US20070181293A1 - Heat exchanger and producing method thereof - Google Patents
Heat exchanger and producing method thereof Download PDFInfo
- Publication number
- US20070181293A1 US20070181293A1 US11/700,569 US70056907A US2007181293A1 US 20070181293 A1 US20070181293 A1 US 20070181293A1 US 70056907 A US70056907 A US 70056907A US 2007181293 A1 US2007181293 A1 US 2007181293A1
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- United States
- Prior art keywords
- hole
- header tank
- header
- heat exchanger
- connectors
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Classifications
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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
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/0246—Arrangements for connecting header boxes with flow lines
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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
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/0219—Arrangements for sealing end plates into casing or header box; Header box sub-elements
- F28F9/0224—Header boxes formed by sealing end plates into covers
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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
- F28D1/05366—Assemblies of conduits connected to common headers, e.g. core type radiators
Definitions
- This invention relates to a heat exchanger having connectors for connecting pipes through which a heat-exchanging fluid flows in and out, and a method of producing the heat exchanger.
- Patent Document 1 discloses a heat exchanger used as a condenser for condensing by radiating the heat of the refrigerant into the air.
- This conventional heat exchanger includes a pair of header tanks of a segmentation type on one of which the connectors are mounted.
- the header tank of segmentation type is defined as a cylindrical header tank with a second header member fitted on a first header member connected to the tubes in which the heat-exchanging fluid flows.
- the first and second header members of the heat exchanger disclosed in Patent Document 1 have notches, respectively, formed in the fitting portions thereof fitted with each other, and by fitting the first and second header members on each other, a rectangular through hole is formed by the notches.
- the connectors are each formed with a protrusion adapted to the shape of and insertable into the corresponding through hole.
- the through holes for tacking the connectors are formed by combining the notches formed on the first and second header members. Once the relative positions of the notches are shifted by the dimensional error or assembly error in the manufacture of the first and second header members, therefore, the shape of each through hole fails to fit the shape of the protrusion of each connector.
- the object of this invention is to couple the connectors properly to the header tank.
- a heat exchanger comprising a cylindrical header tank ( 14 ) connected with a plurality of tubes ( 11 ) through which a fluid passes and a pair of connectors ( 20 , 21 ) for fluid pipe connection, wherein the connectors ( 20 , 21 ) have a tacked portion ( 20 b ) engaging the header tank ( 14 ), and the connectors ( 20 , 21 ) and the header tank ( 14 ) have coupling surfaces, respectively, coupled by brazing to each other.
- the connectors ( 20 , 21 ) have the tacked portion ( 20 b ) engaging the header tank ( 14 ), and therefore, the connectors ( 20 , 21 ) can be coupled to and tacked on the header tank ( 14 ) positively.
- the connectors ( 20 , 21 ) and the header tank ( 14 ) each have a coupling surface, and therefore a sufficient coupling strength can be secured between them.
- the header tank ( 14 ) has a through hole ( 17 b ) establishing communication between inside and outside of the header tank ( 14 ), and the connectors ( 20 , 21 ) each have the protrusion ( 20 b ) inserted into the through hole ( 17 b ).
- the tacked portion therefore, may be engaging portions ( 20 g ) configured by deforming the protrusion ( 20 b ).
- the protrusion ( 20 b ) inserted into the through hole ( 17 b ) is deformed and makes up the engaging portions ( 20 g ). Therefore, the connectors ( 20 , 21 ) can be easily tacked on the header tank ( 14 ). Further, as compared with the case in which the engaging portion ( 20 b ) is formed on the outer peripheral surface of the header tank ( 14 ), the header tank ( 14 ) is not unnecessarily made bulky.
- the connectors ( 20 , 21 ) can be properly connected to the header tank ( 14 ) without increasing the size of the heat exchanger.
- the protrusion ( 20 b ) may be caulked on the inner periphery of the through hole ( 17 b ). Then, since the protrusion ( 20 ) is caulked on the through hole ( 17 b ), the connectors ( 20 , 21 ) can be tacked more strongly on the header tank ( 14 ).
- the through hole ( 17 b ) may alternatively be formed on the side of the cylinder of the header tank ( 14 ). Also, the opening of the through hole ( 17 b ) may be elongated along the length of the header tank ( 14 ). Furthermore, the engaging portions ( 20 g ) may be arranged at the two ends of the protrusion ( 20 ) along the length of the header tank ( 14 ).
- the cylindrical header tank ( 14 ) is elongated.
- each engaging portion ( 20 g ) is deformed toward the inner periphery of the through hole ( 17 b ) with a load imposed in the direction parallel to the longitudinal direction, the deformation of the through hole ( 17 b ) can be suppressed more than in the case where the deforming load is imposed in the other directions.
- the protrusion ( 20 b ) is deformed toward the inner periphery of the through hole ( 17 b ) while being caulked by the load in the directions of arrows E providing the load along the circumference of the header tank ( 14 ). Then, the through hole ( 17 b ) is easily extended and deformed along the outer periphery of the header tank ( 14 ).
- the header tank ( 14 ) is not easily deformed in longitudinal direction and therefore the deformation of the through hole ( 17 b ) can be suppressed.
- the protrusion ( 20 b ) can be deformed under the load parallel to the length of the header tank ( 14 ).
- the deformation of the through hole ( 17 b ) is suppressed, and the connectors ( 20 , 21 ) can be more properly coupled to the header tank ( 14 ).
- the header tank ( 14 ) is configured by fitting the second header member ( 17 ) on the first header member ( 16 ) connected with a plurality of the tubes ( 11 ), and the through hole ( 17 b ) can alternatively be formed in the second header member ( 17 ).
- the connectors ( 20 , 21 ) can be tacked on the second header member ( 17 ).
- the header tank ( 14 ) not yet cylindrical, therefore, the connectors ( 20 , 21 ) can be tacked on the second header member ( 17 ).
- the workability of tacking the connectors ( 20 , 21 ) on the second header member ( 17 ) is improved.
- the improved workability reduces the production cost of the heat exchanger.
- the through hole ( 17 b ) can be easily formed in the second header member ( 17 ) in press, etc. and therefore, unlike in the prior art in which a notch is formed on each of the two component parts including the second header member ( 17 ) and the first header member ( 16 ), the production cost of the heat exchanger is reduced while at the same time improving the geometric dimensional accuracy of the through hole ( 17 b ).
- the second header member ( 17 ) has a pair of fitting steps ( 17 a ) having an L-shaped section fitted with the first header member ( 16 ), and the through hole ( 17 b ) may be arranged adjacently to any of the fitting steps ( 17 a ).
- the fitting steps ( 17 a ) having the L-shaped section not only facilitate the positioning of the first header member ( 16 ) on the second header member ( 17 ) but also improve the rigidity of the second header member ( 17 ).
- the through hole ( 17 b ) adjacent to any one of the fitting steps ( 17 a ) therefore, the deformation of the through hole ( 17 b ) at the time of tacking by caulking can be suppressed further.
- the through hole ( 17 b ) is open in the direction (B) perpendicular to the length of the tubes ( 11 ), and the connectors ( 20 , 21 ) may be arranged on the header tank ( 14 ) in such a manner as to project outward in the direction (B) perpendicular to the length of the tubes ( 11 ) from the opening of the through hole ( 17 b ).
- the connectors ( 20 , 21 ) are not projected to an unnecessary degree outward along the length of the tubes ( 11 ) from the header tank ( 14 ), with the result that the connectors ( 20 , 21 ) can be properly coupled to the header tank ( 14 ) without increasing the size of the heat exchanger.
- the connectors ( 20 , 21 ) each have positioning portions ( 20 c ) set in position by contact with the outer peripheral portion of the header tank ( 14 ), and the coupling surface may be the contact portion between the positioning portions ( 20 c ) and the header tank ( 14 ).
- the connectors ( 20 , 21 ) can be tacked on the header tank ( 14 ) with a higher positioning accuracy and, therefore, the mounting dimensional accuracy is improved after coupling the connectors ( 20 , 21 ) and the header tank ( 14 ).
- the contact portion between the positioning portions ( 20 c ) and the header tank ( 14 ) makes up a coupling surface
- the coupling strength between the connectors ( 20 , 21 ) and the second header member ( 17 ) can be improved by shaping the positioning portions ( 20 c ) adapted to the outer periphery of the header tank ( 14 ).
- a method of producing a heat exchanger including a cylindrical header tank ( 14 ) connected to a plurality of tubes with a fluid passing therein and a pair of connectors ( 20 , 21 ) for fluid pipe connection, comprising the steps of tacking the connectors ( 20 , 21 ) on the header tank ( 14 ) by deforming a part of the connectors ( 20 , 21 ), and coupling by brazing the connectors ( 20 , 21 ) and the header tank ( 14 ) to each other after the tacking step.
- the heat exchanger according to the first aspect can be produced.
- the tacking step of the heat exchanger production method may include the step of preparing the header tank ( 14 ) having a through hole ( 17 b ) communicating between inside and outside thereof, the step of preparing the connectors ( 20 , 21 ) each having a protrusion ( 20 b ) insertable into the through hole ( 17 b ) and the step of expanding the protrusion ( 20 b ) toward the inner periphery of the through hole ( 17 b ) after being inserted into the through hole ( 17 b ).
- the protrusion ( 20 b ) is inserted in the through hole ( 17 b ) and further expanded toward the inner periphery of the through hole ( 17 b ). Therefore, the connectors ( 20 , 21 ) can be easily tacked on the header tank ( 14 ). Further, the connectors ( 20 , 21 ) can be caulked on the outer peripheral surface of the header tank ( 14 ) without unnecessarily increasing the size of the header tank ( 14 ).
- the tacking step of the heat exchanger production method according to the second aspect described above may include the step of imposing a load on the protrusion ( 20 b ) in the direction parallel to the length of the header tank ( 14 ) after inserting the protrusion ( 20 b ) into the through hole ( 17 b ).
