipe 131 is bonded to one tank body 121 (e.g., on the upper side in FIG. 1 ).
- An outlet pipe 132 is bonded to another tank body 121 (e.g., on the lower side in FIG. 1 ). Both of the pipes 131 , 132 communicate with the insides of the header tanks 120 , respectively.
- hot water flows through the tubes 112 via one header tank 120 from the inlet pipe 131 and is collected by another header tank 120 and flows out of the outlet pipe 132 .
- the hot water flowing through the tubes 112 exchanges heat with air for air conditioning supplied from the outside in the direction of the long diameter in the cross section of the tube 112 to heat the air for air conditioning. At this time, the heat exchange is accelerated by the fins 111 .
- a method for manufacturing the heater core 100 will be described with reference to FIG. 2 to FIG. 4 .
- predetermined pieces of fins 111 are laminated at predetermined intervals by using a laminating jig (not shown) as a guide.
- the tubes 112 are inserted into the respective insertion holes 111 a and then a tube expanding tool (not shown) is inserted into each of the tubes 112 to expand the tubes 112 and to press-fit the tube 112 to the fin 111 (step of assembling core portion).
- the end portion in the longitudinal direction of the tube 112 is inserted into the tube hole portion 113 a of the header plate 113 and the header plate 113 is pounded by a press (not shown) so as to project the tube 112 to a side opposite to an insertion side.
- a press not shown
- a chamfered portion 113 c is previously formed on the tube insertion side of the tube hole portion 113 a and a tapered portion 113 b is previously formed on a side opposite to the insertion side (i.e., the side of the flange portion 112 b ) (step of pounding a header plate).
- the end portion in the longitudinal direction of the tube 112 protruding from the header plate 113 is expanded. That is, first, the end portion of the tube 112 is expanded in the shape of a bell at a predetermined angle by a preliminary tube expanding jig 211 ( FIG. 3A ). Further, the tip portion of the tube 112 is bent along the plane portion 113 d of the header plate 113 in such a way as to expand nearly at 90 degrees by a tube expanding jig 212 ( FIG. 3B ).
- a flange portion 112 b is formed at the tip portion of the tube 112 , whereby an abutting portion 114 where the flange portion 112 b abuts on the header plate 113 (plane portion 113 d ) is formed. Further, an expanded portion 112 c is formed between the insertion portion 112 a of the tube 112 and the flange portion 112 b by the tube expanding jig 212 , and abuts on the tapered portion 113 b (step of expanding tube).
- the tube 112 and the header plate 113 are bonded to each other in a solid phase by a vibrator 220 .
- the vibrator 220 has an external shape along the flange portion 112 b and the expanded portion 112 c.
- the vibrator 220 vibrates in a direction in which the surface of the abutting portion 114 extends (in left-right direction in FIG. 4 ) and at the same time applies a predetermined load to the tube 112 in the direction that makes the flange portion 112 b abut on the header plate 113 .
- the vibration conditions of the vibrator 220 are as follows: frequency is 20 kHz; amplitude is from 20 ⁇ m to 60 ⁇ m; and pressure is from 50 kg to 100 kg.
- the working time per one tube of the vibrator 220 is from 0.2 sec to 0.5 sec.
- a heater (high frequency resistance heating) 230 as a heating unit is mounted near the abutting portion 114 where the flange portion 112 b abuts on the header plate 113 .
- the flange portion 112 b and the expanded portion 112 c of the tube 112 are vibrated in the left-right direction in FIG. 4 by the action of this vibrator 220 .
- the tube 112 and the header plate 113 have their oxide films removed in the abutting portion 114 and the tapered portion 113 b, and are heated to temperatures (from 200 to 300° C.) between the recrystallization temperature and the melting point of the part by frictional heat and the heat of the heater 230 and further have pressure applied thereto, thereby being bonded to each other in the solid phase (step of bonding tube).
- the thickness of the tube 112 is 0.1 mm or more so as to secure a basic strength as the heater core 100 and is 0.5 mm or less so as to transmit vibrations from the vibrator 220 to the side of the header plate 113 without attenuation.
- the two tank bodies 121 to which the inlet pipe 131 and the outlet pipe 132 are previously welded are fitted inside the erect edge portion 113 e of the header plates 113 , respectively, and then are welded along the whole periphery by laser welding (step of welding tank).
- the heater core 100 having the core portion 110 including the fins 111 and the tubes 112 that are mechanically bonded to each other, the tube 112 and the header plate 113 are bonded to each other in the solid phase. For this reason, the heater core 100 can be formed without necessitating a furnace of high temperature. Therefore, energy consumption can be reduced in the manufacture, and equipment cost for a furnace can be reduced.
- the flange portion 112 b is formed in the tube 112 and is bonded to the header plate 113 at the abutting portion 114 where the flange portion 112 b abuts on the header plate 113 . Therefore, when the vibrator 220 applies supersonic vibrations to the tube 112 , positioning accuracy between the vibrator 220 and the tube 112 is eliminated and the solid bonding can be easily performed. Moreover, the inside hot water can be easily hermetically held, and the tube 112 can be stably bonded to the header plate 113 .
- the flange portion 112 b is formed, it can prevent the end portion in the longitudinal direction of the tube 112 from protruding into the header tank 120 , and thereby reducing the flowing resistance of the hot water flowing inside the header tank 120 and improving performance as the heater core 100 .
- the heater 230 heats the tube 112 and the header plate 113 near the abutting portion 114 . For this reason, the stabilization of temperature condition necessary for the solid bonding can be easily performed, whereby the tube 112 can be stably bonded to the header plate 113 .
- the tapered portion 113 b is formed at the tube hole portion 113 a of the header plate 113 .
- the expanded portion 112 c is formed in the tube 112 so that the tube 112 is bent along this tapered portion 113 b. Hence, this can increase the bonding area of the tube 112 and the header plate 113 and can perform a further stable bonding.
