US20070204983A1 - Heat Exchanger - Google Patents
Heat Exchanger Download PDFInfo
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- US20070204983A1 US20070204983A1 US11/578,552 US57855205A US2007204983A1 US 20070204983 A1 US20070204983 A1 US 20070204983A1 US 57855205 A US57855205 A US 57855205A US 2007204983 A1 US2007204983 A1 US 2007204983A1
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- Prior art keywords
- tank
- tank formation
- tube
- members
- header
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B9/00—Compression machines, plants or systems, in which the refrigerant is air or other gas of low boiling point
- F25B9/002—Compression machines, plants or systems, in which the refrigerant is air or other gas of low boiling point characterised by the refrigerant
- F25B9/008—Compression machines, plants or systems, in which the refrigerant is air or other gas of low boiling point characterised by the refrigerant the refrigerant being carbon dioxide
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B39/00—Evaporators; Condensers
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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
- F28D1/03—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 plate-like or laminated conduits
- F28D1/0391—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 plate-like or laminated conduits a single plate being bent to form one or more conduits
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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
- F28D1/05391—Assemblies of conduits connected to common headers, e.g. core type radiators with multiple rows of conduits or with multi-channel conduits combined with a particular flow pattern, e.g. multi-row multi-stage radiators
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F1/00—Tubular elements; Assemblies of tubular elements
- F28F1/02—Tubular elements of cross-section which is non-circular
- F28F1/022—Tubular elements of cross-section which is non-circular with multiple channels
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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
- F28F9/001—Casings in the form of plate-like arrangements; Frames enclosing a heat exchange core
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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
- F28F9/0202—Header boxes having their inner space divided by partitions
- F28F9/0204—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions
- F28F9/0207—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions the longitudinal or transversal partitions being separate elements attached to header boxes
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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
- F28F9/0229—Double end plates; Single end plates with hollow spaces
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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
- F28F9/0246—Arrangements for connecting header boxes with flow lines
- F28F9/0251—Massive connectors, e.g. blocks; Plate-like connectors
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2309/00—Gas cycle refrigeration machines
- F25B2309/06—Compression machines, plants or systems characterised by the refrigerant being carbon dioxide
- F25B2309/061—Compression machines, plants or systems characterised by the refrigerant being carbon dioxide with cycle highest pressure above the supercritical pressure
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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
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0068—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for refrigerant cycles
- F28D2021/0073—Gas coolers
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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
- F28F2225/00—Reinforcing means
- F28F2225/08—Reinforcing means for header boxes
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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
- F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
- F28F2255/16—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes extruded
Definitions
- the present invention relates to a heat exchanger, and more particularly to a heat exchanger favorably usable as a gas cooler or an evaporator of a supercritical refrigeration cycle in which a CO 2 (carbon dioxide) refrigerant or a like supercritical refrigerant is used.
- a CO 2 (carbon dioxide) refrigerant or a like supercritical refrigerant is used.
- the downstream side of flow (represented by arrow X in FIGS. 1 and 13 ) of air in a heat exchanger is referred to as the “front,” and the opposite side as the “rear,” and the term “aluminum” encompasses aluminum alloys in addition to pure aluminum.
- a conventionally known heat exchanger for use in a supercritical refrigeration cycle includes a pair of header tanks disposed apart from each other; heat exchange tubes disposed in parallel at intervals between the two header tanks and having opposite ends connected to the respective header tanks; and fins disposed in respective air-passing clearances between adjacent heat exchange tubes (Japanese Patent Application Laid-Open (kokai) No. 2001-133, FIGS. 6 and 7 ).
- Each of the two header tanks includes a cylindrical tank formation member formed from an extrudate, and a tube-connecting plate having a minor-arcuate cross section.
- the tank formation member has an arcuate-segment portion in which a plurality of tube insertion holes are formed and arranged apart from each other in the longitudinal direction thereof.
- the tube-connecting plate has a plurality of tube insertion holes formed therein and arranged apart from each other in the longitudinal direction thereof, and is joined to the tank formation member while being fitted to the arcuate-segment portion of the tank formation member.
- each of the header tanks of the heat exchanger described in the above-mentioned publication includes the cylindrical tank formation member having a refrigerant channel of a circular cross section.
- the header tanks fail to assume an appropriate cross-sectional profile in accordance with, for example, an installation space for the heat exchanger.
- An object of the present invention is to overcome the above problems and to provide a heat exchanger which allows the cross-sectional profile of a header tank thereof to be selected as appropriate in accordance with an installation space therefor and which readily allows a change in the cross-sectional shape and area of a refrigerant channel of the header tank.
- the present invention comprises the following modes.
- a heat exchanger comprising a pair of header tanks disposed apart from each other, and a plurality of heat exchange tubes disposed in parallel between the two header tanks and each having opposite end portions connected to the respective header tanks,
- the two header tanks each comprising a hollow tank formation member, and a partition member disposed within and joined to the tank formation member and adapted to divide the interior of the tank formation member into a plurality of refrigerant channels extending in the longitudinal direction of the tank formation member and arranged in the front-rear direction.
- a heat exchanger according to par. 1), wherein a plurality of tube insertion holes are formed in the tank formation members; a plurality of tube-end fit cutouts for partially receiving corresponding end portions of heat exchange tubes are formed on the partition members in such a manner as to align with the corresponding tube insertion holes; and the heat exchange tubes are connected to the two header tanks such that end portions thereof are inserted through the corresponding tube insertion holes of the tank formation members and are fitted into the corresponding tube-end fit cutouts of the partition members.
- a heat exchanger according to par. 1), further comprising tube-connecting plates joined to corresponding outer surfaces of the tank formation members, wherein a plurality of tube insertion holes are formed in the tube-connecting plates in such a manner as to align with the corresponding tube insertion holes of the tank formation members, and the heat exchange tubes are connected to the two header tanks such that end portions thereof are inserted through the tube insertion holes of the tube-connecting plates.
- a heat exchanger according to par. 1) wherein the partition members assume the form of an elongated plate and are disposed such that the width direction thereof coincides with the height direction of hollow portions of the tank formation members.
- a heat exchanger according to par. 1) wherein the partition members have a cross section resembling the letter U, and the partition members are disposed such that the width direction of a pair of opposed walls of each partition member coincides with the height direction of the hollow portions of the tank formation members and such that ends of the opposed walls face the tube insertion holes.
- a heat exchanger according to par. 1) wherein the partition members assume the form of a corrugated plate comprising a plurality of flat portions in parallel with one another and a plurality of connection portions each connecting adjacent flat portions, and the width direction of the flat portions coincides with the height direction of the hollow portions of the tank formation members.
- a heat exchanger according to par. 1), wherein a first header tank of the paired header tanks comprises a plurality of tank formation members aligned with one another in a longitudinal direction thereof; a second header tank of the paired header tanks comprises tank formation members numbering one fewer than the tank formation members of the first header tank and is disposed so as to oppose two adjacent tank formation members of the first header tank; and a refrigerant entering one tank formation member of the first header tank flows through all the heat exchange tubes and the tank formation members of the second header tank and enters another tank formation member of the first header tank.
- a heat exchanger according to par. 7), wherein the number of tank formation members of the first header tank is two; the two tank formation members are joined together via a separation plate so as to avoid communication between hollow portions thereof: and the number of tank formation members of the second header tank is one.
- a heat exchanger according to par. 1), wherein the first header tank of the paired header tanks comprises two tank formation members aligned with each other in the longitudinal direction thereof; the second header tank of the paired header tanks is disposed so as to oppose the two tank formation members of the first header tank;
- the tank formation members of the two header tanks each have a plurality of hole groups provided in a plurality of rows separated from one another in the front-rear direction, each hole group comprising a plurality of tube insertion holes formed therein apart from one another in the longitudinal direction thereof;
- a partition member assuming the form of a corrugated plate comprising a plurality of flat portions in parallel with one another and a plurality of connection portions each connecting adjacent flat portions is disposed within each of the tank formation members of the two header tanks such that the width direction of the flat portions coincides with the height direction of a hollow portion of each of the tank formation members and such that at least one flat portion is located between tube insertion holes adjacent to each other in the front-rear direction of the tank formation member;
- a plurality of tube-end fit cutouts for partially receiving corresponding end portions of heat exchange tubes are formed on the partition members in such a manner as to align with the corresponding tube insertion holes; the heat exchange tubes are connected to the two header tanks such that end portions thereof are inserted through the corresponding
- refrigerant passage holes are formed in the flat portions of the partition member disposed within one of the two tank formation members of the first header tank.
- a supercritical refrigeration cycle which comprises a compressor, a gas cooler, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator and in which a supercritical refrigerant is used, the gas cooler comprising a heat exchanger according to any one of pars. 1) to 8).
- a supercritical refrigeration cycle which comprises a compressor, a gas cooler, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator and in which a supercritical refrigerant is used, the evaporator comprising a heat exchanger according to any one of pars. 1) to 6) and 9 ).
- the header tank comprises the hollow tank formation member, and the partition member disposed within and joined to the tank formation member and adapted to divide the interior of the tank formation member into a plurality of refrigerant channels extending in the longitudinal direction of the tank formation member and arranged in the front-rear direction, so that the partition member functions to enhance withstand pressure of the header tank.
- This enables the header tank, or the tank formation member, to assume an appropriate cross-sectional profile in accordance with, for example, an installation space for an associated heat exchanger.
- the cross-sectional shape and area of the refrigerant channels in the header tank can be readily changed so as to enhance heat exchange performance of the heat exchanger in various applications.
- costs become lower.
- a plurality of tube insertion holes are formed in the tank formation member, and a plurality of tube-end fit cutouts for partially receiving corresponding end portions of the heat exchange tubes are formed on the partition member in such a manner as to align with the corresponding tube insertion holes. Accordingly, in the course of assembling the heat exchanger, the heat exchange tubes can be connected to the header tank in a relatively easy manner by utilizing the tube insertion holes of the tank formation member. Further, since the end portions of the heat exchange tubes are fitted into the corresponding tube-end fit cutouts of the partition member, all of the end portions of the heat exchange tubes can readily assume a predetermined length of projection into the header tank, or the tank formation member. Therefore, the length of projection can be set to an appropriate value for enhancing the performance of the heat exchanger.
- the heat exchanger according to par. 3) further comprises a tube-connecting plate joined to the outer surface of the tank formation member, and a plurality of tube insertion holes are formed in the tube-connecting plate in such a manner as to align with the corresponding tube insertion holes of the tank formation member. Accordingly, in the course of assembling the heat exchanger by using the header tank, the heat exchange tubes can be connected to the header tank in a relatively easy manner by utilizing the tube insertion holes of the tank formation member and those of the tube-connecting plate.
- the flow of refrigerant can be appropriately set for enhancing heat exchange performance.
- the heat exchanger when used as a gas cooler of a supercritical refrigeration cycle, the gas cooler exhibits enhanced heat exchange performance.
- the flow of refrigerant can be appropriately set for enhancing heat exchange performance.
- the heat exchanger when used as an evaporator of a supercritical refrigeration cycle, the evaporator exhibits enhanced heat exchange performance.
- FIG. 1 is a perspective view showing the overall construction of a gas cooler to which the heat exchanger according to the present invention is applied;
- FIG. 2 is a fragmentary view in vertical section showing the gas cooler of FIG. 1 as it is seen frontward from rear;
- FIG. 3 is a perspective view showing a first header tank of the gas cooler of FIG. 1 ;
- FIG. 4 is an exploded perspective view of the first header tank of the gas cooler of FIG. 1 ;
- FIG. 5 is an enlarged view in section taken along line A-A of FIG. 2 ;
- FIG. 6 is an enlarged view in section taken along line B-B of FIG. 2 ;
- FIG. 7 is an exploded perspective view of the second header tank of the gas cooler of FIG. 1 ;
- FIG. 8 is an enlarged view in section taken along line C-C of FIG. 2 ;
- FIG. 9 is a diagram showing the flow of a refrigerant through the gas cooler of FIG. 1 ;
- FIG. 10 is a fragmentary perspective view showing a first modified embodiment of the partition member disposed within a tank formation member of the gas cooler of FIG. 1 ;
- FIG. 11 is a fragmentary perspective view showing a second modified embodiment of the partition member disposed within a tank formation member of the gas cooler of FIG. 1 ;
- FIG. 12 is a fragmentary perspective view showing a third modified embodiment of the partition member disposed within a tank formation member of the gas cooler of FIG. 1 ;
- FIG. 13 is a perspective view showing the overall construction of an evaporator to which the heat exchanger according to the present invention is applied;
- FIG. 14 is a fragmentary view in vertical section showing the evaporator of FIG. 13 as it is seen frontward from rear;
- FIG. 15 is an enlarged view in section taken along line DD of FIG. 14 ;
- FIG. 16 is an exploded perspective view showing a first header tank of the evaporator of FIG. 13 ;
- FIG. 17 is an enlarged view in section taken along line E-E of FIG. 14 ;
- FIG. 18 is an enlarged view in section taken along line F-F of FIG. 14 ;
- FIG. 19 is an exploded perspective view showing a second header tank of the evaporator of FIG. 13 ;
- FIG. 20 is a diagram showing the flow of a refrigerant through the evaporator of FIG. 13 ;
- FIG. 21 is a cross-sectional view showing a first modified embodiment of the heat exchange tube
- FIG. 22 is a fragmentary enlarged view of FIG. 21 ;
- FIG. 23 is a series of views showing a method of manufacturing the heat exchange tube shown in FIG. 21 ;
- FIG. 24 is a cross-sectional view showing a second modified embodiment of the heat exchange tube
- FIG. 25 is a cross-sectional view showing a third modified embodiment of the heat exchange tube.
- FIG. 26 is a fragmentary enlarged view of FIG. 25 ;
- FIG. 27 is a series of views showing a method of manufacturing the heat exchange tube shown in FIG. 25 .