- the header tank ( 14 ) is not easily deformed in longitudinal direction, and therefore the deformation of the through hole ( 17 b ) can be suppressed also under the load imposed on the protrusion ( 20 b ) in the direction parallel to the length of the header tank ( 14 ).
- the tacking step of the heat exchanger production method may include the step of preparing the header tank ( 14 ) so configured that the second header member ( 17 ) having the through hole ( 17 b ) is fitted on the first header member ( 16 ) connected with a plurality of the tubes ( 11 ) and the step of fitting the second header member ( 17 ) on the first header member ( 16 ) after deforming the protrusion ( 20 b ) by being inserted into the through hole ( 17 b ).
- the connectors ( 20 , 21 ) are tacked on the second header member ( 17 ). Therefore, the connectors ( 20 , 21 ) can be tacked on the second header member ( 17 ) with the header tank ( 14 ) not yet cylindrical. As a result, the workability of tacking the connectors ( 20 , 21 ) on the second header member ( 17 ) is improved.
- the tacking step of the heat exchanger production method may include the step of preparing the header tank ( 14 ) with the through hole ( 17 b ) open in the direction (B) perpendicular to the length of the tubes ( 11 ) and the step of arranging the connectors ( 20 , 21 ) on the header tank ( 14 ) in such a manner as to project outward in the direction (B) perpendicular to the length of the tubes ( 11 ) from the opening of the through hole ( 17 b ).
- the connectors ( 20 , 21 ) are arranged on the header tank ( 14 ) in such a manner as to project outward in the direction (B) perpendicular to the length of the tubes ( 11 ) from the opening of the through hole ( 17 b ), and therefore, a heat exchanger can be produced in which the connectors ( 20 , 21 ) are not projected to an unnecessary degree outward along the length of the tubes ( 11 ) from the header tank ( 14 ).
- FIG. 1 is a diagram showing a general configuration of a heat exchanger according to an embodiment of the invention.
- FIG. 2 is a sectional view taken in line A-A in FIG. 1 .
- FIG. 3A is a sectional view, taken in line A-A in FIG. 1 , showing the second header member as a unit according to an embodiment
- FIG. 3B is a front view of the second header member shown in FIG. 3A .
- FIG. 4A is a sectional view, taken in line A-A in FIG. 1 , showing the connector as a unit according to an embodiment
- FIG. 4B is a front view of the connector shown in FIG. 4A .
- FIG. 5A is a sectional view, taken in line A-A in FIG. 1 , showing the second header member and the connector according to an embodiment
- FIG. 5B is a sectional view thereof taken in line C-C in FIG. 5A .
- FIG. 6 is a diagram for explaining the first tacking step according to an embodiment.
- FIG. 1 is a front view showing a general configuration of the heat exchanger according to an embodiment of the invention.
- This heat exchanger functions as a condenser of an automotive air conditioning system in which a high-temperature high-pressure refrigerant discharged from a compressor (not shown) is condensed by radiating heat into the air.
- the fluid according to this embodiment therefore, is a refrigerant.
- arrows “up”, “down”, “left” and “right” indicate the directions as viewed from the front of the vehicle with the heat exchanger mounted thereon.
- the condenser 1 is so configured that a multiplicity of refrigerant tubes 11 with the refrigerant flowing therein are stacked, and fins 12 for promoting the heat exchange between the refrigerant and the air are arranged between the adjacent refrigerant tubes 11 .
- the refrigerant tubes 11 and the fins 12 make up a substantially rectangular core unit constituting a heat exchange unit.
- the refrigerant tubes 11 each have a flat cross section and a single or a multiplicity of holes.
- the multiplicity of the refrigerant tubes 11 are arranged in parallel at predetermined spatial intervals with the flat surfaces thereof parallel to each other.
- the air with which the refrigerant exchanges heat flows from the front to rear side of the vehicle, i.e. from the front toward the back of the page in FIG. 1 .
- a first refrigerant header tank 14 for distributing the refrigerant to the refrigerant tubes 11 and a second refrigerant header tank 15 for collecting the refrigerant from the refrigerant tubes 11 are arranged at the longitudinal ends, respectively, of the refrigerant tubes 11 .
- the first and second refrigerant header tanks 14 , 15 are cylindrical members extending along the direction in which the multiplicity of the refrigerant tubes 11 are arranged.
- the first and second refrigerant header tanks 14 , 15 each have an inner surface connected with the refrigerant tubes 11 , a back surface located out on the other side far from the inner surface, a front surface located forward in the direction of air flow and a rear surface located backward in the direction of air flow.
- the first refrigerant header tank 14 is a cylindrical header tank of segmentation type formed of a first header member 16 extending vertically and connected with the tubes 11 and a second header member 17 extending vertically in conformity with, and fitted on, the first header member 16 .
- the second refrigerant header tank 15 is a cylindrical header tank of segmentation type formed of a first header member 18 and a second header member 19 fitted one on the other.
- first header members 16 , 18 are called the plate headers
- second header members 17 , 19 the tank headers.
- the first header members 16 , 18 each have as many slits (not shown) as the refrigerant tubes 11 , through which the first header members 16 , 18 communicate with all the refrigerant tubes 11 .
- the second header member 17 of the first refrigerant header tank 14 is coupled to a first connector 20 connected to a refrigerant inflow pipe (not shown) through which the refrigerant flows into the condenser 1 and a second connector 21 connected to a refrigerant outflow pipe (not shown) through which the refrigerant flows out of the condenser 1 .
- the second header members 17 , 19 are gutter-shaped plate members (having a substantially arcuate cross section).
- the second header members 17 , 19 each have a convex back surface curved outward, and fitting steps 17 a having an L-shaped cross section for receiving and fitted with the first header members 16 , 18 are spread from the curved surface part along the length of the first and second refrigerant header tanks 14 , 15 on both sides of the curved surface part.
- the curved surface part and the fitting steps make up the front and rear surfaces, respectively.
- the fitting steps 17 a each include an enlarged portion 17 c expanded along the direction of air flow B and a side wall portion 17 d expanded to receive the first header members 16 , 18 along the length of the refrigerant tubes 11 .
- the fitting steps 17 a both facilitate the positioning of the first header members 16 , 18 and improve the rigidity.
- the upper and lower ends of the first and second refrigerant header tanks 14 , 15 are closed by dished tabular members (tank caps 27 , 28 ).
- FIG. 2 is an enlarged sectional view taken in line A-A in FIG. 1 .
- the first header member 16 of the first refrigerant header tank 14 substantially tabular and vertically elongate, has the slits as described above. Further, flat plate portions 16 a to be combined with the second header member 17 are arranged along the vertically extending ends thereof.
- FIG. 3A is a sectional view of the same portion of a unit of the second header member 17 as the section taken in line A-A in FIG. 1
- FIG. 3B is a front view of FIG. 3A .
- the second header member 17 having a substantially semicircular cross section, is vertically elongated. Further, the second header member 17 includes vertically-extending fitting steps 17 a each having an L-shaped section adapted to receive and fit on the first header member 16 and a rectangular through hole 17 b for establishing communication between inner and outer surface of peripheries of the second header member 17 .
- the fitting steps 17 a are combined with the flat plate portions 16 a of the first header member 16 .
- the first refrigerant header tank 14 is formed cylindrically thereby to make up a refrigerant space 14 b for collecting/distributing the refrigerant therein as shown in FIG. 2 .
- the through hole 17 b is opened in such a manner as to establish communication between the inner and outer surface of peripheries of the second header member.
- the through hole 17 is open in the direction (along arrow B) perpendicular to the length of the tubes 11 .
- This through hole 17 b is connected with the first connector 20 .
- the expression “open in the direction (along arrow B) perpendicular to the length of the tubes 11 ” means that the opening 17 b is visible as viewed from at least the direction (along arrow B) perpendicular to the length of the tubes 11 .
- the meaning “open in the direction (along arrow B) perpendicular to the length of the tubes 11 ” includes a case in which even if the opening is visible when the second header member 17 is viewed from the direction along the length of the tubes 11 as indicated by arrow B′, the opening is visible from the direction (along arrow B) perpendicular to the length of the tubes 11 .
- the through hole 17 b is open in the front-rear direction from one of the front and rear surfaces of the first refrigerant header tank 14 .
- the through hole 17 b is open in the direction perpendicular to both the length of the tubes 11 and the length of the first refrigerant header tank 14 .
- the through hole 17 b is arranged in the vicinity of one of the fitting steps 17 a , or according to this embodiment, adjacently to the fitting step 17 a .
- the through hole 17 b has a longitudinal axis along the length of the second header member 17 (first refrigerant header tank 14 ).
- the opening of the through hole 17 b may be rectangular or elliptical and elongate along the length of the second header member 17 (first refrigerant header tank 14 ).
- FIG. 4A is a sectional view of the first connector 20 as a unit taken at the same point as line A-A in FIG. 1
- FIG. 4B a front view taken from the rear side of the vehicle in FIG. 4A
- the first connector 20 as shown in FIG. 2 , is projected outward in the direction (along arrow B) perpendicular to the length of the tubes 11 from the opening of the through hole 17 b of the second header member 17 .
- the first connector 20 includes a pipe connecting portion 20 a connected to the refrigerant inflow pipe, a protrusion 20 b inserted into the through hole 17 b of the second header member 17 and two positioning portions 20 c set in position by contact with the outer periphery of the second header member 17 around the through hole 17 b.
- the pipe connecting portion 20 a has a connecting hole 20 d adapted to the outer diameter of the refrigerant inflow pipe and a threaded hole 20 e to fix a flange (not shown) mounted on the refrigerant inflow pipe.
- the protrusion 20 b has a communication hole 20 f for establishing communication between the connecting hole 20 d and the interior of the first refrigerant header tank 14 .