- the tube 112 is a flat tube 12 having a flat cross section. Therefore, this flat tube 112 can enhance a heat transfer coefficient of hot water flowing in the tube 112 and can reduce a flow resistance to air for air conditioning flowing outside the tube 112 to enhance the heat exchange performance of the heater core 100 .
- the heating of the tapered portion 113 b of the header plate 113 and the expanded portion 112 c of the tube 112 by the heater 230 can be stopped according to the bonding strength at the abutting portion 114 due to the flange portion 112 b.
- FIG. 5A to FIG. 7 The second embodiment of the present invention will be shown in FIG. 5A to FIG. 7 .
- the shape of the flange portion 112 b of the tube 112 is changed in comparison with the first embodiment. That is, the shape of end portion in the longitudinal direction of the tube 112 before forming the flange portion 112 b is changed.
- FIG. 6 is an enlarged sectional view to show the vicinity of the flange portion 112 b in FIG. 5 in a state where the flange portion 112 b abuts on the header plate 113
- FIG. 7 is an enlarged sectional view to show the vicinity of the flange portion 112 b in FIG. 5 after the solid bonding of the flange portion 112 b to the header plate 113 is performed.
- cut-out portions 112 d are previously formed as stress relieving portions in predetermined portions along the entire periphery of the end portion in the longitudinal direction of the tube 112 .
- the end portion of the tube 112 has a recess portion removed by a large radius of R in the direction of long diameter in the cross section of the tube 112 .
- the end portion of the tube 112 is cut out (removed) in the vertical direction with respect to the surface of paper in FIGS. 5A and 5B by a cutter corresponding to a shape shown by a double dot and dash line in FIGS. 5A and 5B to form the cut-out portion 112 d.
- a chamfered portion (corresponding to the first chamfered portion in this invention) 113 c is formed on the side of the tube hole portion 113 a to which the tube 112 is inserted and a chamfered portion (corresponding to the second chamfered portion in this invention) 113 g is formed also on the side of the flange portion 112 b of the tube hole portion 113 a.
- the end portion in the longitudinal direction of the tube 112 is inserted into the tube hole portion 113 a and is expanded and bent approximately 90 degrees to form the flange portion 112 b. Then, the tube 112 is bonded to the header plate 113 in a solid phase by the vibrator (not shown in FIGS. 5A and 5B ).
- the flange portion 112 b By forming the flange portion 112 b on the tube 112 , a clearance ⁇ between the tube 112 and the tube hole portion 113 a is absorbed in the solid bonding. For this reason, the area of the flange portion 112 b needs to be increased. Hence, as shown in a comparative example shown in FIGS. 8A and 8B , the amount of protrusion (h) of the tube 112 is usually increased. However, when the amount of protrusion (h) is simply increased, a tensile stress generated at an R portion on the end side in the direction of long diameter of the flange portion 112 b becomes large and the flange portion 112 b is apt to be broken at the R portion. Hence, after all, the area of the flange portion 112 b can not be increased.
- the thickness of the flange portion 112 b is reduced.
- the portion has stress concentrated thereon, which might reduce the strength of the flange portion 112 b.
- the cut-out portion 112 d previously formed on the end portion in the longitudinal direction of the tube 112 can relieve the tensile stress generated in a circumferential direction of the cut-out portion 112 d when the tube 112 is expanded and bent approximately 90 degrees to form the flange portion 112 b. Hence, it can prevent cracks when the flange portion 112 b is formed, and thereby sufficiently securing the area of the flange portion 112 b. Accordingly, the clearance 8 between the tube 112 and the tube hole portion 113 a can be absorbed, and the tube 112 can be bonded to the header plate 113 .
- the tube hole portion 113 a is provided with the chamfered portions 113 c and 113 g.
- the flowing material (shown by a white arrow in FIG. 7 ) of the header plate 113 when a portion near the tube hole portion 113 a of the header plate 113 is deformed can be absorbed in a space formed between the chamfered portion 113 c and the tube 112 .
- a load applied to the vicinity of the bent portion of the flange portion 112 b is relieved to prevent the flange portion 112 b form being reduced in thickness in the vicinity of the bent portion of the flange portion 112 b.
- a fixing member for fixing the bottom surface of the header plate, 113 by a receiving jig is used.
- the deflection of the header plate 113 can be reduced by increasing the thickness of the header plate 113 .
- the flowing material shown by a black arrow in FIG.
- the third embodiment of the present invention will be shown in FIGS. 10A and 10B .
- the shape in the vicinity of the tube hole portion 113 a of the header plate 113 is changed as compared with the above-described second embodiment.
- the header plate 113 is previously provided with a protruding portion 113 f which reduces a contact area with the flange portion 112 b in the abutting portion 114 where the flange portion 112 b abuts on the header plate 113 .
- the protruding portion 113 f is formed in such a way as to raise the peripheral portion of the tube hole portion 113 a of the header plate 113 to the end side in the longitudinal direction of the tube 112 .
- the end portion in the longitudinal direction of the tube 112 is inserted into the tube hole portion 113 a and is expanded and bent nearly 90 degrees, thereby the flange portion 112 b is formed.
- the tube 112 is bonded to the header plate 113 in the solid phase by the vibrator (not shown in FIG. 10 ).
- the header plate 113 is provided with the protruding portion 113 f to reduce the contact area of the flange portion 112 b with the header plate 113 .
- the tube 112 can be bonded to the header plate 113 while absorbing the clearance 6 between the tube 112 and the tube hole portion 113 a. Still further, because the protruding portion 113 f is formed, it can provide the same function as the chamfered portion 113 c of the second embodiment and hence the inserting performance of the tube 112 to be inserted into the tube hole portion 113 a can be improved.
- the specific shape of the cut-out portion 112 d is not limited to the above-described one.