- FIGS. 1, 2 , 13 , and 14 will be referred to as “upper,” “lower,” “left,” and “right,” respectively.
- This embodiment is shown in FIGS. 1 to 9 and is implemented by applying a heat exchanger according to the present invention to a gas cooler of a supercritical refrigeration cycle.
- a gas cooler 1 of a supercritical refrigeration cycle wherein a supercritical refrigerant, such as CO 2 , is used includes two header tanks 2 , 3 extending vertically and separated from each other in the left-right direction; a plurality of flat heat exchange tubes 4 arranged in parallel between the two header tanks 2 , 3 and separated from one another in the vertical direction; corrugated fins 5 arranged in respective air-passing clearances between adjacent heat exchange tubes 4 and at the outside of the upper-end and lower-end heat exchange tubes 4 and each brazed to the adjacent heat exchange tubes 4 or to the upper-end or lower-end heat exchange tube 4 ; and side plates 6 of bare aluminum material arranged externally of and brazed to the respective upper-end and lower-end corrugated fins 5 .
- the header tank 2 at the right will be referred to as the “first header tank,” and the header tank 3 at the left as the “second header tank.”
- the first header tank 2 includes two hollow tank formation members 7 A, 7 B extending and arranged vertically; a tube-connecting plate 8 opposed to the two tank formation members 7 A, 7 B and joined to the outer surfaces of the inner side walls with respect to the left-right direction; i.e., the left-hand side walls, of the two tank formation members 7 A, 7 B; partition members 9 A, 9 B disposed within and brazed to the tank formation members 7 A, 7 B, respectively; caps 11 adapted to close the upper end opening of the upper tank formation member 7 A, and the lower end opening of the lower tank formation member 7 B; and a separation plate 12 disposed between and joined to the upper and lower tank formation members 7 A, 7 B and adapted to close the lower end opening of the upper tank formation member 7 A, and the upper end opening of the lower tank formation member 7 B.
- the tank formation members 7 A, 7 B are formed from a hollow aluminum extrudate and have a rectangular cross-sectional shape elongated in the front-rear direction.
- a plurality of tube insertion holes 13 elongated in the front-rear direction are formed through the inner side walls with respect to the left-right direction; i.e., the left-hand side walls, of the tank formation members 7 A, 7 B and are vertically separated from one another.
- a refrigerant inlet 14 is formed in the outer side wall with respect to the left-right direction; i.e., the right-hand side wall, of the upper tank formation member 7 A.
- a refrigerant inlet member 15 of aluminum having a refrigerant inflow channel 16 in communication with the refrigerant inlet 14 is joined to the outer surface of the right-hand side wall of the upper tank formation member 7 A by, in the present embodiment, brazing.
- a refrigerant outlet 17 is formed in the right-hand side wall of the lower tank formation member 7 B.
- a refrigerant outlet member 18 of aluminum having a refrigerant outflow channel 19 in communication with the refrigerant outlet 17 is joined to the outer surface of the right-hand side wall of the lower tank formation member 7 B by, in the present embodiment, brazing.
- the tank formation members 7 A, 7 B are formed, by press work, from a hollow aluminum extrudate such that the tube insertion holes 13 and the refrigerant inlet 14 or the refrigerant outlet 17 are formed. An upper end portion of the upper tank formation member 7 A and a lower end portion of the lower tank formation member 7 B project outward beyond the tube-connecting plate 8 .
- the tube-connecting plate 8 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof and is brazed to the two tank formation members 7 A, 7 B by utilizing the brazing material layer on one side thereof.
- a plurality of tube insertion holes 21 elongated in the front-rear direction are formed through the tube-connecting plate 8 in such a manner as to align with the corresponding tube insertion holes 13 of the two tank formation members 7 A, 7 B and are vertically separated from one another.
- the tube-connecting plate 8 has a projecting wall 8 a formed at each of the front and rear side edges and projecting outward with respect to the left-right direction.
- the two projecting walls 8 a are brazed to the outer surfaces of the front and rear side walls of the two tank formation members 7 A, 7 B while opposing the two tank formation members 7 A, 7 B.
- the tube-connecting plate 8 is formed, by press work, from an aluminum brazing sheet such that the tube insertion holes 21 and the projecting walls 8 a are formed.
- the partition members 9 A, 9 B are formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof and assume the form of an elongated plate.
- the partition members 9 A, 9 B are disposed within the tank formation members 7 A, 7 B, respectively, at the respective centers with respect to the front-rear direction such that the width direction thereof coincides with the left-right direction (the height direction of the hollow portions of the tank formation members 7 A, 7 B) and in such a manner as to extend along the entire lengths of the tank formation members 7 A, 7 B.
- the partition members 9 A, 9 B are brazed to the inner surfaces of the left-hand and right-hand side walls of the two tank formation members 7 A, 7 B.
- the partition members 9 A, 9 B disposed within the tank formation members 7 A, 7 B, respectively, partially define refrigerant channels 22 arranged in the front-rear direction and extending in the longitudinal direction thereof.
- End portions oriented toward the tube insertion holes 13 of the tank formation members 7 A, 7 B; i.e., left-hand end portions, of the partition members 9 A, 9 B have a plurality of tube-end fit cutouts 23 formed thereon in such a manner as to be vertically separated from one another and to align with the corresponding tube insertion holes 13 , 21 of the tank formation members 7 A, 7 B and the tube-connecting plate 8 .
- the partition members 9 A, 9 B are formed, by press work, from an aluminum brazing sheet such that the tube-end fit cutouts 23 are formed.
- a cap 11 is formed from an aluminum brazing sheet that has a brazing material layer on at least one side thereof.
- a recess 24 is formed on the side of the cap 11 on which the brazing material layer is present, for receiving a portion of the tank formation member 7 A or 7 B that projects beyond the tube-connecting plate 8 .
- the caps 11 are brazed to the corresponding tank formation members 7 A, 7 B while the projecting portion of the upper tank formation member 7 A and the projecting portion of the lower tank formation member 7 B are fitted into the corresponding recesses 24 of the caps 11 .
- the cap 11 is formed, by press work, from an aluminum brazing sheet such that the recess 24 is formed.
- the separation plate 12 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof. By utilizing the brazing material layers on the opposite surfaces, the separation plate 12 is brazed to the lower end surfaces of the upper tank formation member 7 A and the upper partition member 9 A and to the upper end surfaces of the lower tank formation member 7 B and the lower partition member 9 B.
- the second header tank 3 has substantially the same construction as the first header tank 2 and is in the mirror image of the first header tank 2 .
- the two header tanks 2 , 3 are disposed such that the respective tube-connecting plates 8 face each other.
- like features and parts are designated by like reference numerals.
- the second header tank 3 differs from the first header tank 2 in that in place of the two tank formation members 7 A, 7 B, one tank formation member 7 C is used which extends along the entire length of the second header tank 3 ; one partition member 9 C is disposed within the tank formation member 7 C and extends along the entire length of the tank formation member 7 C; neither the refrigerant inlet 14 nor the refrigerant outlet 17 is formed on the tank formation member 7 C; and the separation plate 12 is not provided.
- Each of the heat exchange tubes 4 is formed from an aluminum extrudate; is in the form of a flat tube having an increased width in the front-rear direction; and has inside thereof a plurality of refrigerant channels 4 a extending in the longitudinal direction thereof and arranged in parallel. Opposite end portions of the heat exchange tubes 4 are inserted through the corresponding tube insertion holes 21 of the tube-connecting plates 8 for the two header tanks 2 , 3 and through the tube insertion holes 13 of the tank formation members 7 A, 7 B, 7 C, and central portions with respect to the front-rear direction of the opposite end portions of the heat exchange tubes 4 are fitted into the cutouts 23 of the partition members 9 A, 9 B, 9 C.
- the opposite end portions of the heat exchange tubes 4 are brazed to the tube-connecting plates 8 and to the tank formation members 7 A, 7 B, 7 C by utilizing the brazing material layers of the tube-connecting plates 8 .
- the opposite end faces of the heat exchange tubes 4 abut the corresponding bottoms of the cutouts 23 of the partition members 9 A, 9 B, 9 C.
- Each of the corrugated fins 5 is made in a wavy form from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof.
- the gas cooler 1 is manufactured by subjecting an assembly of all members to batch brazing.
- the gas cooler 1 together with a compressor, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator, constitutes a supercritical refrigeration cycle.
- the refrigeration cycle is installed in a vehicle, for example, in a motor vehicle, as a vehicular air conditioner.
- CO 2 having passed through a compressor flows through the refrigerant inflow channel 16 of the refrigerant inlet member 15 and enters the two refrigerant channels 22 of the upper tank formation member 7 A of the first header tank 2 through the refrigerant inlet 14 . Then, the CO 2 flows through the two refrigerant channels 22 and flows into the refrigerant channels 4 a of all the heat exchange tubes 4 in communication with the upper tank formation member 7 A. The CO 2 in the refrigerant channels 4 a flows leftward through the refrigerant channels 4 a and enters the tank formation member 7 C of the second header tank 3 .
- the CO 2 in the tank formation member 7 C flows downward through the two refrigerant channels 22 ; flows into the refrigerant channels 4 a of all the heat exchange tubes 4 in communication with the lower tank formation member 7 B; changes its course; flows rightward through the refrigerant channels 4 a ; and enters the two refrigerant channels 22 of the lower tank formation member 7 B of the first header tank 2 . Subsequently, the CO 2 flows through the two refrigerant channels 22 and flows out of the gas cooler 1 via the refrigerant outlet 17 and the refrigerant outflow channel 19 of the refrigerant outlet member 18 . While flowing through the refrigerant channels 4 a of the heat exchange tubes 4 , the CO 2 is subjected to heat exchange with the air flowing through the air-passing clearances in the direction of arrow X shown in FIG. 9 , thereby being cooled.
- FIGS. 10 to 13 show modified embodiments of the partition member disposed within the tank formation member of the gas cooler.
- FIG. 10 a plurality of, two in the present modified embodiment, partition members 9 A ( 9 B, 9 C) of Embodiment 1 are disposed within the tank formation member 7 A ( 7 B, 7 C) and are separated from each other in the front-rear direction.
- the refrigerant channels 22 numbering one greater than the partition members 9 A ( 9 B, 9 C) are formed within the tank formation member 7 A ( 7 B, 7 C).
- FIG. 10 ( a ) shows the tank formation member 7 A ( 7 B) of the first header tank 2
- FIG. 10 ( b ) shows the tank formation member 7 C of the second header tank 3 .
- the refrigerant inlet 14 and the refrigerant outlet 17 of the tank formation members 7 A, 7 B, respectively have such a size as to oppose all the refrigerant channels 22 .
- a partition member 30 A ( 30 B, 30 C) has a cross section resembling the letter U; is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof; and is disposed within the tank formation member 7 A ( 7 B, 7 C) such that the width direction of a pair of opposed walls 30 a thereof coincides with the height direction (left-right direction) of the hollow portion of the tank formation member 7 A ( 7 B, 7 C) and such that the ends of the opposed walls 30 a face the tube insertion holes 13 of the tank formation member 7 A ( 7 B, 7 C) (inward with respect to the left-right direction).
- the partition member 30 A ( 30 B, 30 C) is brazed to the inner surfaces of the left-hand and right-hand side walls of the tank formation member 7 A ( 7 B, 7 C) by utilizing the brazing material layers provided on the opposite surfaces thereof.
- FIG. 11 ( a ) shows the tank formation member 7 A ( 7 B) of the first header tank 2
- FIG. 11 ( b ) shows the tank formation member 7 C of the second header tank 3 .
- Tube-end fit cutouts 32 are formed on end portions of the opposed walls 30 a of the partition members 30 A, 30 B, 30 C.
- the partition members 30 A, 30 B, 30 C are formed, by press work, from an aluminum brazing sheet in such a manner as to assume a cross section resembling the letter U and to have the tube-end fit cutouts 32 .
- a refrigerant passage through-hole 34 is formed in a connection wall 30 b connecting the opposed walls 30 a of the partition member 30 A ( 30 B) at a position aligned with the refrigerant inlet 14 (refrigerant outlet 17 ).
- the refrigerant inlet 14 and the refrigerant outlet 17 of the tank formation members 7 A, 7 B, respectively, have such a size as to oppose all the refrigerant channels 22 .
- a partition member 35 A ( 35 B, 35 C) is formed from an aluminum brazing sheet having a brazing material layer on opposite surfaces thereof and assumes the form of a corrugated plate.
- the corrugated plate is composed of a plurality of, three in the present modified embodiment, flat walls 35 a in parallel with one another, and connection portions 35 b each connecting the adjacent flat walls 35 a in a staggered manner with respect to the height direction of a hollow portion of the tank formation member 7 A ( 7 B, 7 C) (with respect to the left-right direction).
- the partition member 35 A ( 35 B, 35 C) is disposed within the tank formation member 7 A ( 7 B, 7 C) such that the width direction of the flat walls 35 a coincides with the height direction of the hollow portion of the tank formation member 7 A ( 7 B, 7 C) (left-right direction).
- the partition member 35 A ( 35 B, 35 C) is brazed to the inner surfaces of the left-hand and right-hand side walls of the tank formation member 7 A ( 7 B, 7 C) by utilizing the brazing material layers provided on the opposite surfaces thereof.
- FIG. 12 ( a ) shows the tank formation member 7 A ( 7 B) of the first header tank 2
- FIG. 12 ( b ) shows the tank formation member 7 C of the second header tank 3 .
- Tube-end fit cutouts 36 are formed on the connection portions 35 b of the partition members 35 A, 35 B, 35 C located on the side toward the tube insertion holes 13 of the tank formation members 7 A, 7 B, and 7 C and on the flat walls 35 a connected by said connection portions 35 b .
- the tube-end fit cutouts 37 are formed on end portions of other flat walls 35 a located on the side toward the tube insertion holes 13 .