- the outer periphery of the protrusion 20 b is in a shape adapted to the through hole 17 b of the second header member 17 , and before forming the engaging portions 20 g described later, the protrusion 20 b is insertable into the through hole 17 b .
- the engaging portion 20 g is arranged at each end of the protrusion 20 b in longitudinal direction of the second header member 17 (first refrigerant header tank 14 ) at the forward end of the protrusion 20 b.
- the engaging portions 20 g provide a mechanical engaging means to tack the first connector 20 on the second header member 17 (first refrigerant header tank 14 ).
- the engaging portions 20 g are located inside the first refrigerant header tank 14 .
- the second header member 17 is held between the engaging portions 20 g and the pipe connecting portion 20 a of the connector 20 located outside the first refrigerant header tank 14 and sufficiently larger than the through hole 17 b thereby to tack the first connector 20 .
- the outer periphery of the protrusion 20 b is caulked and strongly tacked on the inner periphery of the through hole 17 b by deforming the engaging portions 20 g.
- a coupling surface is formed by the outer surface of the second header member 17 around the through hole 17 b .
- Another coupling surface is formed by the outer surface of the positioning portion 20 c of the connector 20 around the base of the protrusion 20 b . These coupling surfaces are coupled by brazing with a brazing material interposed therebetween.
- the protrusion 20 b is inserted into the through hole 17 b , and therefore, the refrigerant flowing out of the refrigerant inflow pipe flows into the first refrigerant header tank 14 through the connecting hole 20 d and the communication hole 20 f .
- the connecting hole 20 d and the communication hole 20 f thus make up a fluid path of the first connector 20 according to this embodiment.
- One of the two positioning portions 20 c is in a shape adapted to the curved outer peripheral surface of the second header member 17 , and the other positioning portion 20 c in a shape adapted to the outside of each fitting step 17 a of the second header member 17 .
- the second header member 17 of the first refrigerant header tank 14 has a through hole (not shown) similar to the through hole 17 b for coupling the second connector 21 .
- This through hole of the fist refrigerant header tank 14 is coupled to the second connector 21 having a similar configuration to the first connector 20 .
- a gas-liquid separator 22 is arranged, as shown in FIG. 1 , on the left side (far from the core unit 13 ) of the second refrigerant header tank 15 .
- This gas-liquid separator 22 is a receiver capable of storing the liquid-phase refrigerant by separating the gas-phase refrigerant and the liquid-phase refrigerant from each other.
- the second refrigerant header tank 15 and the gas-liquid separator 22 are coupled to each other through a mounting member 22 a . Further, the second refrigerant header tank 15 and the gas-liquid separator 22 communicate with each other at two points through a plate 23 having two through holes 23 a , 23 b .
- the through hole 23 a is arranged above the through hole 23 b.
- a first separator 14 a is arranged at the lower part in the first refrigerant header tank 14
- a second separator 15 a is arranged at the same height as the first separator 14 a in the second refrigerant header tank 15 .
- the core unit 13 is divided into two heat exchange units by the first and second separators 14 a , 15 a.
- the upper part of the first and second separators 14 a , 15 a of the core unit 13 makes up a condensing portion 13 a for condensing the refrigerant by heat exchange between the air and the gas-phase refrigerant influent from the first connector 20 .
- the refrigerant flowing out of the condensing portion 13 a flows into the gas-liquid separator 22 by way of a through hole 23 a of a plate 23 .
- the first connector 20 is arranged above the first separator 14 a , and the through hole 23 a above the second separator 15 a.
- the lower part of the first and second separators 14 a , 15 a of the core unit 13 makes up a supercooling portion 13 b for cooling the liquid-phase refrigerant by heat exchange between the air and the liquid-phase refrigerant flowing in by way of a through hole 23 b from the gas-liquid separator 22 .
- the refrigerant cooled by the supercooling portion 13 b flows out from a refrigerant outlet port 17 .
- the second connector 21 is arranged below the first separator 14 a , and the through hole 23 b below the second separator 15 a.
- the supercooling portion 13 b is arranged below the condensing portion 13 a
- the gas-liquid separator 22 is arranged on the side of the condensing portion 13 a and the supercooling portion 13 b
- the upper part of the gas-liquid separator 22 is projected above the upper end surface of the condensing portion 13 a
- a first bracket 24 for coupling the condenser 1 to other parts is arranged on the part of the gas-liquid separator 22 projected above the upper end surface of the condensing portion 13 a.
- a pair of side plates 25 extending in parallel to the refrigerant tubes 11 for reinforcing the core unit 13 are arranged on the side ends of the core unit 13 in the direction in which the refrigerant tubes 11 are stacked.
- a pair of brackets 26 for mounting the condenser 1 on other component parts are arranged at two points on the side plate 25 at the lower side end of the core unit 13 in the direction in which the refrigerant tubes 11 are stacked.
- Tank caps 27 , 28 are arranged at the upper and lower ends, respectively, of the first refrigerant header tank 14 and the second refrigerant header tank 15 .
- the tank caps 27 are arranged at the lower end of the first refrigerant header tank 14 and at the upper and lower ends of the second refrigerant header tank 15 thereby to close the respective ends of the refrigerant header tanks.
- the tank cap 28 arranged at the upper end of the first refrigerant header tank 14 , closes the upper end of the first refrigerant header tank 14 , and includes a second bracket 29 for coupling the condenser 1 to other component parts.
- the condenser 1 is configured as described above. Further, according to this embodiment, all the component parts of the condenser 1 are made of an aluminum alloy and integrally coupled by brazing.
- brazing as described in “Connection and Coupling Techniques”, Publication Office, Tokyo Electrical Engineering College, for example, is the technique for coupling a base metal, without melting it, using a brazing or soldering material.
- the coupling technique using a filler material (brazing material) having the melting point of not lower than 450° C. is called brazing
- the coupling technique using a filler material (solder) having the melting point of lower than 450° C. is called soldering.
- the component parts of the condenser 1 are coupled to each other integrally by brazing.
- the process of producing the condenser 1 is explained.
- the first and second connectors 20 , 21 are tacked on the second header member 17 , and further, the second header member 17 and the first header member 16 are fitted and tacked on each other.
- this process constitutes the tacking.
- the step of tacking the first and second connectors 20 , 21 on the second header member 17 is called the first tacking step
- the step of fitting and tacking the second header member 17 and the first header member 16 on each other is called the second tacking step.
- the first tacking step is explained in detail with reference to FIGS. 5A, 5B , 6 .
- the step of tacking the first connector 20 on the second header member 17 and the step of tacking the second connector 21 are similar to each other. Therefore, only the step of tacking the first connector 20 is explained with reference to FIGS. 5A, 5B and 6 .
- FIGS. 5A, 5B the protrusion 20 b of the first connector 20 is inserted into the through hole 17 b of the second header member 17 .
- FIG. 5A is a sectional view at the same part as the sectional view taken in line A-A in FIG. 1 with the protrusion 20 b of the first connector 20 inserted into the through hole 17 b of the second header member 17 .
- FIG. 5B is a sectional view taken in line C-C in FIG. 5A .
- FIG. 6 is a diagram for explaining the tacking operation of the first tacking step.
- the protrusion 20 b is inserted into the through hole 17 b in such a manner that the positioning portion 20 c formed on the first connector 20 is in contact with the periphery of the through hole 17 b of the second header member 17 .
- the first connector 20 is set in position on the second header member 17 .
- the first connector 20 is arranged on the first refrigerant header tank 14 in such a manner as to project outward in the direction (along arrow B) perpendicular to the length of the tubes 11 from the opening of the through hole 17 b.
- the forward end of the engaging portion-forming jig 31 is in such a shape as to be insertable into the communication hole 20 f of the first connector 20 and has a progressively larger sectional area along the direction of arrow F in FIG. 5B .
- the forward end of the protrusion 20 b of the first connector 20 is deformed in the longitudinal direction of the second header member 17 on the inner periphery of the through hole 17 b thereby to form engaging portions 20 g .
- the outer periphery of the protrusion 20 b of the first connector 20 is tacked by being caulked on the inner periphery of the through hole 17 b.
- the outer periphery of the protrusion 20 b is forcibly widened along the length of the second header member 17 (the direction of arrow F in FIG. 5B ). This is by reason of the fact that in the case where the protrusion 20 b is deformed under the load in the directions of arrows E in FIG. 5A , for example, the through hole 17 b is easily extended and easily deformed in the circumferential direction along the curved outer periphery of the second header member 17 .
- the deformation of the through hole 17 b can be suppressed.
- the first connector 20 can be positively tacked on the second header member 17 .
- the second connector 21 is similarly tacked on the second header member 17 .
- the second header member 17 and the first header member 16 are fitted and tacked one on the other in the second tacking step.
- the flat plate portions 16 a of the first header member 16 are fitted and tacked on the fitting steps 17 a , respectively, of the second header member 17 thereby to form the cylindrical first refrigerant header tank 14 .
- a hook (not shown) is formed at a predetermined position on each fitting step 17 a of the second header member 17 and bent along the outer periphery of the first header member 16 , so that the second header member 17 and the first header member 16 are tacked by caulking one on the other.
- the cylindrical second refrigerant header tank 15 is formed by combining and tacking by caulking the second header member 19 and the first header member 18 one on the other as in the first refrigerant header tank 14 .
- a multiplicity of the refrigerant tubes 11 are inserted into the slits formed in the first refrigerant header tank 14 and the second refrigerant header tank 15 .
- the fins 12 are interposed between the refrigerant tubes 11 thereby to assemble the condenser 1 .
- One side plate 25 is arranged above the uppermost refrigerant tube 11 through the fins 12 , and the other side plate 25 is arranged through the fins 12 under the lowest refrigerant tube 11 . This assembly then is tacked by being bound vertically with a wire.