- the tube 112 is cut out in the shape of a circumference having a radius R at two end portions in the direction of long diameter in the flat cross section of the tube 112 to form the cut-out portions 112 d.
- the end portion of the tube 112 in the longitudinal direction of the tube 112 can be cut out in such a way as to be tangent to a circumference having a radius R along the entire length between the opposed cut-out portions 112 d shown in FIGS. 11A, 11B or in a manner similar to this.
- the shape of this cut-out portion 112 d can be applied also to the second embodiment.
- the abutting portion 114 where the tube 112 is bonded to the header plate 113 is formed by forming the flange portion 112 b.
- the tube hole portion 113 a can be a simple through hole or a burring hole, and a portion (insertion portion), where the tube 112 is made to abut on the header plate 113 when the tube 112 is inserted into the tube hole portion 113 a, may be used as an abutting portion.
- the tube 112 may be a circular tube or an ellipsoidal tube in place of a flat tube.
- the heater core 100 has been described as the heat exchanger of the present invention.
- the heat exchanger of the present invention can be used for a radiator for cooling an engine, a condenser for a refrigeration cycle and the like.
- the materials of the respective parts may be copper-based material, stainless steel, or the like in place of the aluminum alloy.
- the tank body 121 does not necessarily need to be bonded to the header plate 113 by laser welding. Further, a sealing material may be interposed between the tank body 121 and the header plate 113 , and a claw portion provided at the erect edge portion 113 e of the header plate 113 may be caulked to bond the tank body 121 to the header plate 113 .
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- Mechanical Engineering (AREA)
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- Thermal Sciences (AREA)
- General Engineering & Computer Science (AREA)
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- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
- Details Of Heat-Exchange And Heat-Transfer (AREA)
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Abstract
In a heat exchanger, a core portion includes a plurality of plate fins each shaped like a flat plate and a plurality of tubes in which a fluid flows and each of which is inserted into each of the plate fins to be mechanically bonded thereto. Further, an end portion in a longitudinal direction of each of the tubes is bonded to a header plate which constructs a part of a header tank. In this heat exchanger, the tube is bonded to the header plate in a solid phase. Therefore, the plate fins are mechanically bonded to the tube and the end portion of the tube in the longitudinal direction of the tube can be bonded to the header plate without a furnace of a high temperature.
Description
- This application is based on Japanese Patent Applications No. 2003-153105 filed on May 29, 2003, No. 2003-332291 filed on Sep. 24, 2003, and No. 2004-110372 filed on Apr. 2, 2004, the disclosure of which is incorporated herein by reference.
- The present invention relates to a heat exchanger having a core portion in which plate fins are mechanically connected to a tube by expanding the tube, and a method for manufacturing the same. The present invention is suitably used for a heater core for a heating apparatus and a radiator for cooing an engine.
- In a plate fin type heat exchanger proposed in JA-A-2002-340490, plate fins are mechanically connected to a tube by expanding the tube. In order to enhance performance, a flat tube having a flat cross section is used, and a radius of curvature on an inner wall side at an end in a direction of long diameter of the cross section is at least ½ of a size in a direction of short diameter on the inner wall side nearly at the center in the direction of long diameter. With this, when the tube is expanded, the whole outer periphery of the tube can be nearly uniformly expanded to prevent the tube from being cracked or broken to enhance durability.
- However, an end portion in a longitudinal direction of tube is bonded to a header plate (core plate) by use of brazing (soldering) or an adhesive made of thermosetting resin material. For this reason, a furnace at high temperature is required and energy consumption is increased in a manufacture. In view of the fact that the reduction of CO2 is strongly required in recent years so as to prevent global warming, the inventors think that the reduction of energy consumption is extremely important.
- In view of the problems described above, an object of the present invention is to enable the bonding of an end portion in a longitudinal direction of a tube to a header plate without a furnace of high temperature, in a heat exchanger in which plate fins are mechanically bonded to the tube and in a method for manufacturing the same.
- According to the present invention, a heat exchanger has a core portion (110) including a plurality of plate fins (111) each shaped like a flat plate, and a tube (112) in which fluid flows and which is inserted into the plate fins (111) to be mechanically connected thereto. An end portion of the tube (112) in the longitudinal direction of the tube (112) is bonded to a header plate (113) which constructs a part of a header tank (120). In this heat exchanger, the tube (112) and the header plate (113) are bonded to each other by a solid bonding. This can provide a heat exchanger for eliminating the need for providing a furnace of high temperature.
- Preferably, the tube (112) has a flange portion (112 b) expanded and bent to the surface of the header plate (113) along the whole periphery on the tip side of an insertion portion (112 a) inserted into a tube hole portion (113 a) provided in the header plate (113). A portion where the tube (112) and the header plate (113) are bonded to each other has an abutting portion (114) where the flange portion (112 b) abuts on the header plate (113). This can facilitate the solid bonding and can stably bond the tube (112) to the header plate (113).
- For example, the flange portion (112 b) is formed in such a way as to be expanded and bent nearly 90 degrees along the surface of the header plate (113). This can prevent the end portion of the tube (112) in the longitudinal direction of the tube (112) from protruding into the header tank (120) and hence can reduce a flowing resistance of the fluid flowing in the header tank (120).
- Preferably, a tapered portion (113 b) is formed on a side of the flange (112 b) in the tube hole portion (113 a). In this case, the tube (112) is formed along the tapered portion (113 b) and is bonded to the header plate (113) also in a portion where the tube (112) abuts on the tapered portion (113 b). This can increase the bonding area of the tube (112) and the header plate (113) to provide a heat exchanger (100) with the further stabilized bonding.