- the flat walls 35 a of the partition members 35 A, 35 B, 35 C disposed within the tank formation members 7 A, 7 B, 7 C, respectively, partially define the refrigerant channels 22 arranged in the front-rear direction.
- the partition members 35 A, 35 B, 35 C are formed, by press work, from an aluminum brazing sheet in such a manner as to assume the form of a corrugated plate and to have the tube-end fit cutouts 36 , 37 .
- a refrigerant passage through-hole 38 is formed in the connection portion 35 b of the partition member 35 A ( 35 B) located outward with respect to the left-right direction at a position aligned with the refrigerant inlet 14 (refrigerant outlet 17 ).
- the refrigerant inlet 14 and the refrigerant outlet 17 of the tank formation members 7 A, 7 B, respectively, have such a size as to oppose all the refrigerant channels 22 .
- This embodiment is shown in FIGS. 13 to 20 and is implemented by applying a heat exchanger according to the present invention to an evaporator of a supercritical refrigeration cycle.
- an evaporator 40 of a supercritical refrigeration cycle wherein a supercritical refrigerant, such as CO 2 , is used includes two header tanks 41 , 42 extending in the left-right direction and separated from each other in the vertical direction; a plurality of flat heat exchange tubes 43 arranged in parallel between the two header tanks 41 , 42 and separated from one another in the left-right direction; corrugated fins 44 arranged in respective air-passing clearances between adjacent heat exchange tubes 43 and at the outside of the left-end and right-end heat exchange tubes 43 and each brazed to the adjacent heat exchange tubes 43 or to the left-end or right-end heat exchange tube 43 ; and side plates 45 of bare aluminum material arranged externally of and brazed to the respective left-end and right-end corrugated fins 44 .
- the upper header tank 41 will be referred to as the “first header tank,” and the lower header tank 42 as the “second header tank.”
- the first header tank 41 includes a right-hand tank formation member 46 A and a left-hand tank formation member 46 B each extending in the left-right direction and assuming a hollow form; a tube-connecting plate 47 opposed to the two tank formation members 46 A, 46 B and joined to the outer surfaces of the lower walls of the two tank formation members 46 A, 46 B; partition members 48 A, 48 B disposed within and brazed to the tank formation members 46 A, 46 B, respectively; a refrigerant inlet-outlet member 49 joined to a right end portion of the right-hand tank formation member 46 A; a cap 51 adapted to close the left end opening of the left-hand tank formation member 46 B; and a separation plate 52 disposed between and joined to the two tank formation members 46 A, 46 B and adapted to close the left end opening of the right-hand tank formation member 46 A and the right end opening of the left-hand tank formation member 46 B.
- the tank formation members 46 A, 46 B are formed from a hollow aluminum extrudate and have a rectangular cross-sectional shape elongated in the front-rear direction.
- a plurality of tube insertion holes 53 elongated in the front-rear direction are formed, in front and rear rows, through the lower walls of the tank formation members 46 A, 46 B and are separated from one another in the left-right direction.
- the tube insertion holes 53 in the front row and the tube insertion holes 53 in the rear row are aligned with each other with respect to the left-right direction.
- the tank formation members 46 A, 46 B are formed, by press work, from a hollow aluminum extrudate such that the tube insertion holes 53 are formed.
- a left end portion of the left-hand tank formation member 46 B and a right-end portion of the right-hand tank formation member 46 A project outward beyond the tube-connecting plate 47 .
- the tube-connecting plate 47 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof and is brazed to the two tank formation members 46 A, 46 B by utilizing the brazing material layer on one side thereof.
- a plurality of tube insertion holes 54 elongated in the front-rear direction are formed in front and rear rows through the tube-connecting plate 47 in such a manner as to align with the corresponding tube insertion holes 53 of the two tank formation members 46 A, 46 B and are separated from one another in the left-right direction.
- the tube-connecting plate 47 has a projecting wall 47 a integrally formed at each of the front and rear side edges and projecting outward with respect to the vertical direction (upward in the present embodiment).
- the two projecting walls 47 a are brazed to the outer surfaces of the front and rear side walls of the two tank formation members 46 A, 46 B while opposing the two tank formation members 46 A, 46 B.
- the tube-connecting plate 47 is formed, by press work, from an aluminum brazing sheet such that the tube insertion holes 54 and the projecting walls 47 a are formed.
- the partition members 48 A, 48 B are formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof and assumes the form of a corrugated plate.
- the corrugated plate is composed of a plurality of, five in the present embodiment, flat walls 48 a in parallel with one another, and connection portions 48 b each connecting the adjacent flat walls 48 a in a staggered manner with respect to the height direction of a hollow portion of the tank formation member 46 A ( 46 B) (with respect to the vertical direction).
- the partition member 48 A ( 48 B) is disposed within the tank formation member 46 A ( 46 B) along the entire length of the tank formation member 46 A ( 46 B) such that the width direction of the flat walls 48 a coincides with the vertical direction.
- the partition member 48 A ( 48 B) is brazed to the inner surfaces of the upper and lower walls of the tank formation member 46 A ( 46 B) by utilizing the brazing material layers provided on the opposite surfaces thereof.
- the flat walls 48 a of the partition members 48 A, 48 B disposed within the tank formation members 46 A, 46 B, respectively, partially define the refrigerant channels 55 arranged in the front-rear direction.
- a plurality of tube-end fit cutouts 56 are formed on the front-side connection portions 48 b of the partition members 48 A, 48 B located on the side toward the tube insertion holes 53 of the tank formation members 46 A, 46 B and on the flat walls 48 a connected by said connection portions 48 b in such a manner as to be separated from one another in the left-right direction so as to be aligned with the front-side tube insertion holes 53 of the tank formation members 46 A, 46 B and the front-side tube insertion holes 54 of the tube-connecting plate 47 .
- a plurality of tube-end fit cutouts 57 are formed on the rear-side connection portions 48 b of the partition members 48 A, 48 B located on the side toward the tube insertion holes 53 of the tank formation members 46 A, 46 B and on the flat walls 48 a located on the rear side of said connection portions 48 b in such a manner as to be separated from one another in the left-right direction so as to be aligned with the rear-side tube insertion holes 53 of the tank formation members 46 A, 46 B and the rear-side tube insertion holes 54 of the tube-connecting plate 47 .
- a plurality of tube-end fit cutouts 58 are formed on end portions of rearmost flat walls 48 a of the partition members 48 A, 48 B located on the side toward the tube insertion holes 53 of the tank formation members 46 A, 46 B in such a manner as to be separated from one another in the left-right direction so as to be aligned with the rear-side tube insertion holes 53 of the tank formation members 46 A, 46 B and the rear-side tube insertion holes 54 of the tube-connecting plate 47 .
- a plurality of refrigerant passage holes 59 are formed through all the flat walls 48 a of the partition member 48 B disposed within the left-hand tank formation member 46 B in such a manner as to be separated from one another in the left-right direction.
- the right-hand partition member 48 A is formed, by press work, from an aluminum brazing sheet in such a manner as to assume the form of a corrugated plate and to have the tube-end fit cutouts 56 , 57 , 58 .
- the left-hand partition member 48 B is formed, by press work, from an aluminum brazing sheet in such a manner as to assume the form of a corrugated plate and to have the tube-end fit cutouts 56 , 57 , 58 and the refrigerant passage holes 59 .
- the refrigerant inlet-outlet member 49 has a recess 61 formed on its left-hand side surface for receiving a portion of the right-hand tank formation member 46 A that projects beyond the tube-connecting plate 47 .
- the refrigerant inlet-outlet member 49 is brazed to the right-hand tank formation member 46 A while the projecting portion of the right-hand tank formation member 46 A is fitted into the recess 61 .
- the refrigerant inlet-outlet member 49 has a refrigerant inflow channel 62 formed therein in communication with the front-side three refrigerant channels 55 in the tank formation member 46 A, and a refrigerant outflow channel 63 formed therein in communication with the rear-side three refrigerant channels 55 in the tank formation member 46 A.
- a refrigerant inlet pipe (not shown) to communicate with the refrigerant inflow channel 62 and a refrigerant outlet pipe (not shown) to communicate with the refrigerant outflow channel 63 are connected to the refrigerant inlet-outlet member 49 .
- the cap 51 is formed from an aluminum brazing sheet that has a brazing material layer on at least one side thereof.
- a recess 64 is formed on the side of the cap 51 on which the brazing material layer is present, for receiving a portion of the left-hand tank formation member 46 B that projects beyond the tube-connecting plate 47 .
- the cap 51 is brazed to the left-hand tank formation member 46 B while the projecting portion of the left-hand tank formation member 46 B is fitted into the recess 64 of the cap 51 .
- the cap 51 is formed, by press work, from an aluminum brazing sheet such that the recess 64 is formed.
- the separation plate 52 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof. By utilizing the brazing material layers on the opposite surfaces, the separation plate 52 is brazed to the left end surfaces of the right-hand tank formation member 46 A and the right-hand partition member 48 A and to the right end surfaces of the left-hand tank formation member 46 B and the left-hand partition member 48 B.
- the second header tank 42 has substantially the same construction as the first header tank 41 and is in the upside-down image of the first header tank 42 .
- the two header tanks 41 , 42 are disposed such that the respective tube-connecting plates 47 face each other.
- like features and parts are designated by like reference numerals.
- the second header tank 42 differs from the first header tank 41 in that in place of the two tank formation members 46 A, 46 B, one tank formation member 46 C is used which extends along the entire length of the second header tank 42 ; one partition member 48 C is disposed within the tank formation member 46 C and extends along the entire length of the tank formation member 46 C; the refrigerant inlet-outlet member 49 is not attached to a right end portion of the tank formation member 46 C, but the cap 51 is brazed to the right end portion as in the case of the left end portion; the refrigerant passage holes 59 are not formed in the partition member 48 C; and the separation plate 52 is not provided.
- a portion of the right-hand tank formation member 46 A of the first header tank 41 that is located on the front side with respect to the central flat wall 48 a of the partition member 48 A serves as an inlet header portion 65
- a portion on the rear side serves as an outlet header portion 66
- a portion of the tank formation member 46 C of the second header tank 42 that is located on the front side with respect to the central flat wall 48 a of the partition member 48 C serves as a first intermediate header portion 67 .
- a portion of the left-hand tank formation member 46 B of the first header tank 41 that is located on the front side with respect to the central flat wall 48 a of the partition member 48 B serves as a second intermediate header portion 68
- a portion on the rear side serves as a third intermediate header portion 69 .
- a portion of the tank formation member 46 C of the second header tank 42 that is located on the rear side with respect to the central flat wall 48 a of the partition member 48 C serves as a fourth intermediate header portion 70 .
- Each of the heat exchange tubes 43 is formed from an aluminum extrudate; is in the form of a flat tube having an increased width in the front-rear direction; and has inside thereof a plurality of refrigerant channels 43 a extending in the longitudinal direction thereof and arranged in parallel. Opposite end portions of the heat exchange tubes 43 are inserted through the corresponding tube insertion holes 54 of the tube-connecting plates 47 for the two header tanks 41 , 42 and through the tube insertion holes 53 of the tank formation members 46 A, 46 B, 46 C and are fitted into the cutouts 56 , 57 , 58 of the partition members 48 A, 48 B, 48 C.
- a plurality of heat-exchange-tube groups 43 A each consisting of a plurality of heat exchange tubes 43 arranged in parallel and separated from one another in the left-right direction, are arranged in a plurality of rows, in two rows in the present embodiment, separated from each other in the front-rear direction.
- the heat exchange tubes 43 positioned in the right half of the front heat-exchange-tube group 43 A communicate with the inlet header portion 65 and the first intermediate header portion 67
- the heat exchange tubes 43 positioned in the left half of the front heat-exchange-tube group 43 A communicate with the first intermediate header portion 67 and the second intermediate header portion 68
- the heat exchange tubes 43 positioned in the right half of the rear heat-exchange-tube group 43 A communicate with the outlet header portion 66 and the fourth intermediate header portion 70
- the heat exchange tubes 43 positioned in the left half of the rear heat-exchange-tube group 43 A communicate with the third intermediate header portion 69 and the fourth intermediate header portion 70 .
- Each of the corrugated fins 44 is made in a wavy form from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof. Connecting portions interconnecting crest portions and trough portions of the fin are provided with a plurality of louvers arranged in parallel in the front-rear direction.
- the corrugated fin 44 is used in common for the front and rear heat-exchange-tube groups 43 A and has a front-to-rear width which is substantially equal to the distance between the front edge of the heat exchange tube 43 of the front heat-exchange-tube group 43 A and the rear edge of the corresponding heat exchange tube 43 of the rear heat-exchange-tube group 43 A.
- a corrugated fin may be provided between each adjacent pair of heat exchange tubes 43 in each of the heat-exchange-tube groups 43 A.
- the evaporator 1 is manufactured by subjecting an assembly of all members to batch brazing.
- the evaporator 1 together with a compressor, a gas cooler, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator, constitutes a supercritical refrigeration cycle.
- the refrigeration cycle is installed in a vehicle, for example, in a motor vehicle, as a vehicular air conditioner.
- CO 2 passing through a pressure-reducing device and undergoing pressure reduction therein flows through the refrigerant inflow channel 62 of the refrigerant inlet-outlet member 49 into the inlet header portion 65 of the first header tank 41 and thereafter flows through the refrigerant channels 55 into the refrigerant channels 43 a of all the heat exchange tubes 43 of the front heat-exchange-tube group 43 A in communication with the inlet header portion 65 .
- the CO 2 in the refrigerant channels 43 a flows downward through the refrigerant channels 43 a and enters the first intermediate header portion 67 of the second header tank 42 .