- first separator 14 a is tacked at a predetermined position in the first refrigerant header tank 14 .
- the plate 23 is tacked by being caulked at the position of the communication hole formed in advance in the second refrigerant header tank 15
- the gas-liquid separator 22 with the first bracket 24 tacked by being caulked thereon is tacked by being caulked through a mounting member 22 a .
- the second separator 15 a is tacked by being caulked at a predetermined position in the second refrigerant header tank 15 .
- bracket 26 for mounting other parts is tacked by being caulked on the lower side plate 25 . Under this condition, the whole assembly is fixed in position by exclusive jigs from both sides.
- the tank caps 27 are tacked by caulking at the upper and lower ends of the second refrigerant header tank 15 and the lower end of the first refrigerant header tank 14 .
- the tank cap 28 having the second bracket 29 is tacked by caulking at the upper end of the first refrigerant header tank 14 .
- this brazing step makes up the coupling step for coupling the first and second connectors 20 , 21 , the second header member 17 and the first header member 16 .
- the forward end of the first connector 20 is deformed in the longitudinal direction of the second header member 17 on the inner periphery of the through hole 17 b thereby to make up the engaging portions 20 g . Therefore, the first connector 20 can be positively tacked on the first refrigerant header tank 14 .
- the outer periphery of the protrusion 20 b of the first connector 20 is strongly tacked by caulking on the inner periphery of the through hole 17 b.
- the first refrigerant header tank 14 is not yet cylindrical in shape at the time of tacking the first connector 20 on the second header member 17 .
- the workability of tacking the first connector 20 on the second header member 17 is improved.
- the improved workability reduces the production cost of the condenser 1 . Further, since the through hole 17 b can be easily formed in the second header member 17 by press work or the like, the production cost of the condenser 1 can be reduced as compared with the conventional technique in which a notch is formed on each of the two component parts, i.e. the second header member 17 and the first header member 16 .
- the first connector 20 which is arranged to project in the direction (along arrow B) perpendicular to the length of the tubes 11 from the opening of the through hole 17 b of the second header member 17 , is not projected outward along the length of the tubes 11 from the first refrigerant header tank 14 .
- the condenser 1 can be reduced in size.
- the wording “the first connector 20 is not projected outward along the length of the tubes 11 from the first refrigerant header tank 14 ” means that as in this embodiment, for example, the axes of the connection hole 20 d and the communication hole 20 f formed in the first connector 20 follow the direction (the direction of arrow B) perpendicular to the length of the tubes 11 , and therefore the first connector 20 is not unnecessarily displaced outward along the length of the tubes from the first refrigerant header tank 14 .
- the through hole 17 b is formed directly in the second header member 17 .
- the dimensional accuracy of the through hole 17 b is improved.
- the absence of a step around the through hole 17 b reduces the geometric variations of the periphery of the through hole 17 b.
- the through hole 17 b is arranged adjacently to the fitting step 17 a of the second header member 17 , the deformation of the through hole 17 b in the first tacking step is suppressed.
- the protrusion 20 b can be tacked positively in the through hole 17 b .
- the positioning portions 20 c assure a more positive positioning, thereby improving the mounting dimensional accuracy after coupling the first connector 20 and the first refrigerant header tank 14 to each other.
- the contact portion between the positioning portions 20 c and the second header member 17 constitutes a coupling surface for an improved coupling strength between the first connector 20 and the second header member 17 .
- the geometric variations around the through hole 17 b can be reduced, and therefore, the shape adjustment of the first connector 20 , which otherwise might be required by an independent cutting process to assure adaptation of the shape of the protrusion 20 b and the positioning portions 20 c of the first connector 20 to the outer periphery of the first refrigerant header tank 14 , is not required.
- the first connector 20 can be easily produced by cold forging or the like. As a result, the production cost of the first connector 20 can be reduced, thereby reducing the production cost of the condenser 1 as a whole. Exactly the same effects are obtained for the second connector 21 as for the first connector 20 .
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Abstract
A heat exchanger and a production method thereof are disclosed. A through hole (17) is formed in a second header member (17) of a first refrigerant header tank (14) of segmentation type. A protrusion (20 a) of a first connector (20) for pipe connection is deformed by being inserted into the through hole (17 b) and thus tacked by engagement. Under this condition, the first header member (16) is fitted and tacked on the second header member (17) so that the first connector (20), the second head member (17) and the first head member (16) are integrally brazed and coupled. By doing so, the first connector (20) can be properly coupled to the first refrigerant header tank (14). Further, the first connector (20) can be tacked by engagement before the first refrigerant header tank (14) assumes a cylindrical shape, and therefore the workability of tacking the first connector (20) is improved.
Description
- 1. Field of the Invention
- This invention relates to a heat exchanger having connectors for connecting pipes through which a heat-exchanging fluid flows in and out, and a method of producing the heat exchanger.
- 2. Description of the Related Art
- Japanese Unexamined Patent Publication No. 2004-108638 (Patent Document 1) discloses a heat exchanger used as a condenser for condensing by radiating the heat of the refrigerant into the air. This conventional heat exchanger includes a pair of header tanks of a segmentation type on one of which the connectors are mounted. The header tank of segmentation type is defined as a cylindrical header tank with a second header member fitted on a first header member connected to the tubes in which the heat-exchanging fluid flows.
- The method of mounting the connectors on the header tank of the heat exchanger according to Patent Document 1 is explained below. First, the first and second header members of the heat exchanger disclosed in Patent Document 1 have notches, respectively, formed in the fitting portions thereof fitted with each other, and by fitting the first and second header members on each other, a rectangular through hole is formed by the notches.
- The connectors, on the other hand, are each formed with a protrusion adapted to the shape of and insertable into the corresponding through hole. By inserting the protrusions into the through holes and further caulking the protrusions on the inner periphery of the through holes, the connectors are tacked on the header tank. With the connectors tacked on the header tank, the first and second header members and the connectors are brazed to each other thereby to mount the connectors on the header tank.
- In the heat exchanger disclosed in Patent Document 1, the through holes for tacking the connectors are formed by combining the notches formed on the first and second header members. Once the relative positions of the notches are shifted by the dimensional error or assembly error in the manufacture of the first and second header members, therefore, the shape of each through hole fails to fit the shape of the protrusion of each connector.
- In the case where the shape of the connector protrusions and the shape of the through holes fail to coincide with each other, a sufficient tacking strength of the connectors tacked and caulked on the header tank cannot be obtained. As a result, at the time of coupling by brazing, the tacked state between the connectors and the header tanks cannot be maintained, and the dimensional accuracy and the coupling strength of the connectors mounted on and coupled to the header tank are adversely affected, thereby making it impossible to properly couple the connectors to the header tank.
- In view of this situation, the object of this invention is to couple the connectors properly to the header tank.
- In order to achieve the aforementioned object, according to a first aspect of the invention, there is provided a heat exchanger comprising a cylindrical header tank (14) connected with a plurality of tubes (11) through which a fluid passes and a pair of connectors (20, 21) for fluid pipe connection, wherein the connectors (20, 21) have a tacked portion (20 b) engaging the header tank (14), and the connectors (20, 21) and the header tank (14) have coupling surfaces, respectively, coupled by brazing to each other.
- In this aspect, the connectors (20, 21) have the tacked portion (20 b) engaging the header tank (14), and therefore, the connectors (20, 21) can be coupled to and tacked on the header tank (14) positively.
- As a result, the reduction in the accuracy of the mounting dimensions and the coupling strength of the connectors (20, 21) to the header tank (14) after coupling can be suppressed and the connectors (20, 21) can be coupled properly to the header tank (14).
- Further, the connectors (20, 21) and the header tank (14) each have a coupling surface, and therefore a sufficient coupling strength can be secured between them.
- In the heat exchanger according to the first aspect described above, the header tank (14) has a through hole (17 b) establishing communication between inside and outside of the header tank (14), and the connectors (20, 21) each have the protrusion (20 b) inserted into the through hole (17 b). The tacked portion, therefore, may be engaging portions (20 g) configured by deforming the protrusion (20 b).
- In this case, the protrusion (20 b) inserted into the through hole (17 b) is deformed and makes up the engaging portions (20 g). Therefore, the connectors (20, 21) can be easily tacked on the header tank (14). Further, as compared with the case in which the engaging portion (20 b) is formed on the outer peripheral surface of the header tank (14), the header tank (14) is not unnecessarily made bulky.
- Thus, the connectors (20, 21) can be properly connected to the header tank (14) without increasing the size of the heat exchanger.
- Also, in the heat exchanger according to the first aspect having the through hole (17 b), the protrusion (20 b) may be caulked on the inner periphery of the through hole (17 b). Then, since the protrusion (20) is caulked on the through hole (17 b), the connectors (20, 21) can be tacked more strongly on the header tank (14).
- Further, in the heat exchanger according to the first aspect described above, the through hole (17 b) may alternatively be formed on the side of the cylinder of the header tank (14). Also, the opening of the through hole (17 b) may be elongated along the length of the header tank (14). Furthermore, the engaging portions (20 g) may be arranged at the two ends of the protrusion (20) along the length of the header tank (14).
- Generally, the cylindrical header tank (14) is elongated. In the case where each engaging portion (20 g) is deformed toward the inner periphery of the through hole (17 b) with a load imposed in the direction parallel to the longitudinal direction, the deformation of the through hole (17 b) can be suppressed more than in the case where the deforming load is imposed in the other directions.
- Specifically, as shown in
FIG. 5 for explaining an embodiment described later, the protrusion (20 b) is deformed toward the inner periphery of the through hole (17 b) while being caulked by the load in the directions of arrows E providing the load along the circumference of the header tank (14). Then, the through hole (17 b) is easily extended and deformed along the outer periphery of the header tank (14). - In the case where the protrusion (20 b) is caulked by the load along the direction of arrow F parallel to the length of the header tank (14), on the other hand, the header tank (14) is not easily deformed in longitudinal direction and therefore the deformation of the through hole (17 b) can be suppressed.