- More preferably, at a predetermined position of an outer peripheral portion of the flange portion (112 b), a stress relieving portion (112 d) is formed. The stress relieving portion (112 d) is for relieving a tensile stress generated in a peripheral direction when the flange portion (112 b) is formed. This can prevent the flange portion (112 b) from being cracked when the flange portion (112 b) is formed and secure the sufficient area of the flange portion (112 b). Moreover, the tube (112) can be bonded to the header plate (113) while absorbing a clearance (δ) between the tube (112) and the tube hole portion (113 a). For example, the stress relieving portion (112 d) can be formed as a cut-out portion (112 d) in which the outer peripheral portion of the flange portion (112 b) is cut out in a circumferential shape.
- Alternatively, on a side of the header plate (113) in a bonding portion where the tube (112) is bonded to the header plate (113), a protruding portion (113 f) for reducing a contact area with the tube (112) side is formed. This can reduce the contact area of the tube (112) side and the header plate (113) and hence can increase a bearing stress even if a load applied in the solid bonding is decreased, thereby providing reliable bonding and preventing the deformation of the tube (112) and the header plate (113).
- A first chamfered portion (113 c) is formed on a side of the tube hole portion (113 a) in which the tube (112) is inserted. This can improve the ease with which the tube (112) is inserted into the tube hole portion (113 a). Moreover, a second chamfered portion (113 g) is formed on a side of the flange portion (112 b) in the tube hole portion (113 a). Therefore, a space formed between the second chamfered portion (113 g) and the flange portion (112 b) absorbs a material flowed by a load applied to the header plate (113) when the flange portion (112 b) is bonded to the header plate (113) in the solid bonding. Hence, this can restrict the flange portion (112 b) from being reduced in thickness near its bent portion and can form the bent portion in a shape resistant to stress concentration and hence can enhance the strength of the flange portion (112 b). In this invention, preferably, the tube (112) has a thickness that is in a range from 0.1 mm to 0.5 mm.
- In a method for manufacturing a heat exchanger in accordance with the present invention, a tube (112) in which a fluid flows is inserted into a plurality of plate fins (111) each shaped like a flat plate and the tube (112) is expanded to make the plate fins (111) be mechanically bonded to the tube (112) to form a core portion (110). In a bonding of an end portion of the tube (112) in the longitudinal direction of the tube (112) to a header plate (113) forming a part of a header tank (120), while vibrating the tube (112) by a supersonic vibration in a direction in which a surface of an abutting portion (114) where the tube (112) abuts on the header plate (113) extends, a predetermined load is applied in a direction in which the tube (112) abuts on the header plate (113) to bond the tube (112) to the header plate (113) in a solid bonding. This can manufacture a heat exchanger (100) without use of a furnace of a high temperature and hence can reduce energy consumption in the manufacturing.
- Preferably, the method for manufacturing the heat exchanger further includes a step of passing the tube (112) into a tube hole portion (113 a) made in the header plate (113) and then bending the end portion in the longitudinal direction of the tube (112) along its whole periphery in such a way as to expand to a surface side of the header plate (113) to form a flange portion (112 b) and to make the flange portion (112 b) abut on the header plate (113), in a forming step of the abutting portion (114). This can eliminate the need for increasing the position accuracy of a vibrator (220) and the tube (112) when the supersonic vibration is applied, and can realize stable bonding necessary for hermetically holding the fluid flowing in the tube (112).
- Other objects, features, and advantages of the present invention will become apparent from the following detailed description made with reference to the accompanying drawings, in which:
-
FIG. 1 is an exploded perspective view showing a general construction of a heater core of the present invention; -
FIG. 2 is a cross-sectional view showing a step of pounding a header plate in a first embodiment of the present invention; -
FIG. 3A is a cross-sectional view showing a step of preliminarily expanding the tip portion of a tube in the first embodiment of the present invention, andFIG. 3B is a cross-sectional view showing a step of finally expanding the tip portion of the tube; -
FIG. 4 is a cross-sectional view showing a step of bonding the tube to the header plate in a solid bonding in the first embodiment of the present invention; -
FIGS. 5A and 5B are cross-sectional views showing the tip portion of a tube and a header plate in a second embodiment of the present invention; -
FIG. 6 is an enlarged cross-sectional view showing the vicinity of the bent portion of a flange portion inFIG. 5 before the solid bonding; -
FIG. 7 is an enlarged cross-sectional view showing the vicinity of the bent portion of a flange portion inFIG. 5 after the solid bonding; -
FIGS. 8A and 8B are comparative examples of the second embodiment shown inFIGS. 5A and 5B and are cross-sectional views in a case where R cut-out portions and chamfered portions are not formed; -
FIG. 9 is a comparative example ofFIG. 7 and an enlarged cross-sectional view showing the vicinity of the bent portion of a flange portion after the solid bonding; -
FIGS. 10A and 10B are cross-sectional views showing the tip portion of a tube and a header plate in a third embodiment of the present invention; -
FIGS. 11A and 11B are cross-sectional views showing the tip portion of a tube and a header plate in a modified example 1 of the third embodiment; and -
FIGS. 12A and 12B are cross-sectional views showing the tip portion of a tube and a header plate in a modified example 2 of the third embodiment. - The first embodiment of the present invention will be described with reference to
FIG. 1 toFIG. 4 . In the first embodiment, a heat exchanger of the present invention is applied to aheater core 100 for a heating apparatus that heats air for air conditioning by using a hot water (inside fluid). - First, the basic construction of the