- the CO 2 in the first intermediate header portion 67 flows leftward through the refrigerant channels 55 ; flows into the refrigerant channels 43 a of all the heat exchange tubes 43 of the front heat-exchange-tube group 43 A in communication with the second intermediate header portion 68 ; changes its course and flows upward through the refrigerant channels 43 a ; and enters the second intermediate header portion 68 of the first header tank 41 .
- the CO 2 flows through the refrigerant passage holes 59 of the flat walls 48 a of the partition member 48 B in the left-hand tank formation member 46 B into the third intermediate header portion 69 ; dividedly flows into the refrigerant channels 43 a of all the heat exchange tubes 43 of the rear heat-exchange-tube group 43 A in communication with the third intermediate header portion 69 ; changes its course and flows downward through the refrigerant channels 43 a and enters the fourth intermediate header portion 70 of the second header tank 42 .
- the CO 2 in the fourth intermediate header portion 70 flows rightward through the refrigerant channels 55 ; dividedly flows into the refrigerant channels 43 a of all the heat exchange tubes 43 of the rear heat-exchange-tube group 43 A in communication with the outlet header portion 55 ; changes its course and flows upward through the refrigerant channels 43 a ; and enters the outlet header portion 66 of the first header tank 41 .
- the CO 2 thereafter flows through the refrigerant channels 55 and flows out of the evaporator 40 via the refrigerant outflow channel 63 of the refrigerant inlet-outlet member 49 .
- the CO 2 While flowing through the refrigerant channels 43 a of the heat exchange tubes 43 , the CO 2 is subjected to heat exchange with the air flowing through the air-passing clearances in the direction of arrow X shown in FIGS. 13 and 20 and flows out from the evaporator 40 in a vapor phase.
- the refrigerant is not limited thereto, but ethylene, ethane, nitrogen oxide, or the like is alternatively used.
- FIGS. 21 to 27 show modified embodiments of a heat exchange tube for use in the above-described gas cooler 1 and evaporator 40 .
- the upper, lower, left-hand, and right-hand sides of FIGS. 21 to 27 will be referred to as “upper,” “lower,” “left,” and “right,” respectively.
- a heat exchange tube 160 shown in FIGS. 21 and 22 includes mutually opposed flat upper and lower walls 161 , 162 (a pair of flat walls); left and right side walls 163 , 164 that extend over left and right side ends, respectively, of the upper and lower walls 161 , 162 ; and a plurality of reinforcement walls 165 that are provided at predetermined intervals between the left and right side walls 163 , 164 and extend longitudinally and between the upper and lower walls 161 , 162 .
- the heat exchange tube 160 internally has a plurality of refrigerant channels 166 arranged in the width direction thereof.
- the reinforcement walls 165 serve as partition walls between adjacent refrigerant channels 166 .
- the width of each refrigerant channel 166 remains unchanged along the entire height of the refrigerant channel 166 .
- the left side wall 163 has a dual structure and includes an outer side-wall-forming elongated projection 167 that is integrally formed with the left side end of the upper wall 161 in a downward raised condition and extends along the entire height of the heat exchange tube 160 ; an inner side-wall-forming elongated projection 168 that is located inside the outer side-wall-forming elongated projection 167 and is integrally formed with the upper wall 161 in a downward raised condition; and an inner side-wall-forming elongated projection 169 that is integrally formed with the left side end of the lower wall 162 in an upward raised condition.
- the outer side-wall-forming elongated projection 167 is brazed to the two inner side-wall-forming elongated projections 168 , 169 and the lower wall 162 while a lower end portion thereof is engaged with a left side edge portion of the lower surface of the lower wall 162 .
- the two inner side-wall-forming elongated projections 168 , 169 are brazed together while butting against each other.
- a right side wall 164 is integrally formed with the upper and lower walls 161 , 162 .
- a projection 169 a is integrally formed on the tip end face of the inner side-wall-forming projection 169 of the lower wall 162 and extends in the longitudinal direction of the inner side-wall-forming projection 169 along the entire length thereof.
- a groove 168 a is formed on the tip end face of the inner side-wall-forming elongated projection 168 of the upper wall 161 and extends in the longitudinal direction of the inner side-wall-forming elongated projection 168 along the entire length thereof.
- the projection 169 a is press-fitted into the groove 168 a.
- Each of the reinforcement walls 165 is formed such that a reinforcement-wall-forming elongated projection 170 , which is integrally formed with the upper wall 161 in a downward raised condition, and a reinforcement-wall-forming elongated projection 171 , which is integrally formed with the lower wall 162 in an upward raised condition, are brazed together while butting against each other.
- the heat exchange tube 160 is manufactured by use of a tube-forming metal sheet 175 as shown in FIG. 23 ( a ).
- the tube-forming metal sheet 175 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof.
- the tube-forming metal sheet 175 includes a flat upper-wall-forming portion 176 (flat-wall-forming portion); a lower-wall-forming portion 177 (flat-wall-forming portion); a connection portion 178 connecting the upper-wall-forming portion 176 and the lower-wall-forming portion 177 and adapted to form the right side wall 164 ; the inner side-wall-forming elongated projections 168 , 169 , which are integrally formed with the side ends of the upper-wall-forming and lower-wall-forming portions 176 , 177 opposite the connection portion 178 in an upward raised condition and which are adapted to form an inner portion of the side wall 163 ; an outer side-wall-forming-elongated-projection forming portion 179 , which extends in the left-
- the reinforcement-wall-forming elongated projections 170 of the upper-wall-forming portion 176 and the reinforcement-wall-forming elongated projections 171 of the lower-wall-forming portion 177 are located symmetrically with respect to the centerline of the width direction of the tube-forming metal sheet 175 .
- the projection 169 a is formed on the tip end face of the inner side-wall-forming elongated projection 169 of the lower wall 162
- the groove 168 a is formed on the tip end face of the inner side-wall-forming elongated projection 168 of the upper wall 161 .
- the two inner side-wall-forming elongated projections 168 , 169 and all the reinforcement-wall-forming elongated projections 170 , 171 have the same height.
- the vertical thickness of the connection portion 178 is greater than the thickness of the upper-wall-forming and lower-wall-forming portions 176 , 177 .
- the top end face of the connection portion 178 is substantially flush with the top end faces of the inner side-wall-forming elongated projections 168 , 169 and the reinforcement-wall-forming elongated projections 170 , 171 .
- the inner side-wall-forming elongated projections 168 , 169 and the reinforcement-wall-forming elongated projections 170 , 171 are integrally formed on one side of the aluminum brazing sheet whose opposite sides are clad with a brazing material, whereby a brazing material layer (not shown) is formed on the opposite side surfaces and tip end faces of the inner side-wall-forming elongated projections 168 , 169 , on those of the reinforcement-wall-forming elongated projections 170 , 171 , and on the vertically opposite surfaces of the upper-wall-forming and lower-wall-forming portions 176 , 177 .
- the brazing material layer on the tip end faces of the inner side-wall-forming elongated projections 168 , 169 and the reinforcement-wall-forming elongated projections 170 , 171 is greater in thickness than the brazing material layer on other portions of the tube-forming metal sheet 175 .
- the tube-forming metal sheet 175 is gradually folded at left and right side edges of the connection portion 178 by a roll forming process (see FIG. 23 ( b )) until a hairpin form is assumed.
- the inner side-wall-forming elongated projections 168 , 169 are caused to butt against each other; the reinforcement-wall-forming elongated projections 170 , 171 are caused to butt against each other; and the projection 169 a is caused to be press-fitted into the groove 168 a.
- the outer side-wall-forming-elongated-projection forming portion 179 is folded along the outer surfaces of the inner side-wall-forming elongated projections 168 , 169 , and a tip end portion thereof is deformed so as to be engaged with the lower-wall-forming portion 177 , thereby yielding a folded member 180 (see FIG. 23 ( c )).
- the folded member 180 is heated at a predetermined temperature so as to braze together tip end portions of the inner side-wall-forming elongated projections 168 , 169 ; to braze together tip end portions of the reinforcement-wall-forming elongated projections 170 , 171 ; and to braze the outer side-wall-forming-elongated-projection forming portion 179 to the inner side-wall-forming elongated projections 168 , 169 and to the lower-wall-forming portion 177 .
- the heat exchange tubes 160 are manufactured in the course of manufacture of the gas cooler 1 or the evaporator 40 .
- a projection 186 extending along the entire length thereof and a groove 187 extending along the entire length thereof are alternately formed on the tip end faces of all the reinforcement-wall-forming elongated projections 170 of the upper wall 161 .
- a groove 188 into which the corresponding projection 186 of the reinforcement-wall-forming elongated projection 170 of the upper wall 161 is fitted and a projection 186 to be fitted into the corresponding groove 187 of the reinforcement-wall-forming elongated projection 170 of the upper wall 161 are alternately formed on the tip end faces of all the reinforcement-wall-forming elongated projections 171 of the lower wall 162 , along the entire length thereof.
- Other structural features are similar to those of the heat exchange tube 160 shown in FIGS. 21 and 22 .
- the heat exchange tube 185 is manufactured in a manner similar to that for the heat exchange tube 160 shown in FIGS. 21 and 22 .
- the reinforcement wall 165 formed such that a reinforcement-wall-forming elongated projection 192 formed integrally with the lower wall 162 and in an upward raised condition is brazed to the upper wall 161 are alternately provided in the left-right direction;
- the upper and lower walls 161 , 162 have projections 193 extending along the entire length thereof and formed integrally at portions thereof that abut the corresponding reinforcement-wall-forming elongated projections 192 , 191 ; recesses 194 are formed on the corresponding tip end faces of the projections 193 so as to allow corresponding tip end portions of the reinforcement-wall-forming elongated projections 191 , 192 to be fitted thereinto; and the tip end portions of the reinforcement-wall-forming elong
- the thickness of the projection 193 as measured in the left-right direction is slightly greater than that of the reinforcement-wall-forming elongated projections 191 , 192 .
- Other structural features of the heat exchange tube 190 are similar to those of the heat exchange tube 160 shown in FIGS. 21 and 22 .
- the heat exchange tube 190 is manufactured by use of a tube-forming metal sheet 195 as shown in FIG. 27 ( a ).
- the tube-forming metal sheet 195 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof.
- the tube-forming metal sheet 195 includes a plurality of reinforcement-wall-forming elongated projections 191 , 192 , which are integrally formed with the upper-wall-forming and lower-wall-forming portions 176 , 177 in an upward raised condition and which are arranged at predetermined intervals in the left-right direction.
- the reinforcement-wall-forming elongated projections 191 of the upper-wall-forming portion 176 and the reinforcement-wall-forming elongated projections 192 of the lower-wall-forming portion 177 are located asymmetrically with respect to the centerline of the width direction of the tube-forming metal sheet 195 .
- the reinforcement-wall-forming elongated projections 191 , 192 have the same height, which is about two times the height of the inner side-wall-forming elongated projections 168 , 169 .
- the projections 193 are integrally formed, in such a manner as to extend along the entire length of the upper-wall-forming and lower-wall-forming portions 176 , 177 , at those portions of the upper-wall-forming and lower-wall-forming portions 176 , 177 which the corresponding reinforcement-wall-forming elongated projections 192 , 191 of the lower-wall-forming and upper-wall-forming portions 177 , 176 abut.
- the recesses 194 are formed on the corresponding tip end faces of the projections 193 so as to allow corresponding tip end portions of the reinforcement-wall-forming elongated projections 191 , 192 to be fitted thereinto.
- Other structural features of the tube-forming metal sheet 195 are similar to those of the tube-forming metal sheet 175 shown in FIG. 23 .
- the tube-forming metal sheet 195 is gradually folded at left and right side edges of the connection portion 178 by a roll forming process (see FIG. 27 ( b )) until a hairpin form is assumed.
- the inner side-wall-forming elongated projections 168 , 169 are caused to butt against each other, and the projection 169 a is caused to be press-fitted into the groove 168 a .
- tip end portions of the reinforcement-wall-forming elongated projections 191 of the upper-wall-forming portion 176 are caused to be fitted into the corresponding grooves 194 of the projections 193 of the lower-wall-forming portion 177
- tip end portions of the reinforcement-wall-forming elongated projections 192 of the lower-wall-forming portion 177 are caused to be fitted into the corresponding grooves 194 of the projections 193 of the upper-wall-forming portion 176 .
- the outer side-wall-forming-elongated-projection forming portion 179 is folded along the outer surfaces of the inner side-wall-forming elongated projections 168 , 169 , and a tip end portion thereof is deformed so as to be engaged with the lower-wall-forming portion 177 , thereby yielding a folded member 196 (see FIG. 27 ( c )).
- the folded member 196 is heated at a predetermined temperature so as to braze together tip end portions of the inner side-wall-forming elongated projections 168 , 169 ; to braze tip end portions of the reinforcement-wall-forming elongated projections 191 , 192 to the corresponding projections 193 ; and to braze the outer side-wall-forming-elongated-projection forming portion 179 to the inner side-wall-forming elongated projections 168 , 169 and to the lower-wall-forming portion 177 .
- the heat exchange tubes 190 are manufactured in the course of manufacture of the gas cooler 1 or the evaporator 40 .
- the heat exchanger of the present invention is favorably used as a gas cooler or an evaporator of a supercritical refrigeration cycle in which a CO 2 (carbon dioxide) refrigerant or a like supercritical refrigerant is used.
Abstract
A heat-exchanger header tank of a gas cooler includes a tank formation member, a tube-connecting plate joined to the tank formation member outer surface, and a partition disposed within and joined to the tank formation member to divide the tank formation member interior into plural refrigerant channels extending in the longitudinal direction of the tank formation member and arranged in the front-rear direction. Tube insertion holes are formed in a wall of the tank formation member and in the tube-connecting plate at mutually aligned positions. Tube-end fit cutouts partially receiving corresponding end portions of heat exchange tubes are formed on the partition to align with corresponding tube insertion holes. The cross-sectional profile of the header tank can be appropriately selected for an installation space for the gas cooler, and the cross-sectional shape and area of a refrigerant channel can be readily changed.