- By arranging the engaging portion (20 g) at each longitudinal end of the inner periphery of the through hole (17 b) along the length of the header tank (14), therefore, the protrusion (20 b) can be deformed under the load parallel to the length of the header tank (14). Thus, the deformation of the through hole (17 b) is suppressed, and the connectors (20, 21) can be more properly coupled to the header tank (14).
- In the heat exchanger according to the first aspect having the through hole (17 b) described above, the header tank (14) is configured by fitting the second header member (17) on the first header member (16) connected with a plurality of the tubes (11), and the through hole (17 b) can alternatively be formed in the second header member (17).
- In this case, before tacking the second header member (17) and the first header member (16) to each other, the connectors (20, 21) can be tacked on the second header member (17). With the header tank (14) not yet cylindrical, therefore, the connectors (20, 21) can be tacked on the second header member (17). As a result, the workability of tacking the connectors (20, 21) on the second header member (17) is improved.
- Further, the improved workability reduces the production cost of the heat exchanger. Also, the through hole (17 b) can be easily formed in the second header member (17) in press, etc. and therefore, unlike in the prior art in which a notch is formed on each of the two component parts including the second header member (17) and the first header member (16), the production cost of the heat exchanger is reduced while at the same time improving the geometric dimensional accuracy of the through hole (17 b).
- Also, in the heat exchanger according to the first aspect having the first header member (16) and the second header member (17) described above, the second header member (17) has a pair of fitting steps (17 a) having an L-shaped section fitted with the first header member (16), and the through hole (17 b) may be arranged adjacently to any of the fitting steps (17 a).
- In this case, the fitting steps (17 a) having the L-shaped section not only facilitate the positioning of the first header member (16) on the second header member (17) but also improve the rigidity of the second header member (17). By arranging the through hole (17 b) adjacent to any one of the fitting steps (17 a), therefore, the deformation of the through hole (17 b) at the time of tacking by caulking can be suppressed further.
- Also, in the heat exchanger according to the first aspect described above, the through hole (17 b) is open in the direction (B) perpendicular to the length of the tubes (11), and the connectors (20, 21) may be arranged on the header tank (14) in such a manner as to project outward in the direction (B) perpendicular to the length of the tubes (11) from the opening of the through hole (17 b).
- In this case, the connectors (20, 21) are not projected to an unnecessary degree outward along the length of the tubes (11) from the header tank (14), with the result that the connectors (20, 21) can be properly coupled to the header tank (14) without increasing the size of the heat exchanger.
- Also, in the heat exchanger according to the first aspect described above, the connectors (20, 21) each have positioning portions (20 c) set in position by contact with the outer peripheral portion of the header tank (14), and the coupling surface may be the contact portion between the positioning portions (20 c) and the header tank (14).
- In this case, the connectors (20, 21) can be tacked on the header tank (14) with a higher positioning accuracy and, therefore, the mounting dimensional accuracy is improved after coupling the connectors (20, 21) and the header tank (14).
- Further, since the contact portion between the positioning portions (20 c) and the header tank (14) makes up a coupling surface, the coupling strength between the connectors (20, 21) and the second header member (17) can be improved by shaping the positioning portions (20 c) adapted to the outer periphery of the header tank (14).
- According to a second aspect of the invention, there is provided a method of producing a heat exchanger including a cylindrical header tank (14) connected to a plurality of tubes with a fluid passing therein and a pair of connectors (20, 21) for fluid pipe connection, comprising the steps of tacking the connectors (20, 21) on the header tank (14) by deforming a part of the connectors (20, 21), and coupling by brazing the connectors (20, 21) and the header tank (14) to each other after the tacking step.
- In this case, the heat exchanger according to the first aspect can be produced. Thus, there is provided a heat exchanger with the connectors (20, 21) properly coupled to the header tank (14).
- Also, the tacking step of the heat exchanger production method according to the second aspect described above may include the step of preparing the header tank (14) having a through hole (17 b) communicating between inside and outside thereof, the step of preparing the connectors (20, 21) each having a protrusion (20 b) insertable into the through hole (17 b) and the step of expanding the protrusion (20 b) toward the inner periphery of the through hole (17 b) after being inserted into the through hole (17 b).
- In this case, specifically, the protrusion (20 b) is inserted in the through hole (17 b) and further expanded toward the inner periphery of the through hole (17 b). Therefore, the connectors (20, 21) can be easily tacked on the header tank (14). Further, the connectors (20, 21) can be caulked on the outer peripheral surface of the header tank (14) without unnecessarily increasing the size of the header tank (14).
- Also, the tacking step of the heat exchanger production method according to the second aspect described above may include the step of imposing a load on the protrusion (20 b) in the direction parallel to the length of the header tank (14) after inserting the protrusion (20 b) into the through hole (17 b). By doing so, the header tank (14) is not easily deformed in longitudinal direction, and therefore the deformation of the through hole (17 b) can be suppressed also under the load imposed on the protrusion (20 b) in the direction parallel to the length of the header tank (14).
- Also, the tacking step of the heat exchanger production method according to the second aspect described above may include the step of preparing the header tank (14) so configured that the second header member (17) having the through hole (17 b) is fitted on the first header member (16) connected with a plurality of the tubes (11) and the step of fitting the second header member (17) on the first header member (16) after deforming the protrusion (20 b) by being inserted into the through hole (17 b).
- With this configuration, before fitting the second header member (17) and the first header member (16) one on the other, the connectors (20, 21) are tacked on the second header member (17). Therefore, the connectors (20, 21) can be tacked on the second header member (17) with the header tank (14) not yet cylindrical. As a result, the workability of tacking the connectors (20, 21) on the second header member (17) is improved.
- Also, the tacking step of the heat exchanger production method according to the second aspect described above may include the step of preparing the header tank (14) with the through hole (17 b) open in the direction (B) perpendicular to the length of the tubes (11) and the step of arranging the connectors (20, 21) on the header tank (14) in such a manner as to project outward in the direction (B) perpendicular to the length of the tubes (11) from the opening of the through hole (17 b).
- In this case, the connectors (20, 21) are arranged on the header tank (14) in such a manner as to project outward in the direction (B) perpendicular to the length of the tubes (11) from the opening of the through hole (17 b), and therefore, a heat exchanger can be produced in which the connectors (20, 21) are not projected to an unnecessary degree outward along the length of the tubes (11) from the header tank (14).
- The reference numerals in the parentheses attached to each means described above and in the claims indicate the correspondence with the specific means described in the embodiments below.
- The present invention may be more fully understood from the description of preferred embodiments of the invention, as set forth below, together with the accompanying drawings.
-
FIG. 1 is a diagram showing a general configuration of a heat exchanger according to an embodiment of the invention. -
FIG. 2 is a sectional view taken in line A-A inFIG. 1 . -
FIG. 3A is a sectional view, taken in line A-A inFIG. 1 , showing the second header member as a unit according to an embodiment, andFIG. 3B is a front view of the second header member shown inFIG. 3A . -
FIG. 4A is a sectional view, taken in line A-A inFIG. 1 , showing the connector as a unit according to an embodiment, andFIG. 4B is a front view of the connector shown inFIG. 4A . -
FIG. 5A is a sectional view, taken in line A-A inFIG. 1 , showing the second header member and the connector according to an embodiment, andFIG. 5B is a sectional view thereof taken in line C-C inFIG. 5A . -
FIG. 6 is a diagram for explaining the first tacking step according to an embodiment. -
FIG. 1 is a front view showing a general configuration of the heat exchanger according to an embodiment of the invention. This heat exchanger functions as a condenser of an automotive air conditioning system in which a high-temperature high-pressure refrigerant discharged from a compressor (not shown) is condensed by radiating heat into the air. The fluid according to this embodiment, therefore, is a refrigerant. InFIG. 1 , arrows “up”, “down”, “left” and “right” indicate the directions as viewed from the front of the vehicle with the heat exchanger mounted thereon. - The condenser 1 is so configured that a multiplicity of
refrigerant tubes 11 with the refrigerant flowing therein are stacked, andfins 12 for promoting the heat exchange between the refrigerant and the air are arranged between the adjacentrefrigerant tubes 11. Therefrigerant tubes 11 and thefins 12 make up a substantially rectangular core unit constituting a heat exchange unit. - The
refrigerant tubes 11 each have a flat cross section and a single or a multiplicity of holes. The multiplicity of therefrigerant tubes 11 are arranged in parallel at predetermined spatial intervals with the flat surfaces thereof parallel to each other. The air with which the refrigerant exchanges heat flows from the front to rear side of the vehicle, i.e. from the front toward the back of the page inFIG. 1 . - A first
refrigerant header tank 14 for distributing the refrigerant to therefrigerant tubes 11 and a secondrefrigerant header tank 15 for collecting the refrigerant from therefrigerant tubes 11 are arranged at the longitudinal ends, respectively, of therefrigerant tubes 11. - The first and second
refrigerant header tanks refrigerant tubes 11 are arranged. The first and secondrefrigerant header tanks refrigerant tubes 11, a back surface located out on the other side far from the inner surface, a front surface located forward in the direction of air flow and a rear surface located backward in the direction of air flow. - The first
refrigerant header tank 14 is a cylindrical header tank of segmentation type formed of afirst header member 16 extending vertically and connected with thetubes 11 and asecond header member 17 extending vertically in conformity with, and fitted on, thefirst header member 16. - The second
refrigerant header tank 15, like the firstrefrigerant header tank 14, is a cylindrical header tank of segmentation type formed of afirst header member 18 and asecond header member 19 fitted one on the other. Generally, thefirst header members second header members - The
first header members refrigerant tubes 11, through which thefirst header members refrigerant tubes 11. Also, thesecond header member 17 of the firstrefrigerant header tank 14 is coupled to afirst connector 20 connected to a refrigerant inflow pipe (not shown) through which the refrigerant flows into the condenser 1 and asecond connector 21 connected to a refrigerant outflow pipe (not shown) through which the refrigerant flows out of the condenser 1. - The