heater core 100 will be described with reference toFIG. 1 . Theheater core 100 includes acore portion 110 for exchanging heat and twoheader tanks 120 arranged on end sides in a longitudinal direction of atube 112. The material of the respective parts of theheater core 100 to be described below is aluminum or aluminum alloy. - The
core portion 110 includesplate fins 111 andtubes 112. The plate fin (hereinafter referred to as fin) 111 is a band-shaped member having a thin thickness (here, assumed to be 25 μm) and thefins 111 are laminated at a predetermined pitch (fin pitch). A plurality of sets (three sets) of assemblies of the plurallaminated fins 111 are used. Eachfin 111 has plural insertion holes 111 a (FIG. 4 ) arranged in a longitudinal direction of thefin 111. - The
tube 112 is a flat tube having a thin thickness (for example, 0.2 mm in thickness) and a flat cross section. Thetube 112 is inserted into theinsertion hole 111 a of eachfin 111, and the direction of long diameter in a cross section of thetube 112 is pointed in the longitudinal direction of thefin 111. Thetube 112 is expanded and press-fitted to thefin 111, whereby thetube 112 is mechanically bonded to thefin 111. - Assemblies of the
fins 111 and thetubes 112 bonded to each other in this manner are arranged in such a way as to be adjacent to each other on the longitudinal side of the fin 111 (for example, 3 rows). Moreover, both end portions in the longitudinal direction of thetube 112 are bonded to theheader plates 113. Theheader plate 113 is a plate-shaped member forming a part of theheader tank 120 together with atank body 121 to be described below. In theheader plate 113, anerect edge portion 113 e is formed on the outside periphery of arectangular plane portion 113 d that has a size larger than an outer dimension of thecore portion 110 in a case where thecore portion 110 is projected from the longitudinal direction of thetube 112. - In the
header plate 113, tube holes 113 a corresponding to the tubes 112 (FIG. 2 toFIG. 4 ) are formed. The end portion in the longitudinal direction of eachtube 112 is inserted into thetube hole portions 113 a, whereby thetubes 112 are bonded to theheader plate 113. The present invention is characterized by the bonding structure of thetube 112 and theheader plate 113 and a method for manufacturing the same, which will be described later in detail. - The
tank bodies 121 are bonded to both of theheader plates 113 to form theheader tanks 120. Thetank body 121 is a box-shaped part open at the side of theheader plate 113. The opening side of thetank body 121 is inserted inside theerect edge portion 113 e of theheader plate 113 and is welded to theheader plate 113 along the entire periphery of thetank body 121. Aninlet pipe 131 is bonded to one tank body 121 (e.g., on the upper side inFIG. 1 ). Anoutlet pipe 132 is bonded to another tank body 121 (e.g., on the lower side inFIG. 1 ). Both of thepipes header tanks 120, respectively. - In the
heater core 100 formed in this manner, hot water flows through thetubes 112 via oneheader tank 120 from theinlet pipe 131 and is collected by anotherheader tank 120 and flows out of theoutlet pipe 132. The hot water flowing through thetubes 112 exchanges heat with air for air conditioning supplied from the outside in the direction of the long diameter in the cross section of thetube 112 to heat the air for air conditioning. At this time, the heat exchange is accelerated by thefins 111. - A method for manufacturing the
heater core 100 will be described with reference toFIG. 2 toFIG. 4 . First, predetermined pieces offins 111 are laminated at predetermined intervals by using a laminating jig (not shown) as a guide. Thetubes 112 are inserted into the respective insertion holes 111 a and then a tube expanding tool (not shown) is inserted into each of thetubes 112 to expand thetubes 112 and to press-fit thetube 112 to the fin 111 (step of assembling core portion). - Next, as shown in
FIG. 2 , the end portion in the longitudinal direction of thetube 112 is inserted into thetube hole portion 113 a of theheader plate 113 and theheader plate 113 is pounded by a press (not shown) so as to project thetube 112 to a side opposite to an insertion side. At this time, on thetube 112, aninsertion portion 112 a abutting on thetube hole portion 113 a is formed. A chamferedportion 113 c is previously formed on the tube insertion side of thetube hole portion 113 a and atapered portion 113 b is previously formed on a side opposite to the insertion side (i.e., the side of theflange portion 112 b) (step of pounding a header plate). - Next, as shown in
FIGS. 3A and 3B , the end portion in the longitudinal direction of thetube 112 protruding from theheader plate 113 is expanded. That is, first, the end portion of thetube 112 is expanded in the shape of a bell at a predetermined angle by a preliminary tube expanding jig 211 (FIG. 3A ). Further, the tip portion of thetube 112 is bent along theplane portion 113 d of theheader plate 113 in such a way as to expand nearly at 90 degrees by a tube expanding jig 212 (FIG. 3B ). With this, aflange portion 112 b is formed at the tip portion of thetube 112, whereby an abuttingportion 114 where theflange portion 112 b abuts on the header plate 113 (plane portion 113 d) is formed. Further, an expandedportion 112 c is formed between theinsertion portion 112 a of thetube 112 and theflange portion 112 b by thetube expanding jig 212, and abuts on the taperedportion 113 b (step of expanding tube). - Next, as shown in
FIG. 4 , thetube 112 and theheader plate 113 are bonded to each other in a solid phase by avibrator 220. Thevibrator 220 has an external shape along theflange portion 112 b and the expandedportion 112 c. Thevibrator 220 vibrates in a direction in which the surface of the abuttingportion 114 extends (in left-right direction inFIG. 4 ) and at the same time applies a predetermined load to thetube 112 in the direction that makes theflange portion 112 b abut on theheader plate 113. Here, the vibration conditions of thevibrator 220 are as follows: frequency is 20 kHz; amplitude is from 20 μm to 60 μm; and pressure is from 50 kg to 100 kg. The working time per one tube of thevibrator 220 is from 0.2 sec to 0.5 sec. A heater (high frequency resistance heating) 230 as a heating unit is mounted near the abuttingportion 114 where theflange portion 112 b abuts on theheader plate 113. - The
flange portion 112 b and the expandedportion 112 c of thetube 112 are vibrated in the left-right direction inFIG. 4 by the action of thisvibrator 220. At this time, thetube 112 and theheader plate 113 have their oxide films removed in the abuttingportion 114 and the taperedportion 113 b, and are heated to temperatures (from 200 to 300° C.) between the recrystallization temperature and the melting point of the part by frictional heat and the heat of theheater 230 and further have pressure applied thereto, thereby being bonded to each other in the solid phase (step of bonding tube). - It is preferable that the thickness of the