Description
- This application is an application filed under 35 U.S.C. § 111(a) claiming the benefit pursuant to 35 U.S.C. § 119(e)(1) of the filing dates of Provisional Application Nos. 60/580,145 and 60/662,360 filed Jun. 17, 2004 and Mar. 17, 2005, respectively, pursuant to 35 U.S.C. § 111(b).
- The present invention relates to a heat exchanger, and more particularly to a heat exchanger favorably usable as a gas cooler or an evaporator of a supercritical refrigeration cycle in which a CO2 (carbon dioxide) refrigerant or a like supercritical refrigerant is used.
- Herein and in the appended claims, the downstream side of flow (represented by arrow X in
FIGS. 1 and 13 ) of air in a heat exchanger is referred to as the “front,” and the opposite side as the “rear,” and the term “aluminum” encompasses aluminum alloys in addition to pure aluminum. - A conventionally known heat exchanger for use in a supercritical refrigeration cycle includes a pair of header tanks disposed apart from each other; heat exchange tubes disposed in parallel at intervals between the two header tanks and having opposite ends connected to the respective header tanks; and fins disposed in respective air-passing clearances between adjacent heat exchange tubes (Japanese Patent Application Laid-Open (kokai) No. 2001-133,
FIGS. 6 and 7 ). Each of the two header tanks includes a cylindrical tank formation member formed from an extrudate, and a tube-connecting plate having a minor-arcuate cross section. The tank formation member has an arcuate-segment portion in which a plurality of tube insertion holes are formed and arranged apart from each other in the longitudinal direction thereof. The tube-connecting plate has a plurality of tube insertion holes formed therein and arranged apart from each other in the longitudinal direction thereof, and is joined to the tank formation member while being fitted to the arcuate-segment portion of the tank formation member. - In order to enhance withstand pressure, each of the header tanks of the heat exchanger described in the above-mentioned publication includes the cylindrical tank formation member having a refrigerant channel of a circular cross section. However, the header tanks fail to assume an appropriate cross-sectional profile in accordance with, for example, an installation space for the heat exchanger.
- In order to provide, in various applications, appropriate cross-sectional shapes and areas of the refrigerant channel of the header tank so as to enhance heat exchange performance of the heat exchanger described in the above-mentioned publication, various types of tank formation members having different inside diameters must be prepared beforehand by extrusion, resulting in an increase in cost.
- An object of the present invention is to overcome the above problems and to provide a heat exchanger which allows the cross-sectional profile of a header tank thereof to be selected as appropriate in accordance with an installation space therefor and which readily allows a change in the cross-sectional shape and area of a refrigerant channel of the header tank.
- To fulfill the above object, the present invention comprises the following modes.
- 1) A heat exchanger comprising a pair of header tanks disposed apart from each other, and a plurality of heat exchange tubes disposed in parallel between the two header tanks and each having opposite end portions connected to the respective header tanks,
- the two header tanks each comprising a hollow tank formation member, and a partition member disposed within and joined to the tank formation member and adapted to divide the interior of the tank formation member into a plurality of refrigerant channels extending in the longitudinal direction of the tank formation member and arranged in the front-rear direction.
- 2) A heat exchanger according to par. 1), wherein a plurality of tube insertion holes are formed in the tank formation members; a plurality of tube-end fit cutouts for partially receiving corresponding end portions of heat exchange tubes are formed on the partition members in such a manner as to align with the corresponding tube insertion holes; and the heat exchange tubes are connected to the two header tanks such that end portions thereof are inserted through the corresponding tube insertion holes of the tank formation members and are fitted into the corresponding tube-end fit cutouts of the partition members.
- 3) A heat exchanger according to par. 1), further comprising tube-connecting plates joined to corresponding outer surfaces of the tank formation members, wherein a plurality of tube insertion holes are formed in the tube-connecting plates in such a manner as to align with the corresponding tube insertion holes of the tank formation members, and the heat exchange tubes are connected to the two header tanks such that end portions thereof are inserted through the tube insertion holes of the tube-connecting plates.
- 4) A heat exchanger according to par. 1), wherein the partition members assume the form of an elongated plate and are disposed such that the width direction thereof coincides with the height direction of hollow portions of the tank formation members.
- 5) A heat exchanger according to par. 1), wherein the partition members have a cross section resembling the letter U, and the partition members are disposed such that the width direction of a pair of opposed walls of each partition member coincides with the height direction of the hollow portions of the tank formation members and such that ends of the opposed walls face the tube insertion holes.
- 6) A heat exchanger according to par. 1), wherein the partition members assume the form of a corrugated plate comprising a plurality of flat portions in parallel with one another and a plurality of connection portions each connecting adjacent flat portions, and the width direction of the flat portions coincides with the height direction of the hollow portions of the tank formation members.
- 7) A heat exchanger according to par. 1), wherein a first header tank of the paired header tanks comprises a plurality of tank formation members aligned with one another in a longitudinal direction thereof; a second header tank of the paired header tanks comprises tank formation members numbering one fewer than the tank formation members of the first header tank and is disposed so as to oppose two adjacent tank formation members of the first header tank; and a refrigerant entering one tank formation member of the first header tank flows through all the heat exchange tubes and the tank formation members of the second header tank and enters another tank formation member of the first header tank.
- 8) A heat exchanger according to par. 7), wherein the number of tank formation members of the first header tank is two; the two tank formation members are joined together via a separation plate so as to avoid communication between hollow portions thereof: and the number of tank formation members of the second header tank is one.
- 9) A heat exchanger according to par. 1), wherein the first header tank of the paired header tanks comprises two tank formation members aligned with each other in the longitudinal direction thereof; the second header tank of the paired header tanks is disposed so as to oppose the two tank formation members of the first header tank;
- the tank formation members of the two header tanks each have a plurality of hole groups provided in a plurality of rows separated from one another in the front-rear direction, each hole group comprising a plurality of tube insertion holes formed therein apart from one another in the longitudinal direction thereof; a partition member assuming the form of a corrugated plate comprising a plurality of flat portions in parallel with one another and a plurality of connection portions each connecting adjacent flat portions is disposed within each of the tank formation members of the two header tanks such that the width direction of the flat portions coincides with the height direction of a hollow portion of each of the tank formation members and such that at least one flat portion is located between tube insertion holes adjacent to each other in the front-rear direction of the tank formation member; a plurality of tube-end fit cutouts for partially receiving corresponding end portions of heat exchange tubes are formed on the partition members in such a manner as to align with the corresponding tube insertion holes; the heat exchange tubes are connected to the two header tanks such that end portions thereof are inserted through the corresponding tube insertion holes of the tank formation members and are fitted into the corresponding tube-end fit cutouts of the partition members; no tube-end fit cutouts are formed on the flat portion located between tube insertion holes adjacent to each other in the front-rear direction; and
- refrigerant passage holes are formed in the flat portions of the partition member disposed within one of the two tank formation members of the first header tank.
- 10) A supercritical refrigeration cycle which comprises a compressor, a gas cooler, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator and in which a supercritical refrigerant is used, the gas cooler comprising a heat exchanger according to any one of pars. 1) to 8).
- 11) A supercritical refrigeration cycle which comprises a compressor, a gas cooler, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator and in which a supercritical refrigerant is used, the evaporator comprising a heat exchanger according to any one of pars. 1) to 6) and 9).
- 12) A vehicle having installed therein a supercritical refrigeration cycle according to par. 10) as a vehicular air conditioner.
- 13) A vehicle having installed therein a supercritical refrigeration cycle according to par. 11) as a vehicular air conditioner.
- With the heat exchanger according to par. 1), the header tank comprises the hollow tank formation member, and the partition member disposed within and joined to the tank formation member and adapted to divide the interior of the tank formation member into a plurality of refrigerant channels extending in the longitudinal direction of the tank formation member and arranged in the front-rear direction, so that the partition member functions to enhance withstand pressure of the header tank. This enables the header tank, or the tank formation member, to assume an appropriate cross-sectional profile in accordance with, for example, an installation space for an associated heat exchanger. Also, by means of changing the shape and cross-sectional area of the partition member, the cross-sectional shape and area of the refrigerant channels in the header tank can be readily changed so as to enhance heat exchange performance of the heat exchanger in various applications. As compared with the case where various types of tank formation members having different cross-sectional sizes are prepared, costs become lower.
- With the heat exchanger according to par. 2), a plurality of tube insertion holes are formed in the tank formation member, and a plurality of tube-end fit cutouts for partially receiving corresponding end portions of the heat exchange tubes are formed on the partition member in such a manner as to align with the corresponding tube insertion holes. Accordingly, in the course of assembling the heat exchanger, the heat exchange tubes can be connected to the header tank in a relatively easy manner by utilizing the tube insertion holes of the tank formation member. Further, since the end portions of the heat exchange tubes are fitted into the corresponding tube-end fit cutouts of the partition member, all of the end portions of the heat exchange tubes can readily assume a predetermined length of projection into the header tank, or the tank formation member. Therefore, the length of projection can be set to an appropriate value for enhancing the performance of the heat exchanger.
- The heat exchanger according to par. 3) further comprises a tube-connecting plate joined to the outer surface of the tank formation member, and a plurality of tube insertion holes are formed in the tube-connecting plate in such a manner as to align with the corresponding tube insertion holes of the tank formation member. Accordingly, in the course of assembling the heat exchanger by using the header tank, the heat exchange tubes can be connected to the header tank in a relatively easy manner by utilizing the tube insertion holes of the tank formation member and those of the tube-connecting plate.
- With the heat exchanger according to pars. 7) and 8), the flow of refrigerant can be appropriately set for enhancing heat exchange performance. For example, when the heat exchanger is used as a gas cooler of a supercritical refrigeration cycle, the gas cooler exhibits enhanced heat exchange performance.
- With the heat exchanger according to par. 9), the flow of refrigerant can be appropriately set for enhancing heat exchange performance. For example, when the heat exchanger is used as an evaporator of a supercritical refrigeration cycle, the evaporator exhibits enhanced heat exchange performance.
-
FIG. 1 is a perspective view showing the overall construction of a gas cooler to which the heat exchanger according to the present invention is applied; -
FIG. 2 is a fragmentary view in vertical section showing the gas cooler ofFIG. 1 as it is seen frontward from rear; -
FIG. 3 is a perspective view showing a first header tank of the gas cooler ofFIG. 1 ; -
FIG. 4 is an exploded perspective view of the first header tank of the gas cooler ofFIG. 1 ; -
FIG. 5 is an enlarged view in section taken along line A-A ofFIG. 2 ; -
FIG. 6 is an enlarged view in section taken along line B-B ofFIG. 2 ; -
FIG. 7 is an exploded perspective view of the second header tank of the gas cooler ofFIG. 1 ; -
FIG. 8 is an enlarged view in section taken along line C-C ofFIG. 2 ; -
FIG. 9 is a diagram showing the flow of a refrigerant through the gas cooler ofFIG. 1 ; -
FIG. 10 is a fragmentary perspective view showing a first modified embodiment of the partition member disposed within a tank formation member of the gas cooler ofFIG. 1 ; -
FIG. 11 is a fragmentary perspective view showing a second modified embodiment of the partition member disposed within a tank formation member of the gas cooler ofFIG. 1 ; -
FIG. 12 is a fragmentary perspective view showing a third modified embodiment of the partition member disposed within a tank formation member of the gas cooler ofFIG. 1 ; -
FIG. 13 is a perspective view showing the overall construction of an evaporator to which the heat exchanger according to the present invention is applied; -
FIG. 14 is a fragmentary view in vertical section showing the evaporator ofFIG. 13 as it is seen frontward from rear; -
FIG. 15 is an enlarged view in section taken along line DD ofFIG. 14 ; -
FIG. 16 is an exploded perspective view showing a first header tank of the evaporator ofFIG. 13 ; -
FIG. 17 is an enlarged view in section taken along line E-E ofFIG. 14 ; -
FIG. 18 is an enlarged view in section taken along line F-F ofFIG. 14 ; -
FIG. 19 is an exploded perspective view showing a second header tank of the evaporator ofFIG. 13 ; -
FIG. 20 is a diagram showing the flow of a refrigerant through the evaporator ofFIG. 13 ; -
FIG. 21 is a cross-sectional view showing a first modified embodiment of the heat exchange tube; -
FIG. 22 is a fragmentary enlarged view ofFIG. 21 ; - FIG. 23 is a series of views showing a method of manufacturing the heat exchange tube shown in
FIG. 21 ; -
FIG. 24 is a cross-sectional view showing a second modified embodiment of the heat exchange tube; -
FIG. 25 is a cross-sectional view showing a third modified embodiment of the heat exchange tube; -
FIG. 26 is a fragmentary enlarged view ofFIG. 25 ; and -
FIG. 27 is a series of views showing a method of manufacturing the heat exchange tube shown inFIG. 25 . - Embodiments of the present invention will be described below with reference to the drawings.
- In the following description, the upper, lower, left-hand, and right-hand sides of
FIGS. 1, 2 , 13, and 14 will be referred to as “upper,” “lower,” “left,” and “right,” respectively. - This embodiment is shown in FIGS. 1 to 9 and is implemented by applying a heat exchanger according to the present invention to a gas cooler of a supercritical refrigeration cycle.