second header members second header members fitting steps 17 a having an L-shaped cross section for receiving and fitted with thefirst header members refrigerant header tanks - The
fitting steps 17 a, as shown inFIGS. 2, 3 and described later, each include anenlarged portion 17 c expanded along the direction of air flow B and aside wall portion 17 d expanded to receive thefirst header members refrigerant tubes 11. - The
fitting steps 17 a both facilitate the positioning of thefirst header members refrigerant header tanks - Now, the first
refrigerant header tank 14 and thefirst connector 20 are explained in detail with reference to FIGS. 2 to 4.FIG. 2 is an enlarged sectional view taken in line A-A inFIG. 1 . Thefirst header member 16 of the firstrefrigerant header tank 14, substantially tabular and vertically elongate, has the slits as described above. Further,flat plate portions 16 a to be combined with thesecond header member 17 are arranged along the vertically extending ends thereof. - The direction of arrow B in
FIG. 2 is perpendicular to the length of thetubes 11. The arrow B also represents the direction in which the air to exchange heat with the refrigerant flows. Next, thesecond header member 17 is explained in detail with reference toFIGS. 3A, 3B .FIG. 3A is a sectional view of the same portion of a unit of thesecond header member 17 as the section taken in line A-A inFIG. 1 , andFIG. 3B is a front view ofFIG. 3A . - The
second header member 17, having a substantially semicircular cross section, is vertically elongated. Further, thesecond header member 17 includes vertically-extendingfitting steps 17 a each having an L-shaped section adapted to receive and fit on thefirst header member 16 and a rectangular throughhole 17 b for establishing communication between inner and outer surface of peripheries of thesecond header member 17. - The
fitting steps 17 a are combined with theflat plate portions 16 a of thefirst header member 16. By combining thefitting steps 17 a and theflat plate portions 16 a with each other, the firstrefrigerant header tank 14 is formed cylindrically thereby to make up a refrigerant space 14 b for collecting/distributing the refrigerant therein as shown inFIG. 2 . - The through
hole 17 b is opened in such a manner as to establish communication between the inner and outer surface of peripheries of the second header member. Once thefirst header member 16 is combined with thesecond header member 17 to make up the cylindricalrefrigerant header tank 14, therefore, the throughhole 17 b is formed on the side of the cylinder of the firstrefrigerant header tank 14. - Further, the through
hole 17 is open in the direction (along arrow B) perpendicular to the length of thetubes 11. This throughhole 17 b is connected with thefirst connector 20. The expression “open in the direction (along arrow B) perpendicular to the length of thetubes 11” means that theopening 17 b is visible as viewed from at least the direction (along arrow B) perpendicular to the length of thetubes 11. - Therefore, the meaning “open in the direction (along arrow B) perpendicular to the length of the
tubes 11” includes a case in which even if the opening is visible when thesecond header member 17 is viewed from the direction along the length of thetubes 11 as indicated by arrow B′, the opening is visible from the direction (along arrow B) perpendicular to the length of thetubes 11. - Also, the through
hole 17 b is open in the front-rear direction from one of the front and rear surfaces of the firstrefrigerant header tank 14. Thus, the throughhole 17 b is open in the direction perpendicular to both the length of thetubes 11 and the length of the firstrefrigerant header tank 14. - Further, the through
hole 17 b is arranged in the vicinity of one of thefitting steps 17 a, or according to this embodiment, adjacently to thefitting step 17 a. The throughhole 17 b has a longitudinal axis along the length of the second header member 17 (first refrigerant header tank 14). Specifically, the opening of the throughhole 17 b may be rectangular or elliptical and elongate along the length of the second header member 17 (first refrigerant header tank 14). - Next, the
first connector 20 is explained in detail with reference toFIGS. 4A, 4B .FIG. 4A is a sectional view of thefirst connector 20 as a unit taken at the same point as line A-A inFIG. 1 , andFIG. 4B a front view taken from the rear side of the vehicle inFIG. 4A . Thefirst connector 20, as shown inFIG. 2 , is projected outward in the direction (along arrow B) perpendicular to the length of thetubes 11 from the opening of the throughhole 17 b of thesecond header member 17. - Further, the
first connector 20 includes apipe connecting portion 20 a connected to the refrigerant inflow pipe, aprotrusion 20 b inserted into the throughhole 17 b of thesecond header member 17 and twopositioning portions 20 c set in position by contact with the outer periphery of thesecond header member 17 around the throughhole 17 b. - The
pipe connecting portion 20 a has a connectinghole 20 d adapted to the outer diameter of the refrigerant inflow pipe and a threadedhole 20 e to fix a flange (not shown) mounted on the refrigerant inflow pipe. Also, theprotrusion 20 b has acommunication hole 20 f for establishing communication between the connectinghole 20 d and the interior of the firstrefrigerant header tank 14. - Further, the outer periphery of the
protrusion 20 b is in a shape adapted to the throughhole 17 b of thesecond header member 17, and before forming the engagingportions 20 g described later, theprotrusion 20 b is insertable into the throughhole 17 b. Also, the engagingportion 20 g is arranged at each end of theprotrusion 20 b in longitudinal direction of the second header member 17 (first refrigerant header tank 14) at the forward end of theprotrusion 20 b. - These engaging
portions 20 g, after theprotrusion 20 b is inserted into the throughhole 17 b, are deformed in the longitudinal direction of the second header member 17 (first refrigerant header tank 14) on the inner periphery of the throughhole 17 b. InFIGS. 4A, 4B showing thefirst connector 20 as a unit, reference numeral 20 g designates the points at which the engagingportions 20 g are formed. - As a result, the deformation by expansion of the
fitting steps 17 a is suppressed. Further, the engagingportions 20 g provide a mechanical engaging means to tack thefirst connector 20 on the second header member 17 (first refrigerant header tank 14). - Also, the engaging
portions 20 g are located inside the firstrefrigerant header tank 14. Thesecond header member 17 is held between the engagingportions 20 g and thepipe connecting portion 20 a of theconnector 20 located outside the firstrefrigerant header tank 14 and sufficiently larger than the throughhole 17 b thereby to tack thefirst connector 20. Further, the outer periphery of theprotrusion 20 b is caulked and strongly tacked on the inner periphery of the throughhole 17 b by deforming the engagingportions 20 g. - A coupling surface is formed by the outer surface of the
second header member 17 around the throughhole 17 b. Another coupling surface is formed by the outer surface of thepositioning portion 20 c of theconnector 20 around the base of theprotrusion 20 b. These coupling surfaces are coupled by brazing with a brazing material interposed therebetween. - As shown in
FIG. 2 , theprotrusion 20 b is inserted into the throughhole 17 b, and therefore, the refrigerant flowing out of the refrigerant inflow pipe flows into the firstrefrigerant header tank 14 through the connectinghole 20 d and thecommunication hole 20 f. The connectinghole 20 d and thecommunication hole 20 f thus make up a fluid path of thefirst connector 20 according to this embodiment. - One of the two
positioning portions 20 c is in a shape adapted to the curved outer peripheral surface of thesecond header member 17, and theother positioning portion 20 c in a shape adapted to the outside of eachfitting step 17 a of thesecond header member 17. Thesecond header member 17 of the firstrefrigerant header tank 14 has a through hole (not shown) similar to the throughhole 17 b for coupling thesecond connector 21. This through hole of the fistrefrigerant header tank 14 is coupled to thesecond connector 21 having a similar configuration to thefirst connector 20. - A gas-
liquid separator 22 is arranged, as shown inFIG. 1 , on the left side (far from the core unit 13) of the secondrefrigerant header tank 15. This gas-liquid separator 22 is a receiver capable of storing the liquid-phase refrigerant by separating the gas-phase refrigerant and the liquid-phase refrigerant from each other. - The second
refrigerant header tank 15 and the gas-liquid separator 22 are coupled to each other through a mountingmember 22 a. Further, the secondrefrigerant header tank 15 and the gas-liquid separator 22 communicate with each other at two points through aplate 23 having two throughholes hole 23 a is arranged above the throughhole 23 b. - A
first separator 14 a is arranged at the lower part in the firstrefrigerant header tank 14, and asecond separator 15 a is arranged at the same height as thefirst separator 14 a in the secondrefrigerant header tank 15. Thecore unit 13 is divided into two heat exchange units by the first andsecond separators - First, the upper part of the first and
second separators core unit 13 makes up a condensingportion 13 a for condensing the refrigerant by heat exchange between the air and the gas-phase refrigerant influent from thefirst connector 20. The refrigerant flowing out of the condensingportion 13 a flows into the gas-liquid separator 22 by way of a throughhole 23 a of aplate 23. Thus, thefirst connector 20 is arranged above thefirst separator 14 a, and the throughhole 23 a above thesecond separator 15 a. - Further, the lower part of the first and
second separators core unit 13 makes up a supercooling portion 13 b for cooling the liquid-phase refrigerant by heat exchange between the air and the liquid-phase refrigerant flowing in by way of a throughhole 23 b from the gas-liquid separator 22. The refrigerant cooled by the supercooling portion 13 b flows out from arefrigerant outlet port 17. Thus, thesecond connector 21 is arranged below thefirst separator 14 a, and the throughhole 23 b below thesecond separator 15 a. - In the condenser according to this embodiment, therefore, the supercooling portion 13 b is arranged below the condensing
portion 13 a, the gas-liquid separator 22 is arranged on the side of the condensingportion 13 a and the supercooling portion 13 b, and the upper part of the gas-liquid separator 22 is projected above the upper end surface of the condensingportion 13 a. Afirst bracket 24 for coupling the condenser 1 to other parts (such as the vehicle body or other heat exchangers) is arranged on the part of the gas-liquid separator 22 projected above the upper end surface of the condensingportion 13 a. - Also, a pair of
side plates 25 extending in parallel to therefrigerant tubes 11 for reinforcing thecore unit 13 are arranged on the side ends of thecore unit 13 in the direction in which therefrigerant tubes 11 are stacked. A pair ofbrackets 26 for mounting the condenser 1 on other component parts are arranged at two points on theside plate 25 at the lower side end of thecore unit 13 in the direction in which therefrigerant tubes 11 are stacked. - Tank caps 27, 28 are arranged at the upper and lower ends, respectively, of the first
refrigerant header tank 14 and the secondrefrigerant header tank 15. The tank caps 27 are arranged at the lower end of the firstrefrigerant header tank 14 and at the upper and lower ends of the secondrefrigerant header tank 15 thereby to close the respective ends of the refrigerant header tanks. - Further, the
tank cap 28, arranged at the upper end of the firstrefrigerant header tank 14, closes the upper end of the firstrefrigerant header tank 14, and includes asecond bracket 29 for coupling the condenser 1 to other component parts. - The condenser 1 is configured as described above. Further, according to this embodiment, all the component parts of the condenser 1 are made of an aluminum alloy and integrally coupled by brazing. The term “brazing”, as described in “Connection and Coupling Techniques”, Publication Office, Tokyo Electrical Engineering College, for example, is the technique for coupling a base metal, without melting it, using a brazing or soldering material.