tube 112 is 0.1 mm or more so as to secure a basic strength as theheater core 100 and is 0.5 mm or less so as to transmit vibrations from thevibrator 220 to the side of theheader plate 113 without attenuation. The twotank bodies 121 to which theinlet pipe 131 and theoutlet pipe 132 are previously welded are fitted inside theerect edge portion 113 e of theheader plates 113, respectively, and then are welded along the whole periphery by laser welding (step of welding tank). - In the first embodiment of this invention; in the
heater core 100 having thecore portion 110 including thefins 111 and thetubes 112 that are mechanically bonded to each other, thetube 112 and theheader plate 113 are bonded to each other in the solid phase. For this reason, theheater core 100 can be formed without necessitating a furnace of high temperature. Therefore, energy consumption can be reduced in the manufacture, and equipment cost for a furnace can be reduced. - To be specific, in the solid bonding, the
flange portion 112 b is formed in thetube 112 and is bonded to theheader plate 113 at the abuttingportion 114 where theflange portion 112 b abuts on theheader plate 113. Therefore, when thevibrator 220 applies supersonic vibrations to thetube 112, positioning accuracy between thevibrator 220 and thetube 112 is eliminated and the solid bonding can be easily performed. Moreover, the inside hot water can be easily hermetically held, and thetube 112 can be stably bonded to theheader plate 113. - Because the
flange portion 112 b is formed, it can prevent the end portion in the longitudinal direction of thetube 112 from protruding into theheader tank 120, and thereby reducing the flowing resistance of the hot water flowing inside theheader tank 120 and improving performance as theheater core 100. - Further, in the solid bonding, the
heater 230 heats thetube 112 and theheader plate 113 near the abuttingportion 114. For this reason, the stabilization of temperature condition necessary for the solid bonding can be easily performed, whereby thetube 112 can be stably bonded to theheader plate 113. - Still further, the tapered
portion 113 b is formed at thetube hole portion 113 a of theheader plate 113. Moreover, the expandedportion 112 c is formed in thetube 112 so that thetube 112 is bent along this taperedportion 113 b. Hence, this can increase the bonding area of thetube 112 and theheader plate 113 and can perform a further stable bonding. - Since the
tube hole portion 113 a is provided with the chamferedportion 113 c, the inserting performance of thetube 112 into thetube hole portion 113 a can be improved. Further, thetube 112 is a flat tube 12 having a flat cross section. Therefore, thisflat tube 112 can enhance a heat transfer coefficient of hot water flowing in thetube 112 and can reduce a flow resistance to air for air conditioning flowing outside thetube 112 to enhance the heat exchange performance of theheater core 100. - In addition, the heating of the tapered
portion 113 b of theheader plate 113 and the expandedportion 112 c of thetube 112 by theheater 230 can be stopped according to the bonding strength at the abuttingportion 114 due to theflange portion 112 b. - The second embodiment of the present invention will be shown in
FIG. 5A toFIG. 7 . In the second embodiment, the shape of theflange portion 112 b of thetube 112 is changed in comparison with the first embodiment. That is, the shape of end portion in the longitudinal direction of thetube 112 before forming theflange portion 112 b is changed.FIG. 6 is an enlarged sectional view to show the vicinity of theflange portion 112 b inFIG. 5 in a state where theflange portion 112 b abuts on theheader plate 113, andFIG. 7 is an enlarged sectional view to show the vicinity of theflange portion 112 b inFIG. 5 after the solid bonding of theflange portion 112 b to theheader plate 113 is performed. - Here, cut-out
portions 112 d are previously formed as stress relieving portions in predetermined portions along the entire periphery of the end portion in the longitudinal direction of thetube 112. To be more specific, in the cut-outportions 112 d, the end portion of thetube 112 has a recess portion removed by a large radius of R in the direction of long diameter in the cross section of thetube 112. In the step of forming thetube 112, the end portion of thetube 112 is cut out (removed) in the vertical direction with respect to the surface of paper inFIGS. 5A and 5B by a cutter corresponding to a shape shown by a double dot and dash line inFIGS. 5A and 5B to form the cut-outportion 112 d. - Moreover, a chamfered portion (corresponding to the first chamfered portion in this invention) 113 c is formed on the side of the
tube hole portion 113 a to which thetube 112 is inserted and a chamfered portion (corresponding to the second chamfered portion in this invention) 113 g is formed also on the side of theflange portion 112 b of thetube hole portion 113 a. - As is the case with the first embodiment, the end portion in the longitudinal direction of the
tube 112 is inserted into thetube hole portion 113 a and is expanded and bent approximately 90 degrees to form theflange portion 112 b. Then, thetube 112 is bonded to theheader plate 113 in a solid phase by the vibrator (not shown inFIGS. 5A and 5B ). - By forming the
flange portion 112 b on thetube 112, a clearance δ between thetube 112 and thetube hole portion 113 a is absorbed in the solid bonding. For this reason, the area of theflange portion 112 b needs to be increased. Hence, as shown in a comparative example shown inFIGS. 8A and 8B , the amount of protrusion (h) of thetube 112 is usually increased. However, when the amount of protrusion (h) is simply increased, a tensile stress generated at an R portion on the end side in the direction of long diameter of theflange portion 112 b becomes large and theflange portion 112 b is apt to be broken at the R portion. Hence, after all, the area of theflange portion 112 b can not be increased. - Further, by pressing the
flange portion 112 b onto theheader plate 113 in the solid bonding, as shown in a comparative example inFIG. 9 , the thickness of theflange portion 112 b is reduced. In addition, when a portion of thetube hole portion 113 a on a side of theflange portion 112 b is formed in a sharp angle, the portion has stress concentrated thereon, which might reduce the strength of theflange portion 112 b. - However, in the second embodiment, the cut-out