- With reference to
FIGS. 1 and 2 , agas cooler 1 of a supercritical refrigeration cycle wherein a supercritical refrigerant, such as CO2, is used includes twoheader tanks heat exchange tubes 4 arranged in parallel between the twoheader tanks corrugated fins 5 arranged in respective air-passing clearances between adjacentheat exchange tubes 4 and at the outside of the upper-end and lower-endheat exchange tubes 4 and each brazed to the adjacentheat exchange tubes 4 or to the upper-end or lower-endheat exchange tube 4; andside plates 6 of bare aluminum material arranged externally of and brazed to the respective upper-end and lower-endcorrugated fins 5. In the case of this embodiment, theheader tank 2 at the right will be referred to as the “first header tank,” and theheader tank 3 at the left as the “second header tank.” - As shown in FIGS. 3 to 6, the
first header tank 2 includes two hollowtank formation members plate 8 opposed to the twotank formation members tank formation members partition members tank formation members tank formation member 7A, and the lower end opening of the lowertank formation member 7B; and aseparation plate 12 disposed between and joined to the upper and lowertank formation members tank formation member 7A, and the upper end opening of the lowertank formation member 7B. - The
tank formation members tank formation members refrigerant inlet 14 is formed in the outer side wall with respect to the left-right direction; i.e., the right-hand side wall, of the uppertank formation member 7A. Arefrigerant inlet member 15 of aluminum having arefrigerant inflow channel 16 in communication with therefrigerant inlet 14 is joined to the outer surface of the right-hand side wall of the uppertank formation member 7A by, in the present embodiment, brazing. Arefrigerant outlet 17 is formed in the right-hand side wall of the lowertank formation member 7B. Arefrigerant outlet member 18 of aluminum having arefrigerant outflow channel 19 in communication with therefrigerant outlet 17 is joined to the outer surface of the right-hand side wall of the lowertank formation member 7B by, in the present embodiment, brazing. Thetank formation members refrigerant inlet 14 or therefrigerant outlet 17 are formed. An upper end portion of the uppertank formation member 7A and a lower end portion of the lowertank formation member 7B project outward beyond the tube-connectingplate 8. - The tube-connecting
plate 8 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof and is brazed to the twotank formation members plate 8 in such a manner as to align with the corresponding tube insertion holes 13 of the twotank formation members plate 8 has a projectingwall 8 a formed at each of the front and rear side edges and projecting outward with respect to the left-right direction. By utilizing the brazing material layer of the tube-connectingplate 8, the two projectingwalls 8 a are brazed to the outer surfaces of the front and rear side walls of the twotank formation members tank formation members plate 8 is formed, by press work, from an aluminum brazing sheet such that the tube insertion holes 21 and the projectingwalls 8 a are formed. - The
partition members partition members tank formation members tank formation members tank formation members partition members partition members tank formation members partition members tank formation members refrigerant channels 22 arranged in the front-rear direction and extending in the longitudinal direction thereof. Therefrigerant inlet 14 and therefrigerant outlet 17 of thetank formation members refrigerant channels 22. End portions oriented toward the tube insertion holes 13 of thetank formation members partition members fit cutouts 23 formed thereon in such a manner as to be vertically separated from one another and to align with the corresponding tube insertion holes 13, 21 of thetank formation members plate 8. Thepartition members fit cutouts 23 are formed. - A
cap 11 is formed from an aluminum brazing sheet that has a brazing material layer on at least one side thereof. Arecess 24 is formed on the side of thecap 11 on which the brazing material layer is present, for receiving a portion of thetank formation member plate 8. By utilizing the brazing material layers of thecaps 11, thecaps 11 are brazed to the correspondingtank formation members tank formation member 7A and the projecting portion of the lowertank formation member 7B are fitted into the correspondingrecesses 24 of thecaps 11. Thecap 11 is formed, by press work, from an aluminum brazing sheet such that therecess 24 is formed. - The
separation plate 12 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof. By utilizing the brazing material layers on the opposite surfaces, theseparation plate 12 is brazed to the lower end surfaces of the uppertank formation member 7A and theupper partition member 9A and to the upper end surfaces of the lowertank formation member 7B and thelower partition member 9B. - As shown in
FIGS. 7 and 8 , thesecond header tank 3 has substantially the same construction as thefirst header tank 2 and is in the mirror image of thefirst header tank 2. The twoheader tanks plates 8 face each other. In description of the twoheader tanks second header tank 3 differs from thefirst header tank 2 in that in place of the twotank formation members tank formation member 7C is used which extends along the entire length of thesecond header tank 3; onepartition member 9C is disposed within thetank formation member 7C and extends along the entire length of thetank formation member 7C; neither therefrigerant inlet 14 nor therefrigerant outlet 17 is formed on thetank formation member 7C; and theseparation plate 12 is not provided. - Each of the
heat exchange tubes 4 is formed from an aluminum extrudate; is in the form of a flat tube having an increased width in the front-rear direction; and has inside thereof a plurality ofrefrigerant channels 4 a extending in the longitudinal direction thereof and arranged in parallel. Opposite end portions of theheat exchange tubes 4 are inserted through the corresponding tube insertion holes 21 of the tube-connectingplates 8 for the twoheader tanks tank formation members heat exchange tubes 4 are fitted into thecutouts 23 of thepartition members heat exchange tubes 4 are brazed to the tube-connectingplates 8 and to thetank formation members plates 8. The opposite end faces of theheat exchange tubes 4 abut the corresponding bottoms of thecutouts 23 of thepartition members - Each of the
corrugated fins 5 is made in a wavy form from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof. - The
gas cooler 1 is manufactured by subjecting an assembly of all members to batch brazing. - The
gas cooler 1, together with a compressor, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator, constitutes a supercritical refrigeration cycle. The refrigeration cycle is installed in a vehicle, for example, in a motor vehicle, as a vehicular air conditioner. - As shown in
FIG. 9 , in thegas cooler 1 described above, CO2 having passed through a compressor flows through therefrigerant inflow channel 16 of therefrigerant inlet member 15 and enters the tworefrigerant channels 22 of the uppertank formation member 7A of thefirst header tank 2 through therefrigerant inlet 14. Then, the CO2 flows through the tworefrigerant channels 22 and flows into therefrigerant channels 4 a of all theheat exchange tubes 4 in communication with the uppertank formation member 7A. The CO2 in therefrigerant channels 4 a flows leftward through therefrigerant channels 4 a and enters thetank formation member 7C of thesecond header tank 3. The CO2 in thetank formation member 7C flows downward through the tworefrigerant channels 22; flows into therefrigerant channels 4 a of all theheat exchange tubes 4 in communication with the lowertank formation member 7B; changes its course; flows rightward through therefrigerant channels 4 a; and enters the tworefrigerant channels 22 of the lowertank formation member 7B of thefirst header tank 2. Subsequently, the CO2 flows through the tworefrigerant channels 22 and flows out of thegas cooler 1 via therefrigerant outlet 17 and therefrigerant outflow channel 19 of therefrigerant outlet member 18. While flowing through therefrigerant channels 4 a of theheat exchange tubes 4, the CO2 is subjected to heat exchange with the air flowing through the air-passing clearances in the direction of arrow X shown inFIG. 9 , thereby being cooled. - FIGS. 10 to 13 show modified embodiments of the partition member disposed within the tank formation member of the gas cooler.
- In the modified embodiment shown in
FIG. 10 , a plurality of, two in the present modified embodiment,partition members 9A (9B, 9C) ofEmbodiment 1 are disposed within thetank formation member 7A (7B, 7C) and are separated from each other in the front-rear direction. Therefrigerant channels 22 numbering one greater than thepartition members 9A (9B, 9C) are formed within thetank formation member 7A (7B, 7C).FIG. 10 (a) shows thetank formation member 7A (7B) of thefirst header tank 2, andFIG. 10 (b) shows thetank formation member 7C of thesecond header tank 3. In this case, in thefirst header tank 2, therefrigerant inlet 14 and therefrigerant outlet 17 of thetank formation members refrigerant channels 22. - In the modified embodiment shown in
FIG. 11 , apartition member 30A (30B, 30C) has a cross section resembling the letter U; is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof; and is disposed within thetank formation member 7A (7B, 7C) such that the width direction of a pair of opposedwalls 30 a thereof coincides with the height direction (left-right direction) of the hollow portion of thetank formation member 7A (7B, 7C) and such that the ends of theopposed walls 30 a face the tube insertion holes 13 of thetank formation member 7A (7B, 7C) (inward with respect to the left-right direction). Thepartition member 30A (30B, 30C) is brazed to the inner surfaces of the left-hand and right-hand side walls of thetank formation member 7A (7B, 7C) by utilizing the brazing material layers provided on the opposite surfaces thereof.FIG. 11 (a) shows thetank formation member 7A (7B) of thefirst header tank 2, andFIG. 11 (b) shows thetank formation member 7C of thesecond header tank 3. Tube-endfit cutouts 32 are formed on end portions of theopposed walls 30 a of thepartition members opposed walls 30 a of thepartition members tank formation members refrigerant channels 22 arranged in the front-rear direction. Thepartition members end fit cutouts 32. - In the case of disposition of the
partition members tank formation members Embodiment 1, a refrigerant passage through-hole 34 is formed in aconnection wall 30 b connecting theopposed walls 30 a of thepartition member 30A (30B) at a position aligned with the refrigerant inlet 14 (refrigerant outlet 17). Therefrigerant inlet 14 and therefrigerant outlet 17 of thetank formation members refrigerant channels 22. - In the modified embodiment shown in
FIG. 12 , apartition member 35A (35B, 35C) is formed from an aluminum brazing sheet having a brazing material layer on opposite surfaces thereof and assumes the form of a corrugated plate. The corrugated plate is composed of a plurality of, three in the present modified embodiment,flat walls 35 a in parallel with one another, andconnection portions 35 b each connecting the adjacentflat walls 35 a in a staggered manner with respect to the height direction of a hollow portion of thetank formation member 7A (7B, 7C) (with respect to the left-right direction). Thepartition member 35A (35B, 35C) is disposed within thetank formation member 7A (7B, 7C) such that the width direction of theflat walls 35 a coincides with the height direction of the hollow portion of thetank formation member 7A (7B, 7C) (left-right direction). Thepartition member 35A (35B, 35C) is brazed to the inner surfaces of the left-hand and right-hand side walls of thetank formation member 7A (7B, 7C) by utilizing the brazing material layers provided on the opposite surfaces thereof.FIG. 12 (a) shows thetank formation member 7A (7B) of thefirst header tank 2, andFIG. 12 (b) shows thetank formation member 7C of thesecond header tank 3. Tube-endfit cutouts 36 are formed on theconnection portions 35 b of thepartition members tank formation members flat walls 35 a connected by saidconnection portions 35 b. Also, the tube-endfit cutouts 37 are formed on end portions of otherflat walls 35 a located on the side toward the tube insertion holes 13. Theflat walls 35 a of thepartition members tank formation members refrigerant channels 22 arranged in the front-rear direction. Thepartition members fit cutouts - In the case of disposition of the
partition members tank formation members Embodiment 1, a refrigerant passage through-hole 38 is formed in theconnection portion 35 b of thepartition member 35A (35B) located outward with respect to the left-right direction at a position aligned with the refrigerant inlet 14 (refrigerant outlet 17). Therefrigerant inlet 14 and therefrigerant outlet 17 of thetank formation members refrigerant channels 22. - This embodiment is shown in FIGS. 13 to 20 and is implemented by applying a heat exchanger according to the present invention to an evaporator of a supercritical refrigeration cycle.