- More specifically, the coupling technique using a filler material (brazing material) having the melting point of not lower than 450° C. is called brazing, while the coupling technique using a filler material (solder) having the melting point of lower than 450° C. is called soldering. According to this embodiment, as described later, the component parts of the condenser 1 are coupled to each other integrally by brazing.
- Next, the process of producing the condenser 1 is explained. First, according to this embodiment, the first and
second connectors second header member 17, and further, thesecond header member 17 and thefirst header member 16 are fitted and tacked on each other. According to this embodiment, this process constitutes the tacking. - In the tacking process, as described below, the step of tacking the first and
second connectors second header member 17 is called the first tacking step, and the step of fitting and tacking thesecond header member 17 and thefirst header member 16 on each other is called the second tacking step. - The first tacking step is explained in detail with reference to
FIGS. 5A, 5B , 6. The step of tacking thefirst connector 20 on thesecond header member 17 and the step of tacking thesecond connector 21 are similar to each other. Therefore, only the step of tacking thefirst connector 20 is explained with reference toFIGS. 5A, 5B and 6. - First, in the first tacking step, as shown in
FIGS. 5A, 5B , theprotrusion 20 b of thefirst connector 20 is inserted into the throughhole 17 b of thesecond header member 17.FIG. 5A is a sectional view at the same part as the sectional view taken in line A-A inFIG. 1 with theprotrusion 20 b of thefirst connector 20 inserted into the throughhole 17 b of thesecond header member 17.FIG. 5B is a sectional view taken in line C-C inFIG. 5A .FIG. 6 is a diagram for explaining the tacking operation of the first tacking step. - Under this condition, the
protrusion 20 b is inserted into the throughhole 17 b in such a manner that thepositioning portion 20 c formed on thefirst connector 20 is in contact with the periphery of the throughhole 17 b of thesecond header member 17. As a result, thefirst connector 20 is set in position on thesecond header member 17. - Further, by this positioning process, the
first connector 20 is arranged on the firstrefrigerant header tank 14 in such a manner as to project outward in the direction (along arrow B) perpendicular to the length of thetubes 11 from the opening of the throughhole 17 b. - Next, with the
protrusion 20 b inserted into the throughhole 17 b, as shown inFIG. 6 , thesecond header member 17 and thefirst connector 20 are fixed using backup jigs 30. Under this condition, an engaging portion-formingjig 31 is applied in the direction of arrow D thereby to deform theprotrusion 20 b of thefirst connector 20. - Specifically, the forward end of the engaging portion-forming
jig 31 is in such a shape as to be insertable into thecommunication hole 20 f of thefirst connector 20 and has a progressively larger sectional area along the direction of arrow F inFIG. 5B . By applying the engaging portion-formingjig 31 in the direction of arrow D inFIG. 6 , therefore, the inner periphery of thecommunication hole 20 f is forcibly widened toward the throughhole 17 b thereby to widen the outer periphery of theprotrusion 20 b. - As a result, the forward end of the
protrusion 20 b of thefirst connector 20 is deformed in the longitudinal direction of thesecond header member 17 on the inner periphery of the throughhole 17 b thereby to form engagingportions 20 g. At the same time, the outer periphery of theprotrusion 20 b of thefirst connector 20 is tacked by being caulked on the inner periphery of the throughhole 17 b. - Especially, with the engaging portion-forming
jig 31 according to this embodiment, the outer periphery of theprotrusion 20 b is forcibly widened along the length of the second header member 17 (the direction of arrow F inFIG. 5B ). This is by reason of the fact that in the case where theprotrusion 20 b is deformed under the load in the directions of arrows E inFIG. 5A , for example, the throughhole 17 b is easily extended and easily deformed in the circumferential direction along the curved outer periphery of thesecond header member 17. - By deforming the
protrusion 20 b under the load along the direction of arrow F parallel to the length of thesecond header member 17, on the other hand, the deformation of the throughhole 17 b can be suppressed. As a result, thefirst connector 20 can be positively tacked on thesecond header member 17. Further, according to this embodiment, thesecond connector 21 is similarly tacked on thesecond header member 17. - After the first tacking step described above, the
second header member 17 and thefirst header member 16 are fitted and tacked one on the other in the second tacking step. As described above, theflat plate portions 16 a of thefirst header member 16 are fitted and tacked on thefitting steps 17 a, respectively, of thesecond header member 17 thereby to form the cylindrical firstrefrigerant header tank 14. - Specifically, a hook (not shown) is formed at a predetermined position on each
fitting step 17 a of thesecond header member 17 and bent along the outer periphery of thefirst header member 16, so that thesecond header member 17 and thefirst header member 16 are tacked by caulking one on the other. According to this embodiment, at the same time as the second tacking step, the cylindrical secondrefrigerant header tank 15 is formed by combining and tacking by caulking thesecond header member 19 and thefirst header member 18 one on the other as in the firstrefrigerant header tank 14. - After the second tacking step described above, a multiplicity of the
refrigerant tubes 11 are inserted into the slits formed in the firstrefrigerant header tank 14 and the secondrefrigerant header tank 15. At the same time, thefins 12 are interposed between therefrigerant tubes 11 thereby to assemble the condenser 1. - One
side plate 25 is arranged above the uppermostrefrigerant tube 11 through thefins 12, and theother side plate 25 is arranged through thefins 12 under thelowest refrigerant tube 11. This assembly then is tacked by being bound vertically with a wire. - Further, the
first separator 14 a is tacked at a predetermined position in the firstrefrigerant header tank 14. Theplate 23 is tacked by being caulked at the position of the communication hole formed in advance in the secondrefrigerant header tank 15, and the gas-liquid separator 22 with thefirst bracket 24 tacked by being caulked thereon is tacked by being caulked through a mountingmember 22 a. Also, thesecond separator 15 a is tacked by being caulked at a predetermined position in the secondrefrigerant header tank 15. - Further, the
bracket 26 for mounting other parts is tacked by being caulked on thelower side plate 25. Under this condition, the whole assembly is fixed in position by exclusive jigs from both sides. The tank caps 27 are tacked by caulking at the upper and lower ends of the secondrefrigerant header tank 15 and the lower end of the firstrefrigerant header tank 14. Also, thetank cap 28 having thesecond bracket 29 is tacked by caulking at the upper end of the firstrefrigerant header tank 14. - The whole condenser 1 thus tacked is heated to about 600° C. by a heating means thereby to melt the brazing material clad in advance on the surface of each component part. Then, the condenser 1 is cooled again until the brazing material is solidified. In this way, the component parts are integrally brazed and the condenser 1 is produced. According to this embodiment, therefore, this brazing step makes up the coupling step for coupling the first and
second connectors second header member 17 and thefirst header member 16. - In the condenser 1 according to this embodiment, as described above, the forward end of the
first connector 20 is deformed in the longitudinal direction of thesecond header member 17 on the inner periphery of the throughhole 17 b thereby to make up the engagingportions 20 g. Therefore, thefirst connector 20 can be positively tacked on the firstrefrigerant header tank 14. In addition, the outer periphery of theprotrusion 20 b of thefirst connector 20 is strongly tacked by caulking on the inner periphery of the throughhole 17 b. - Further, in view of the fact that the
first connector 20 is tacked on thesecond header member 17 before thesecond header member 17 and thefirst header member 16 are combined with each other, the firstrefrigerant header tank 14 is not yet cylindrical in shape at the time of tacking thefirst connector 20 on thesecond header member 17. As a result, the workability of tacking thefirst connector 20 on thesecond header member 17 is improved. - The improved workability reduces the production cost of the condenser 1. Further, since the through
hole 17 b can be easily formed in thesecond header member 17 by press work or the like, the production cost of the condenser 1 can be reduced as compared with the conventional technique in which a notch is formed on each of the two component parts, i.e. thesecond header member 17 and thefirst header member 16. - Also, the
first connector 20, which is arranged to project in the direction (along arrow B) perpendicular to the length of thetubes 11 from the opening of the throughhole 17 b of thesecond header member 17, is not projected outward along the length of thetubes 11 from the firstrefrigerant header tank 14. As a result, the condenser 1 can be reduced in size. - In this specification, the wording “the
first connector 20 is not projected outward along the length of thetubes 11 from the firstrefrigerant header tank 14” means that as in this embodiment, for example, the axes of theconnection hole 20 d and thecommunication hole 20 f formed in thefirst connector 20 follow the direction (the direction of arrow B) perpendicular to the length of thetubes 11, and therefore thefirst connector 20 is not unnecessarily displaced outward along the length of the tubes from the firstrefrigerant header tank 14. - The wording “the
first connector 20 is not projected outward along the length of thetubes 11 from the firstrefrigerant header tank 14”, therefore, is applicable substantially to a configuration in which thepipe connecting portion 20 a or the like is displaced outward along the length of thetubes 11 from the firstrefrigerant header tank 14 due to the shape of the flange of the refrigerant inflow pipe and the refrigerant outflow pipe. - Also, in the condenser 1 according to this invention, the through
hole 17 b is formed directly in thesecond header member 17. As compared with the prior art in which the through hole is formed by combining the second header member and the first header member, therefore, the dimensional accuracy of the throughhole 17 b is improved. Further, the absence of a step around the throughhole 17 b reduces the geometric variations of the periphery of the throughhole 17 b. - Furthermore, in view of the fact that the through
hole 17 b is arranged adjacently to thefitting step 17 a of thesecond header member 17, the deformation of the throughhole 17 b in the first tacking step is suppressed. Thus, theprotrusion 20 b can be tacked positively in the throughhole 17 b. Further, thepositioning portions 20 c assure a more positive positioning, thereby improving the mounting dimensional accuracy after coupling thefirst connector 20 and the firstrefrigerant header tank 14 to each other. - In addition, as the
positioning portions 20 c are in such a shape as to adapt to the outer periphery of thesecond header member 17 around the throughhole 17 b, the contact portion between the positioningportions 20 c and thesecond header member 17 constitutes a coupling surface for an improved coupling strength between thefirst connector 20 and thesecond header member 17. - Also, as compared with the prior art, the geometric variations around the through
hole 17 b can be reduced, and therefore, the shape adjustment of thefirst connector 20, which otherwise might be required by an independent cutting process to assure adaptation of the shape of theprotrusion 20 b and thepositioning portions 20 c of thefirst connector 20 to the outer periphery of the firstrefrigerant header tank 14, is not required. - Thus, the
first connector 20 can be easily produced by cold forging or the like. As a result, the production cost of thefirst connector 20 can be reduced, thereby reducing the production cost of the condenser 1 as a whole. Exactly the same effects are obtained for thesecond connector 21 as for thefirst connector 20. - This invention is not limited to the embodiments described above but can be variously modified as described below.