portion 112 d previously formed on the end portion in the longitudinal direction of thetube 112 can relieve the tensile stress generated in a circumferential direction of the cut-outportion 112 d when thetube 112 is expanded and bent approximately 90 degrees to form theflange portion 112 b. Hence, it can prevent cracks when theflange portion 112 b is formed, and thereby sufficiently securing the area of theflange portion 112 b. Accordingly, the clearance 8 between thetube 112 and thetube hole portion 113 a can be absorbed, and thetube 112 can be bonded to theheader plate 113. - Moreover, the
tube hole portion 113 a is provided with the chamferedportions flange portion 112 b is pressed into theheader plate 113 by the solid bonding as shown inFIG. 7 from the state where theflange portion 112 b abuts on theheader plate 113 as shown inFIG. 6 , the flowing material (shown by a white arrow inFIG. 7 ) of theheader plate 113 when a portion near thetube hole portion 113 a of theheader plate 113 is deformed can be absorbed in a space formed between the chamferedportion 113 c and thetube 112. Further, a load applied to the vicinity of the bent portion of theflange portion 112 b is relieved to prevent theflange portion 112 b form being reduced in thickness in the vicinity of the bent portion of theflange portion 112 b. At this time, if theheader plate 113 is deflected, the bonding performance for bonding theflange portion 112 b to theheader plate 113 is reduced. Therefore, a fixing member for fixing the bottom surface of the header plate, 113 by a receiving jig is used. Alternatively, the deflection of theheader plate 113 can be reduced by increasing the thickness of theheader plate 113. Further, the flowing material (shown by a black arrow inFIG. 7 ) of thetube 112 when thetube 112 is pressed onto theheader plate 113 can be absorbed in a space formed between the chamferedportion 113 g and theflange portion 112 b. As a result, it can restrict theflange portion 112 b from being reduced in thickness and can form theflange portion 112 b in a shape in which stress is difficult to be concentrated on the bent portion and hence can enhance the strength of theflange portion 112 b. - The third embodiment of the present invention will be shown in
FIGS. 10A and 10B . In the third embodiment, the shape in the vicinity of thetube hole portion 113 a of theheader plate 113 is changed as compared with the above-described second embodiment. - Here, the
header plate 113 is previously provided with a protrudingportion 113 f which reduces a contact area with theflange portion 112 b in the abuttingportion 114 where theflange portion 112 b abuts on theheader plate 113. The protrudingportion 113 f is formed in such a way as to raise the peripheral portion of thetube hole portion 113 a of theheader plate 113 to the end side in the longitudinal direction of thetube 112. - As in the case with the first embodiment described above, the end portion in the longitudinal direction of the
tube 112 is inserted into thetube hole portion 113 a and is expanded and bent nearly 90 degrees, thereby theflange portion 112 b is formed. Thetube 112 is bonded to theheader plate 113 in the solid phase by the vibrator (not shown inFIG. 10 ). - When the
flange portion 112 b is bonded to theheader plate 113 in the solid phase, a force to be applied thereto needs to be made smaller than a predetermined value to prevent theflange portion 112 b and theheader plate 113 from being deformed. However, when the force to be applied is simply reduced, the solid bonding cannot be surely performed. In this third embodiment, as described above, theheader plate 113 is provided with the protrudingportion 113 f to reduce the contact area of theflange portion 112 b with theheader plate 113. Therefore, even if the force to be applied in the solid bonding is reduced, a bearing stress can be increased and hence the solid bonding can be surely performed and theflange portion 112 b and theheader plate 113 can be prevented from being deformed. Further, thetube 112 can be bonded to theheader plate 113 while absorbing the clearance 6 between thetube 112 and thetube hole portion 113 a. Still further, because the protrudingportion 113 f is formed, it can provide the same function as the chamferedportion 113 c of the second embodiment and hence the inserting performance of thetube 112 to be inserted into thetube hole portion 113 a can be improved. - The specific shape of the cut-out
portion 112 d is not limited to the above-described one. As shown inFIGS. 11A, 11B , thetube 112 is cut out in the shape of a circumference having a radius R at two end portions in the direction of long diameter in the flat cross section of thetube 112 to form the cut-outportions 112 d. Alternatively, as shown inFIGS. 12A, 12B , the end portion of thetube 112 in the longitudinal direction of thetube 112 can be cut out in such a way as to be tangent to a circumference having a radius R along the entire length between the opposed cut-outportions 112 d shown inFIGS. 11A, 11B or in a manner similar to this. The shape of this cut-outportion 112 d can be applied also to the second embodiment. - In the first embodiment to the third embodiment, the abutting
portion 114 where thetube 112 is bonded to theheader plate 113 is formed by forming theflange portion 112 b. However, as for this abutting portion, thetube hole portion 113 a can be a simple through hole or a burring hole, and a portion (insertion portion), where thetube 112 is made to abut on theheader plate 113 when thetube 112 is inserted into thetube hole portion 113 a, may be used as an abutting portion. - Further, the
tube 112 may be a circular tube or an ellipsoidal tube in place of a flat tube. - Still further, the
heater core 100 has been described as the heat exchanger of the present invention. However, the heat exchanger of the present invention can be used for a radiator for cooling an engine, a condenser for a refrigeration cycle and the like. The materials of the respective parts may be copper-based material, stainless steel, or the like in place of the aluminum alloy. - Still further, the
tank body 121 does not necessarily need to be bonded to theheader plate 113 by laser welding. Further, a sealing material may be interposed between thetank body 121 and theheader plate 113, and a claw portion provided at theerect edge portion 113 e of theheader plate 113 may be caulked to bond thetank body 121 to theheader plate 113.