- With reference to
FIGS. 13 and 15 , anevaporator 40 of a supercritical refrigeration cycle wherein a supercritical refrigerant, such as CO2, is used includes twoheader tanks heat exchange tubes 43 arranged in parallel between the twoheader tanks corrugated fins 44 arranged in respective air-passing clearances between adjacentheat exchange tubes 43 and at the outside of the left-end and right-endheat exchange tubes 43 and each brazed to the adjacentheat exchange tubes 43 or to the left-end or right-endheat exchange tube 43; andside plates 45 of bare aluminum material arranged externally of and brazed to the respective left-end and right-endcorrugated fins 44. In the case of this embodiment, theupper header tank 41 will be referred to as the “first header tank,” and thelower header tank 42 as the “second header tank.” - As shown in FIGS. 16 to 18, the
first header tank 41 includes a right-handtank formation member 46A and a left-handtank formation member 46B each extending in the left-right direction and assuming a hollow form; a tube-connectingplate 47 opposed to the twotank formation members tank formation members partition members tank formation members outlet member 49 joined to a right end portion of the right-handtank formation member 46A; acap 51 adapted to close the left end opening of the left-handtank formation member 46B; and aseparation plate 52 disposed between and joined to the twotank formation members tank formation member 46A and the right end opening of the left-handtank formation member 46B. - The
tank formation members tank formation members tank formation members tank formation member 46B and a right-end portion of the right-handtank formation member 46A project outward beyond the tube-connectingplate 47. - The tube-connecting
plate 47 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof and is brazed to the twotank formation members plate 47 in such a manner as to align with the corresponding tube insertion holes 53 of the twotank formation members plate 47 has a projectingwall 47 a integrally formed at each of the front and rear side edges and projecting outward with respect to the vertical direction (upward in the present embodiment). By utilizing the brazing material layer of the tube-connectingplate 47, the two projectingwalls 47 a are brazed to the outer surfaces of the front and rear side walls of the twotank formation members tank formation members plate 47 is formed, by press work, from an aluminum brazing sheet such that the tube insertion holes 54 and the projectingwalls 47 a are formed. - The
partition members flat walls 48 a in parallel with one another, andconnection portions 48 b each connecting the adjacentflat walls 48 a in a staggered manner with respect to the height direction of a hollow portion of thetank formation member 46A (46B) (with respect to the vertical direction). Thepartition member 48A (48B) is disposed within thetank formation member 46A (46B) along the entire length of thetank formation member 46A (46B) such that the width direction of theflat walls 48 a coincides with the vertical direction. Thepartition member 48A (48B) is brazed to the inner surfaces of the upper and lower walls of thetank formation member 46A (46B) by utilizing the brazing material layers provided on the opposite surfaces thereof. Theflat walls 48 a of thepartition members tank formation members refrigerant channels 55 arranged in the front-rear direction. A plurality of tube-endfit cutouts 56 are formed on the front-side connection portions 48 b of thepartition members tank formation members flat walls 48 a connected by saidconnection portions 48 b in such a manner as to be separated from one another in the left-right direction so as to be aligned with the front-side tube insertion holes 53 of thetank formation members plate 47. Also, a plurality of tube-endfit cutouts 57 are formed on the rear-side connection portions 48 b of thepartition members tank formation members flat walls 48 a located on the rear side of saidconnection portions 48 b in such a manner as to be separated from one another in the left-right direction so as to be aligned with the rear-side tube insertion holes 53 of thetank formation members plate 47. Further, a plurality of tube-endfit cutouts 58 are formed on end portions of rearmostflat walls 48 a of thepartition members tank formation members tank formation members plate 47. A plurality of refrigerant passage holes 59 are formed through all theflat walls 48 a of thepartition member 48B disposed within the left-handtank formation member 46B in such a manner as to be separated from one another in the left-right direction. The right-hand partition member 48A is formed, by press work, from an aluminum brazing sheet in such a manner as to assume the form of a corrugated plate and to have the tube-endfit cutouts hand partition member 48B is formed, by press work, from an aluminum brazing sheet in such a manner as to assume the form of a corrugated plate and to have the tube-endfit cutouts - The refrigerant inlet-
outlet member 49 has arecess 61 formed on its left-hand side surface for receiving a portion of the right-handtank formation member 46A that projects beyond the tube-connectingplate 47. By use of an unillustrated appropriate aluminum brazing sheet or brazing material sheet, the refrigerant inlet-outlet member 49 is brazed to the right-handtank formation member 46A while the projecting portion of the right-handtank formation member 46A is fitted into therecess 61. The refrigerant inlet-outlet member 49 has arefrigerant inflow channel 62 formed therein in communication with the front-side threerefrigerant channels 55 in thetank formation member 46A, and arefrigerant outflow channel 63 formed therein in communication with the rear-side threerefrigerant channels 55 in thetank formation member 46A. A refrigerant inlet pipe (not shown) to communicate with therefrigerant inflow channel 62 and a refrigerant outlet pipe (not shown) to communicate with therefrigerant outflow channel 63 are connected to the refrigerant inlet-outlet member 49. - The
cap 51 is formed from an aluminum brazing sheet that has a brazing material layer on at least one side thereof. Arecess 64 is formed on the side of thecap 51 on which the brazing material layer is present, for receiving a portion of the left-handtank formation member 46B that projects beyond the tube-connectingplate 47. By utilizing the brazing material layer of thecap 51, thecap 51 is brazed to the left-handtank formation member 46B while the projecting portion of the left-handtank formation member 46B is fitted into therecess 64 of thecap 51. Thecap 51 is formed, by press work, from an aluminum brazing sheet such that therecess 64 is formed. - The
separation plate 52 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof. By utilizing the brazing material layers on the opposite surfaces, theseparation plate 52 is brazed to the left end surfaces of the right-handtank formation member 46A and the right-hand partition member 48A and to the right end surfaces of the left-handtank formation member 46B and the left-hand partition member 48B. - As shown in
FIG. 19 , thesecond header tank 42 has substantially the same construction as thefirst header tank 41 and is in the upside-down image of thefirst header tank 42. The twoheader tanks plates 47 face each other. In description of the twoheader tanks second header tank 42 differs from thefirst header tank 41 in that in place of the twotank formation members tank formation member 46C is used which extends along the entire length of thesecond header tank 42; onepartition member 48C is disposed within thetank formation member 46C and extends along the entire length of thetank formation member 46C; the refrigerant inlet-outlet member 49 is not attached to a right end portion of thetank formation member 46C, but thecap 51 is brazed to the right end portion as in the case of the left end portion; the refrigerant passage holes 59 are not formed in thepartition member 48C; and theseparation plate 52 is not provided. - A portion of the right-hand
tank formation member 46A of thefirst header tank 41 that is located on the front side with respect to the centralflat wall 48 a of thepartition member 48A serves as aninlet header portion 65, and a portion on the rear side serves as anoutlet header portion 66. A portion of thetank formation member 46C of thesecond header tank 42 that is located on the front side with respect to the centralflat wall 48 a of thepartition member 48C serves as a firstintermediate header portion 67. A portion of the left-handtank formation member 46B of thefirst header tank 41 that is located on the front side with respect to the centralflat wall 48 a of thepartition member 48B serves as a secondintermediate header portion 68, and a portion on the rear side serves as a thirdintermediate header portion 69. A portion of thetank formation member 46C of thesecond header tank 42 that is located on the rear side with respect to the centralflat wall 48 a of thepartition member 48C serves as a fourthintermediate header portion 70. - Each of the
heat exchange tubes 43 is formed from an aluminum extrudate; is in the form of a flat tube having an increased width in the front-rear direction; and has inside thereof a plurality ofrefrigerant channels 43 a extending in the longitudinal direction thereof and arranged in parallel. Opposite end portions of theheat exchange tubes 43 are inserted through the corresponding tube insertion holes 54 of the tube-connectingplates 47 for the twoheader tanks tank formation members cutouts partition members heat exchange tubes 43 are brazed to the tube-connectingplates 47 and to thetank formation members plates 47. Between the twoheader tanks tube groups 43A, each consisting of a plurality ofheat exchange tubes 43 arranged in parallel and separated from one another in the left-right direction, are arranged in a plurality of rows, in two rows in the present embodiment, separated from each other in the front-rear direction. Theheat exchange tubes 43 positioned in the right half of the front heat-exchange-tube group 43A communicate with theinlet header portion 65 and the firstintermediate header portion 67, and theheat exchange tubes 43 positioned in the left half of the front heat-exchange-tube group 43A communicate with the firstintermediate header portion 67 and the secondintermediate header portion 68. Theheat exchange tubes 43 positioned in the right half of the rear heat-exchange-tube group 43A communicate with theoutlet header portion 66 and the fourthintermediate header portion 70, and theheat exchange tubes 43 positioned in the left half of the rear heat-exchange-tube group 43A communicate with the thirdintermediate header portion 69 and the fourthintermediate header portion 70. - Each of the
corrugated fins 44 is made in a wavy form from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof. Connecting portions interconnecting crest portions and trough portions of the fin are provided with a plurality of louvers arranged in parallel in the front-rear direction. Thecorrugated fin 44 is used in common for the front and rear heat-exchange-tube groups 43A and has a front-to-rear width which is substantially equal to the distance between the front edge of theheat exchange tube 43 of the front heat-exchange-tube group 43A and the rear edge of the correspondingheat exchange tube 43 of the rear heat-exchange-tube group 43A. Instead of using onecorrugated fin 44 for the front and rear heat-exchange-tube groups 43A in common, a corrugated fin may be provided between each adjacent pair ofheat exchange tubes 43 in each of the heat-exchange-tube groups 43A. - The
evaporator 1 is manufactured by subjecting an assembly of all members to batch brazing. - The
evaporator 1, together with a compressor, a gas cooler, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator, constitutes a supercritical refrigeration cycle. The refrigeration cycle is installed in a vehicle, for example, in a motor vehicle, as a vehicular air conditioner. - As shown in
FIG. 20 , with theevaporator 40 described above, CO2 passing through a pressure-reducing device and undergoing pressure reduction therein flows through therefrigerant inflow channel 62 of the refrigerant inlet-outlet member 49 into theinlet header portion 65 of thefirst header tank 41 and thereafter flows through therefrigerant channels 55 into therefrigerant channels 43 a of all theheat exchange tubes 43 of the front heat-exchange-tube group 43A in communication with theinlet header portion 65. The CO2 in therefrigerant channels 43 a flows downward through therefrigerant channels 43 a and enters the firstintermediate header portion 67 of thesecond header tank 42. The CO2 in the firstintermediate header portion 67 flows leftward through therefrigerant channels 55; flows into therefrigerant channels 43 a of all theheat exchange tubes 43 of the front heat-exchange-tube group 43A in communication with the secondintermediate header portion 68; changes its course and flows upward through therefrigerant channels 43 a; and enters the secondintermediate header portion 68 of thefirst header tank 41. Subsequently, the CO2 flows through the refrigerant passage holes 59 of theflat walls 48 a of thepartition member 48B in the left-handtank formation member 46B into the thirdintermediate header portion 69; dividedly flows into therefrigerant channels 43 a of all theheat exchange tubes 43 of the rear heat-exchange-tube group 43A in communication with the thirdintermediate header portion 69; changes its course and flows downward through therefrigerant channels 43 a and enters the fourthintermediate header portion 70 of thesecond header tank 42. Then, the CO2 in the fourthintermediate header portion 70 flows rightward through therefrigerant channels 55; dividedly flows into therefrigerant channels 43 a of all theheat exchange tubes 43 of the rear heat-exchange-tube group 43A in communication with theoutlet header portion 55; changes its course and flows upward through therefrigerant channels 43 a; and enters theoutlet header portion 66 of thefirst header tank 41. The CO2 thereafter flows through therefrigerant channels 55 and flows out of theevaporator 40 via therefrigerant outflow channel 63 of the refrigerant inlet-outlet member 49. While flowing through therefrigerant channels 43 a of theheat exchange tubes 43, the CO2 is subjected to heat exchange with the air flowing through the air-passing clearances in the direction of arrow X shown inFIGS. 13 and 20 and flows out from theevaporator 40 in a vapor phase. - Although CO2 is used as a supercritical refrigerant of a supercritical refrigeration cycle in the above-described embodiments, the refrigerant is not limited thereto, but ethylene, ethane, nitrogen oxide, or the like is alternatively used.
- FIGS. 21 to 27 show modified embodiments of a heat exchange tube for use in the above-described
gas cooler 1 andevaporator 40. In the following description, the upper, lower, left-hand, and right-hand sides of FIGS. 21 to 27 will be referred to as “upper,” “lower,” “left,” and “right,” respectively. - A
heat exchange tube 160 shown inFIGS. 21 and 22 includes mutually opposed flat upper andlower walls 161, 162 (a pair of flat walls); left andright side walls lower walls reinforcement walls 165 that are provided at predetermined intervals between the left andright side walls lower walls heat exchange tube 160 internally has a plurality ofrefrigerant channels 166 arranged in the width direction thereof. Thereinforcement walls 165 serve as partition walls between adjacentrefrigerant channels 166. The width of eachrefrigerant channel 166 remains unchanged along the entire height of therefrigerant channel 166. - The
left side wall 163 has a dual structure and includes an outer side-wall-formingelongated projection 167 that is integrally formed with the left side end of theupper wall 161 in a downward raised condition and extends along the entire height of theheat exchange tube 160; an inner side-wall-formingelongated projection 168 that is located inside the outer side-wall-formingelongated projection 167 and is integrally formed with theupper wall 161 in a downward raised condition; and an inner side-wall-formingelongated projection 169 that is integrally formed with the left side end of thelower wall 162 in an upward raised condition. The outer side-wall-formingelongated projection 167 is brazed to the two inner side-wall-formingelongated projections lower wall 162 while a lower end portion thereof is engaged with a left side edge portion of the lower surface of thelower wall 162. The two inner side-wall-formingelongated projections right side wall 164 is integrally formed with the upper andlower walls projection 169 a is integrally formed on the tip end face of the inner side-wall-formingprojection 169 of thelower wall 162 and extends in the longitudinal direction of the inner side-wall-formingprojection 169 along the entire length thereof. Agroove 168 a is formed on the tip end face of the inner side-wall-formingelongated projection 168 of theupper wall 161 and extends in the longitudinal direction of the inner side-wall-formingelongated projection 168 along the entire length thereof. Theprojection 169 a is press-fitted into thegroove 168 a. - Each of the
reinforcement walls 165 is formed such that a reinforcement-wall-formingelongated projection 170, which is integrally formed with theupper wall 161 in a downward raised condition, and a reinforcement-wall-formingelongated projection 171, which is integrally formed with thelower wall 162 in an upward raised condition, are brazed together while butting against each other. - The