- (1) Unlike in the embodiments described above employing the condenser 1 of a subcool type for supercooling the liquid-phase refrigerant, a condenser having neither the supercooling unit 13 b nor the gas-
liquid separator 22 may be used. - (2) The first and
second connectors second header member 17 of the firstrefrigerant header tank 14 in the embodiments described above, may alternatively be coupled to thesecond header member 19 of the secondrefrigerant header tank 15. Theconnectors second header members refrigerant header tanks - (3) Unlike in the embodiments described above in which the
protrusion 20 b is formed on thefirst connector 20 as a tacking portion, the tacking portion is not limited to this configuration. As an alternative, a tabular hook is formed on thefirst connector 20 and bent along the outer periphery of thesecond header member 17. In this way, thefirst connector 20 may be engaged with and tacked on theheader tank 14. - (4) In the embodiments above, the component parts such as the
first connector 20 and thesecond connector 21 are coupled by brazing to the condenser. The component parts of the invention, however, are not limited to the ones used in the embodiments described. Instead, the component parts that can be brazed and, as required by the type and application of the heat exchanger, may be integrally brazed after being tacked by caulking or the like. - (5) Examples of application of the invention to the condenser of the automotive vehicles are described in the aforementioned embodiments. Nevertheless, the condenser according to the invention is applicable to the heat exchangers in general as well as a vehicle condenser without departing from the spirit of the invention.
- While the invention has been described by reference to specific embodiments chosen for purposes of illustration, it should be apparent that numerous modifications could be made thereto, by those skilled in the art, without departing from the basic concept and scope of the invention.
Claims (15)
1. A heat exchanger comprising a cylindrical header tank connected with a plurality of tubes through which a fluid passes and a pair of connectors each for connecting a fluid pipe,
wherein the connectors each have a tacked portion engaging the header tank, and
wherein the connectors and the header tank have a coupling surface therebetween, respectively, coupled by brazing to each other.
2. A heat exchanger according to claim 1 ,
wherein the header tank has a through hole for establishing communication between the inside and the outside of the header tank,
wherein the connectors each have a protrusion adapted to be inserted into the through hole, and
wherein the tacked portion makes up engaging portions configured by deforming the protrusion.
3. A heat exchanger according to claim 2 ,
wherein the protrusion is caulked on the inner periphery of the through hole.
4. A heat exchanger according to claim 2 ,
wherein the through hole is formed on the side of the cylinder of the header tank.
5. A heat exchanger according to claim 2 ,
wherein an opening of the through hole is in the shape elongated along the length of the header tank.
6. A heat exchanger according to claim 2 ,
wherein the engaging portion is arranged on each end of the protrusion in a longitudinal direction of the header tank.
7. A heat exchanger according to claim 2 ,
wherein the header tank is configured by fitting the second header member on the first header member connected with a plurality of the tubes, and
wherein the through hole is formed in the second header member.
8. A heat exchanger according to claim 7 ,
wherein the second header member has a pair of fitting steps each having an L-shaped section fitted with the first header member, and
wherein the through hole is arranged adjacently to the fitting steps.
9. A heat exchanger according to claim 2 ,
wherein the through hole is open in the direction perpendicular to the length of the tubes, and
wherein the connectors are arranged on the header tank in such a manner as to project outward in the direction perpendicular to the length of the tubes from the opening of the through hole.
10. A heat exchanger according to claim 1 ,
wherein the connectors each have a positioning portion set in position by contact with the outer periphery of the header tank, and
wherein the coupling surface is the contact portion between the positioning portion and the header tank.
11. A method of producing a heat exchanger including a cylindrical header tank connected with a plurality of tubes with a fluid passing therein and connectors for fluid pipe connection, comprising the steps of:
tacking the connectors on the header tank by deforming a part of the connectors, and
coupling by brazing the connectors and the header tank one on the other after the tacking step.
12. A method of producing a heat exchanger according to claim 11 ,
wherein the tacking step includes the step of preparing the header tank having a through hole communicating between inside and outside thereof and the connector having a protrusion insertable into a through hole, and
wherein the protrusion is expanded toward the inner periphery of the through hole after being inserted into the through hole.
13. A method of producing a heat exchanger according to claim 12 ,
wherein the tacking step includes the step of imposing a load parallel to the length of the header tank on the protrusion after inserting the protrusion into the through hole.
14. A method of producing a heat exchanger according to claim 12 ,
wherein the tacking step includes the step of preparing the header tank in which the second header member having the through hole is fitted on the first header member connected with a plurality of the tubes, and
wherein after inserting the protrusion into the through hole and deforming the protrusion, the second header member is fitted on the first header member.
15. A method of producing a heat exchanger according to claim 11 ,
wherein the tacking step includes the step of preparing the header tank having the through hole open in the direction perpendicular to the length of the tube, and
wherein the connectors are arranged on the header tank in such a manner as to project outward in the direction perpendicular to the length of the tubes from the opening of the through hole.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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JP2006-024287 | 2006-02-01 | ||
JP2006024287A JP2007205621A (en) | 2006-02-01 | 2006-02-01 | Heat exchanger and its manufacturing method |
Publications (1)
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US20070181293A1 true US20070181293A1 (en) | 2007-08-09 |
Family
ID=38332815
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US11/700,569 Abandoned US20070181293A1 (en) | 2006-02-01 | 2007-01-31 | Heat exchanger and producing method thereof |
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US (1) | US20070181293A1 (en) |
JP (1) | JP2007205621A (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080230214A1 (en) * | 2007-03-19 | 2008-09-25 | Denso Corporation | Heat exchanger and method of manufacturing the same |
DE102019006564B4 (en) | 2018-10-18 | 2024-05-16 | Scania Cv Ab | Heat exchanger, drive train and vehicle |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2016200312A (en) | 2015-04-08 | 2016-12-01 | 株式会社デンソー | Heat exchanger and manufacturing method of heat exchanger |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6293011B1 (en) * | 1998-11-19 | 2001-09-25 | Denso Corporation | Heat exchanger for vehicle air conditioner |
US20040069478A1 (en) * | 2001-01-29 | 2004-04-15 | Soichi Kato | Heat exchanger |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2003027594A1 (en) * | 2001-09-21 | 2003-04-03 | Zexel Valeo Climate Control Corporation | Heat exchanger |
JP2004219027A (en) * | 2003-01-17 | 2004-08-05 | Denso Corp | Mounting structure of connector in condenser |
-
2006
- 2006-02-01 JP JP2006024287A patent/JP2007205621A/en active Pending
-
2007
- 2007-01-31 US US11/700,569 patent/US20070181293A1/en not_active Abandoned
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6293011B1 (en) * | 1998-11-19 | 2001-09-25 | Denso Corporation | Heat exchanger for vehicle air conditioner |
US20040069478A1 (en) * | 2001-01-29 | 2004-04-15 | Soichi Kato | Heat exchanger |
US6860324B2 (en) * | 2001-01-29 | 2005-03-01 | Zexel Valeo Climate Control Corporation | Heat exchanger |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080230214A1 (en) * | 2007-03-19 | 2008-09-25 | Denso Corporation | Heat exchanger and method of manufacturing the same |
DE102019006564B4 (en) | 2018-10-18 | 2024-05-16 | Scania Cv Ab | Heat exchanger, drive train and vehicle |
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