Claims (16)
1. A heat exchanger comprising:
a core portion including a plurality of plate fins each shaped like a flat plate and a tube in which a fluid flows, the tube being inserted into the plate fins to be mechanically connected to the plate fins; and
a header plate to which an end portion of the tube in a longitudinal direction of the tube is bonded, and which construct a part of a header tank,
wherein the tube and the header plate are bonded to each other by a solid bonding.
2. The heat exchanger as in claim 1 ,
wherein the tube has an insertion portion inserted into a tube hole provided in the header plate,
wherein the insertion portion of the tube has a flange portion expanded and bent to a surface of the header plate along the entire periphery on a tip side of the insertion portion, and
wherein the tube and the header plate are bonded to each other at an abutting portion where the flange portion abuts on the header plate.
3. The heat exchanger as in claim 2 , wherein the flange portion is expanded and bent approximately 90 degrees along the surface of the header plate.
4. The heat exchanger as in claim 2 ,
wherein the header plate has a hole wall portion for defining the tube hole, and the hole wall portion has a tapered portion on a side of the flange portion, and
wherein the tube is formed along the tapered portion and is bonded to the tapered portion to contact the tapered portion.
5. The heat exchanger as in claim 2 , wherein the flange portion has a stress relieving portion for relieving a tensile stress that is generated in a peripheral direction when the flange portion is formed at a predetermined position of an outer peripheral portion of the flange portion.
6. The heat exchanger as in claim 5 , wherein the stress relieving portion is a portion in which the outer peripheral portion of the flange portion is cut out in a circumferential shape.
7. The heat exchanger as in claim 1 , wherein the header plate has a protruding portion for reducing a contact area with the tube, in a bonding portion where the tube is bonded to the header plate.
8. The heat exchanger as in claim 2 ,
wherein the header plate has a hole wall portion for defining the tube hole, and
wherein the hole wall portion has a first chamfered portion formed on a side in which the tube is inserted.
9. The heat exchanger as in claim 8 , wherein the hole wall portion has a second chamfered portion formed on a side of the flange portion.
10. The heat exchanger as in claim 1 , wherein the tube has a thickness that is in a range from 0.1 mm to 0.5 mm.
11. The heat exchanger as in claim 1 , wherein the tube is a flat tube having a flat cross section.
12. A method for manufacturing a heat exchanger, comprising the steps of:
inserting a tube in which a fluid flows into a plurality of plate fins each shaped like a flat plate;
expanding the tube to mechanically connect the tube to the plate fins to form a core portion; and
connecting an end portion of the tube in a longitudinal direction of the tube to a header plate forming a part of a header tank;
vibrating the tube by supersonic vibration in a direction in which a surface of an abutting portion where the tube abuts on the header plate extends; and
solid-bonding the tube to the header plate in a solid phase while applying a predetermined load in a direction in which the tube abuts on the header plate.
13. The method for manufacturing a heat exchanger as in claim 12 , further comprising a step of penetrating the tube into a tube hole provided in the header plate upon forming the abutting portion and then bending the end portion in the longitudinal direction of the tube along its entire periphery in such a way as to expand to a surface of the header plate to form a flange portion to make the flange portion abut on the header plate, in the forming of the abutting portion.
14. The method for manufacturing a heat exchanger as in claim 13 , further comprising a step of previously forming a stress relieving portion for relieving a tensile stress generated in a circumferential direction at a predetermined portion along the entire periphery of the end portion of the tube in the longitudinal direction of the tube when the end portion of the tube in the longitudinal direction of the tube is bent to the surface of the header plate before forming the flange portion.
15. The method for manufacturing a heat exchanger as in claim 12 , further comprising a step of previously forming a protruding portion for reducing a contact area with the tube on the header plate in the abutting portion.
16. The method for manufacturing a heat exchanger as in claim 12 , further comprising a step of heating a portion near the abutting portion by heating means when the tube is bonded to the header plate in the solid phase.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/637,846 US7726024B2 (en) | 2003-05-29 | 2006-12-12 | Manufacturing method for a heat exchanger |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2003-153105 | 2003-05-29 | ||
JP2003153105 | 2003-05-29 | ||
JP2003-332291 | 2003-09-24 | ||
JP2003332291 | 2003-09-24 | ||
JP2004110372A JP2005121350A (en) | 2003-05-29 | 2004-04-02 | Heat exchanger and method for manufacturing it |
JP2004-110372 | 2004-04-02 |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/637,846 Division US7726024B2 (en) | 2003-05-29 | 2006-12-12 | Manufacturing method for a heat exchanger |
Publications (1)
Publication Number | Publication Date |
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US20050006079A1 true US20050006079A1 (en) | 2005-01-13 |
Family
ID=33568337
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/857,697 Abandoned US20050006079A1 (en) | 2003-05-29 | 2004-05-28 | Heat exchanger and manufacturing method for the same |
US11/637,846 Expired - Fee Related US7726024B2 (en) | 2003-05-29 | 2006-12-12 | Manufacturing method for a heat exchanger |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US11/637,846 Expired - Fee Related US7726024B2 (en) | 2003-05-29 | 2006-12-12 | Manufacturing method for a heat exchanger |
Country Status (2)
Country | Link |
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US (2) | US20050006079A1 (en) |
JP (1) | JP2005121350A (en) |
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EP2072938A2 (en) * | 2007-06-13 | 2009-06-24 | A.M. S.R.L. | Heat exchanger for boiler, method and tool for the manufacture thereof |
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CN101793478A (en) * | 2010-03-11 | 2010-08-04 | 努奥罗(中国)有限公司 | Improved structure for installing radiating tube of heating radiator |
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Also Published As
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---|---|
US7726024B2 (en) | 2010-06-01 |
US20070114268A1 (en) | 2007-05-24 |
JP2005121350A (en) | 2005-05-12 |
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