heat exchange tube 160 is manufactured by use of a tube-formingmetal sheet 175 as shown inFIG. 23 (a). The tube-formingmetal sheet 175 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof. The tube-formingmetal sheet 175 includes a flat upper-wall-forming portion 176 (flat-wall-forming portion); a lower-wall-forming portion 177 (flat-wall-forming portion); aconnection portion 178 connecting the upper-wall-formingportion 176 and the lower-wall-formingportion 177 and adapted to form theright side wall 164; the inner side-wall-formingelongated projections portions connection portion 178 in an upward raised condition and which are adapted to form an inner portion of theside wall 163; an outer side-wall-forming-elongated-projection forming portion 179, which extends in the left-right direction (rightward) from the side end (right side end) of the upper-wall-formingportion 176 opposite theconnection portion 178; and a plurality of reinforcement-wall-formingelongated projections portions elongated projections 170 of the upper-wall-formingportion 176 and the reinforcement-wall-formingelongated projections 171 of the lower-wall-formingportion 177 are located symmetrically with respect to the centerline of the width direction of the tube-formingmetal sheet 175. Theprojection 169 a is formed on the tip end face of the inner side-wall-formingelongated projection 169 of thelower wall 162, and thegroove 168 a is formed on the tip end face of the inner side-wall-formingelongated projection 168 of theupper wall 161. The two inner side-wall-formingelongated projections elongated projections connection portion 178 is greater than the thickness of the upper-wall-forming and lower-wall-formingportions connection portion 178 is substantially flush with the top end faces of the inner side-wall-formingelongated projections elongated projections - The inner side-wall-forming
elongated projections elongated projections elongated projections elongated projections portions elongated projections elongated projections metal sheet 175. - The tube-forming
metal sheet 175 is gradually folded at left and right side edges of theconnection portion 178 by a roll forming process (seeFIG. 23 (b)) until a hairpin form is assumed. The inner side-wall-formingelongated projections elongated projections projection 169 a is caused to be press-fitted into thegroove 168 a. - Next, the outer side-wall-forming-elongated-
projection forming portion 179 is folded along the outer surfaces of the inner side-wall-formingelongated projections portion 177, thereby yielding a folded member 180 (seeFIG. 23 (c)). - Subsequently, the folded
member 180 is heated at a predetermined temperature so as to braze together tip end portions of the inner side-wall-formingelongated projections elongated projections projection forming portion 179 to the inner side-wall-formingelongated projections portion 177. Thus is manufactured theheat exchange tube 160. Theheat exchange tubes 160 are manufactured in the course of manufacture of thegas cooler 1 or theevaporator 40. - In the case of a
heat exchange tube 185 shown inFIG. 24 , aprojection 186 extending along the entire length thereof and agroove 187 extending along the entire length thereof are alternately formed on the tip end faces of all the reinforcement-wall-formingelongated projections 170 of theupper wall 161. Agroove 188 into which thecorresponding projection 186 of the reinforcement-wall-formingelongated projection 170 of theupper wall 161 is fitted and aprojection 186 to be fitted into thecorresponding groove 187 of the reinforcement-wall-formingelongated projection 170 of theupper wall 161 are alternately formed on the tip end faces of all the reinforcement-wall-formingelongated projections 171 of thelower wall 162, along the entire length thereof. Other structural features are similar to those of theheat exchange tube 160 shown inFIGS. 21 and 22 . Theheat exchange tube 185 is manufactured in a manner similar to that for theheat exchange tube 160 shown inFIGS. 21 and 22 . - In a
heat exchange tube 190 shown inFIGS. 25 and 26 , thereinforcement wall 165 formed such that a reinforcement-wall-formingelongated projection 191 formed integrally with theupper wall 161 and in a downward raised condition is brazed to thelower wall 162, and thereinforcement wall 165 formed such that a reinforcement-wall-formingelongated projection 192 formed integrally with thelower wall 162 and in an upward raised condition is brazed to theupper wall 161, are alternately provided in the left-right direction; the upper andlower walls projections 193 extending along the entire length thereof and formed integrally at portions thereof that abut the corresponding reinforcement-wall-formingelongated projections recesses 194 are formed on the corresponding tip end faces of theprojections 193 so as to allow corresponding tip end portions of the reinforcement-wall-formingelongated projections elongated projections projections 193 while being fitted into therecesses 194 of theprojections 193. The thickness of theprojection 193 as measured in the left-right direction is slightly greater than that of the reinforcement-wall-formingelongated projections heat exchange tube 190 are similar to those of theheat exchange tube 160 shown inFIGS. 21 and 22 . - The
heat exchange tube 190 is manufactured by use of a tube-formingmetal sheet 195 as shown inFIG. 27 (a). The tube-formingmetal sheet 195 is formed from an aluminum brazing sheet having a brazing material layer over opposite surfaces thereof. The tube-formingmetal sheet 195 includes a plurality of reinforcement-wall-formingelongated projections portions elongated projections 191 of the upper-wall-formingportion 176 and the reinforcement-wall-formingelongated projections 192 of the lower-wall-formingportion 177 are located asymmetrically with respect to the centerline of the width direction of the tube-formingmetal sheet 195. The reinforcement-wall-formingelongated projections elongated projections projections 193 are integrally formed, in such a manner as to extend along the entire length of the upper-wall-forming and lower-wall-formingportions portions elongated projections portions recesses 194 are formed on the corresponding tip end faces of theprojections 193 so as to allow corresponding tip end portions of the reinforcement-wall-formingelongated projections metal sheet 195 are similar to those of the tube-formingmetal sheet 175 shown inFIG. 23 . - The tube-forming
metal sheet 195 is gradually folded at left and right side edges of theconnection portion 178 by a roll forming process (seeFIG. 27 (b)) until a hairpin form is assumed. The inner side-wall-formingelongated projections projection 169 a is caused to be press-fitted into thegroove 168 a. Also, tip end portions of the reinforcement-wall-formingelongated projections 191 of the upper-wall-formingportion 176 are caused to be fitted into thecorresponding grooves 194 of theprojections 193 of the lower-wall-formingportion 177, and tip end portions of the reinforcement-wall-formingelongated projections 192 of the lower-wall-formingportion 177 are caused to be fitted into thecorresponding grooves 194 of theprojections 193 of the upper-wall-formingportion 176. - Next, the outer side-wall-forming-elongated-
projection forming portion 179 is folded along the outer surfaces of the inner side-wall-formingelongated projections portion 177, thereby yielding a folded member 196 (seeFIG. 27 (c)). - Subsequently, the folded
member 196 is heated at a predetermined temperature so as to braze together tip end portions of the inner side-wall-formingelongated projections elongated projections projections 193; and to braze the outer side-wall-forming-elongated-projection forming portion 179 to the inner side-wall-formingelongated projections portion 177. Thus is manufactured theheat exchange tube 190. Theheat exchange tubes 190 are manufactured in the course of manufacture of thegas cooler 1 or theevaporator 40. - The heat exchanger of the present invention is favorably used as a gas cooler or an evaporator of a supercritical refrigeration cycle in which a CO2 (carbon dioxide) refrigerant or a like supercritical refrigerant is used.
Claims (13)
1. A heat exchanger comprising a pair of header tanks disposed apart from each other, and a plurality of heat exchange tubes disposed in parallel between the two header tanks and each having opposite end portions connected to the respective header tanks,
the two header tanks each comprising a hollow tank formation member, and a partition member disposed within and joined to the tank formation member and adapted to divide the interior of the tank formation member into a plurality of refrigerant channels extending in the longitudinal direction of the tank formation member and arranged in the front-rear direction.
2. A heat exchanger according to claim 1 , wherein a plurality of tube insertion holes are formed in the tank formation members; a plurality of tube-end fit cutouts for partially receiving corresponding end portions of heat exchange tubes are formed on the partition members in such a manner as to align with the corresponding tube insertion holes; and the heat exchange tubes are connected to the two header tanks such that end portions thereof are inserted through the corresponding tube insertion holes of the tank formation members and are fitted into the corresponding tube-end fit cutouts of the partition members.
3. A heat exchanger according to claim 1 , further comprising tube-connecting plates joined to corresponding outer surfaces of the tank formation members, wherein a plurality of tube insertion holes are formed in the tube-connecting plates in such a manner as to align with the corresponding tube insertion holes of the tank formation members, and the heat exchange tubes are connected to the two header tanks such that end portions thereof are inserted through the tube insertion holes of the tube-connecting plates.
4. A heat exchanger according to claim 1 , wherein the partition members assume the form of an elongated plate and are disposed such that the width direction thereof coincides with the height direction of hollow portions of the tank formation members.
5. A heat exchanger according to claim 1 , wherein the partition members have a cross section resembling the letter U, and the partition members are disposed such that the width direction of a pair of opposed walls of each partition member coincides with the height direction of the hollow portions of the tank formation members and such that ends of the opposed walls face the tube insertion holes.
6. A heat exchanger according to claim 1 , wherein the partition members assume the form of a corrugated plate comprising a plurality of flat portions in parallel with one another and a plurality of connection portions each connecting adjacent flat portions, and the width direction of the flat portions coincides with the height direction of the hollow portions of the tank formation members.
7. A heat exchanger according to claim 1 , wherein a first header tank of the paired header tanks comprises a plurality of tank formation members aligned with one another in a longitudinal direction thereof; a second header tank of the paired header tanks comprises tank formation members numbering one fewer than the tank formation members of the first header tank and is disposed so as to oppose two adjacent tank formation members of the first header tank; and a refrigerant entering one tank formation member of the first header tank flows through all the heat exchange tubes and the tank formation members of the second header tank and enters another tank formation member of the first header tank.
8. A heat exchanger according to claim 7 , wherein the number of tank formation members of the first header tank is two; the two tank formation members are joined together via a separation plate so as to avoid communication between hollow portions thereof; and the number of tank formation members of the second header tank is one.
9. A heat exchanger according to claim 1 , wherein the first header tank of the paired header tanks comprises two tank formation members aligned with each other in the longitudinal direction thereof; the second header tank of the paired header tanks is disposed so as to oppose the two tank formation members of the first header tank;
the tank formation members of the two header tanks each have a plurality of hole groups provided in a plurality of rows separated from one another in the front-rear direction, each hole group comprising a plurality of tube insertion holes formed therein apart from one another in the longitudinal direction thereof; a partition member assuming the form of a corrugated plate comprising a plurality of flat portions in parallel with one another and a plurality of connection portions each connecting adjacent flat portions is disposed within each of the tank formation members of the two header tanks such that the width direction of the flat portions coincides with the height direction of a hollow portion of each of the tank formation members and such that at least one flat portion is located between tube insertion holes adjacent to each other in the front-rear direction of the tank formation member; a plurality of tube-end fit cutouts for partially receiving corresponding end portions of heat exchange tubes are formed on the partition members in such a manner as to align with the corresponding tube insertion holes; the heat exchange tubes are connected to the two header tanks such that end portions thereof are inserted through the corresponding tube insertion holes of the tank formation members and are fitted into the corresponding tube-end fit cutouts of the partition members; no tube-end fit cutouts are formed on the flat portion located between tube insertion holes adjacent to each other in the front-rear direction; and
refrigerant passage holes are formed in the flat portions of the partition member disposed within one of the two tank formation members of the first header tank.
10. A supercritical refrigeration cycle which comprises a compressor, a gas cooler, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator and in which a supercritical refrigerant is used, the gas cooler comprising a heat exchanger according to claim 1 .
11. A supercritical refrigeration cycle which comprises a compressor, a gas cooler, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator and in which a supercritical refrigerant is used, the evaporator comprising a heat exchanger according to claim 1 .
12. A vehicle having installed therein a supercritical refrigeration cycle according to claim 10 as a vehicular air conditioner.
13. A vehicle having installed therein a supercritical refrigeration cycle according to claim 11 as a vehicular air conditioner.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/578,552 US20070204983A1 (en) | 2004-06-14 | 2005-06-14 | Heat Exchanger |
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US66236005P | 2005-03-17 | 2005-03-17 | |
US11/578,552 US20070204983A1 (en) | 2004-06-14 | 2005-06-14 | Heat Exchanger |
PCT/JP2005/011224 WO2005121683A1 (en) | 2004-06-14 | 2005-06-14 | Heat exchanger |
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US20070204983A1 true US20070204983A1 (en) | 2007-09-06 |
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- 2005-06-14 US US11/578,552 patent/US20070204983A1/en not_active Abandoned
- 2005-06-14 WO PCT/JP2005/011224 patent/WO2005121683A1/en active Application Filing
- 2005-06-14 DE DE112005001306T patent/DE112005001306T5/en not_active Ceased
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Cited By (17)
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US7857038B2 (en) * | 2006-04-14 | 2010-12-28 | Halla Climate Control Corporation | Heat exchanger |
US20070240863A1 (en) * | 2006-04-14 | 2007-10-18 | Kihong Kim | Heat exchanger |
US20090151918A1 (en) * | 2006-05-09 | 2009-06-18 | Kon Hur | Heat Exchanger for Automobile and Fabricating Method Thereof |
US8596089B2 (en) * | 2009-02-26 | 2013-12-03 | Honeywell International Inc. | Refrigerant distribution system |
US20100212353A1 (en) * | 2009-02-26 | 2010-08-26 | Ranjit Darke | Refrigerant distribution system |
US20110139420A1 (en) * | 2009-06-30 | 2011-06-16 | Shanghai Oriental MHE Co., Ltd. | Heat exchanger with microchannel, parallel flow, all-aluminium flat tube welding structure and its application |
US8763681B2 (en) * | 2009-08-05 | 2014-07-01 | Abb Research Ltd | Evaporator and cooling circuit |
US20110030400A1 (en) * | 2009-08-05 | 2011-02-10 | Abb Research Ltd. | Evaporator and cooling circuit |
US20150007605A1 (en) * | 2012-02-13 | 2015-01-08 | Daikin Industries, Ltd. | Outdoor unit of refrigeration apparatus |
US9447980B2 (en) * | 2012-02-13 | 2016-09-20 | Daikin Industries, Ltd. | Outdoor unit of refrigeration apparatus |
US20140008044A1 (en) * | 2012-07-06 | 2014-01-09 | Samsung Electronics Co., Ltd. | Heat exchanger and method of manufacturing the same |
US9863722B2 (en) * | 2012-07-06 | 2018-01-09 | Samsung Electronics Co., Ltd. | Refrigerator having heat exchanger including baffle blocking header tube |
US20150377560A1 (en) * | 2014-06-26 | 2015-12-31 | Valeo Autosystemy Sp. Z O.O. | Manifold, in particular for use in a cooler of a cooling system |
US20180038661A1 (en) * | 2015-06-03 | 2018-02-08 | Bayerische Motoren Werke Aktiengesellschaft | Heat Exchanger for a Cooling System, Cooling System, and Assembly |
US20180073819A1 (en) * | 2016-09-13 | 2018-03-15 | Samsung Electronics Co., Ltd. | Heat exchanger, header for the same and manufacturing method thereof |
US10527366B2 (en) * | 2016-09-13 | 2020-01-07 | Samsung Electronics Co., Ltd. | Heat exchanger, header for the same and manufacturing method thereof |
US11536496B2 (en) * | 2018-10-29 | 2022-12-27 | Mitsubishi Electric Corporation | Heat exchanger and refrigeration cycle apparatus |
Also Published As
Publication number | Publication date |
---|---|
WO2005121683A1 (en) | 2005-12-22 |
DE112005001306T5 (en) | 2007-07-19 |
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Legal Events
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Owner name: SHOWA DENKO K.K., JAPAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:ICHIYANAGI, SHIGEHARU;REEL/FRAME:020557/0765 Effective date: 20060619 |
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