US20090151918A1

US20090151918A1 - Heat Exchanger for Automobile and Fabricating Method Thereof

Info

Publication number: US20090151918A1
Application number: US12/226,652
Authority: US
Inventors: Kon Hur; Jung-Soo Bae; Rak-Gyun Kim
Original assignee: Individual
Current assignee: Estra Automotive Systems Co Ltd
Priority date: 2006-05-09
Filing date: 2007-05-08
Publication date: 2009-06-18
Also published as: WO2007129851A1

Abstract

There is provided a heat exchanger of a vehicle including a plurality of tubes spaced apart from each other by a predetermined distance and through which a heat-exchanging fluid flows, an upper header pipe unit coupled and communicated with the upper ends of the tubes, and a lower header pipe unit coupled and communicated with the lower ends of the tubes, and in which a header pipe is made by making and drawing a plate member containing a clad sheet into a pipe so that it does not need to separate and assemble a header from and with a tank and the clad sheet is not separated from the header pipe during transferring, a pair of header pipes have flat surfaces to bring into surface contact with each other such that a plurality of independent header pipes are assembled to closely contact each other, a plurality of same type and same number of communication devices are configured such that the heat-exchanging fluid flows therethrough, and an inlet and outlet end cap, an end cap, and separator are used such that the header pipes are tightly and securely assembled, and a method of manufacturing the heat exchanger.

Description

TECHNICAL FIELD

The present invention relates to a heat exchanger of a vehicle and a manufacturing method thereof, and more particularly, to a heat exchanger of a vehicle including a plurality of tubes spaced apart from each other by a predetermined distance and through which a heat-exchanging fluid flows, an upper header pipe unit coupled and communicated with the upper ends of the tubes, and a lower header pipe unit coupled and communicated with the lower ends of the tubes, and in which a header pipe is made by making and drawing a plate member containing a clad sheet into a pipe so that it does not need to separate and assemble a header from and with a tank and the clad sheet is not separated from the header pipe during transferring, a pair of header pipes have flat surfaces to bring into surface contact with each other such that a plurality of independent header pipes are assembled to closely contact each other and to make rows of the header pipes, a plurality of same type and same number of communication means are configured such that the heat-exchanging fluid flows through the header pipes, and an inlet and outlet end cap, an end cap, and separator are used such that the header pipes are tightly and securely assembled, and a method of manufacturing the heat exchanger.

BACKGROUND ART

A heat exchanger is an air conditioning device which is configured in the form of a plurality of tubes connected between a pair of header pipes, and which is installed on a passage of a cooling or heating system to cool and heat indoor room by which heat exchange between ambient air and a heat exchanging medium is performed when the heat exchanging medium supplied through an inlet of the header pipes passes through the tubes, and by which the heat exchanging medium is guided to be discharged to a passage pipe through an outlet.
The heat exchanger is employed in a vehicular air conditioning system. In the air conditioning system, a condenser to condense the heat exchanging medium of the air conditioning system is installed in front of an engine room, and sequentially a radiator to cool a coolant of an engine is installed in the rear side of the condenser. Since the condenser and the radiator are independently manufactured in spite that the condenser and the radiator have similar configurations, respective layouts for manufacturing the condenser and the radiator are required, and thus installation costs are very heavy. Since the condenser and the radiator must be independently installed in a vehicle, man-hour increases.
Thus, since tanks must be brazed to the header, man-hour for the manufacturing and the assembly increases and productivity is inferior. Moreover, since first and second heat exchangers are spaced apart from each other by protrusions formed in the center of the header, a width of an integrated heat exchanger becomes wider and the heat exchanger scales up.
Since respective lower lateral ends of the tanks are brazed to the header, four places are brazed. Due to many brazing places, there is a serious risk that the heat exchanging medium leaks.
Generally, in the vehicle, several types of heat exchanger are mounted so as to suit indoor temperature condition to a passenger and to cool heat generated by the engine of the vehicle.
The heat exchanger includes an evaporator to cool the indoor of the vehicle, a heat core to heat the indoor of the vehicle, a radiator to cool the engine of the vehicle, and a condenser to condense a refrigerant heated by the evaporator.
Moreover, when a diesel engine is mounted in the vehicle, a charge air cooler to cool supercharged air that is introduced into the diesel engine, and a transmission oil cooler to cool heat generated by an automatic transmission mounted in the vehicle, are installed.
Almost all the heat exchangers are made of aluminum and plastic. In the aluminum heat exchanger, the brazing is used. In the heat exchanger made of a mixture of aluminum and plastic, since the brazing cannot be applied, a gasket made of rubber or silicone is used to prevent an antifreezing solution or the refrigerant in the heat exchanger from leaking.
The heat exchanger includes a tank serving as a passage through which a majority of a fluid enters, fins where heat exchange between the fluid and ambient air is performed, tubes through which the fluid flow between the fins, a header to fix the tubes and the fins at a uniform distance, and a pipe coupled with the header and the tank such that the fluid is distributed to the respective tubes.
The tank of the heat exchanger may be made of plastic and assembled with an aluminum header.
A gasket made of rubber or silicone is employed in the plastic tank and the aluminum pipe to prevent the fluid from leaking. There are several methods of fixing the tank and the header when the metal header and the tank are put into a brazing furnace in order to assemble and integrally braze the metal header and the tank with each other; one is a cleanching in which the header presses the tank, and the other is a side-wall brazing of inserting the tank into the header to fix the tank and the header.
However, in the cleanching of making the header press the tank and in the side-wall brazing of fixing the tank and the header by inserting the tank into the header, since the tank mounted to the header is newly molded whenever a different sized heat exchanger is manufactured, manufacturing costs for the tank increase, therefore it's uneconomical.
Moreover, in the related art, the radiator and the condenser are separated and respective tanks are mounted to the radiator and the condenser.
Since, in spite that the conventional radiator and condenser are independently configured but their shapes and structures are substantially similar, independent molds and assembling devices are required during the manufacturing and the assembling, manufacturing costs increase and a vast engine room is required.
There are several patent applications relating the heat exchanger, such as Korean Patent Application Nos. 2000-0029558, entitled “Refrigerant Evaporator”, 2000-0034886, entitled “Refrigerant Evaporator”, 2001-0036164, entitled “Evaporator”, 2003-7016496, entitled “Evaporator, Manufacturing Method of the Same, Header for Evaporator and Refrigeration System”, 2006-7000293, entitled “Heat Exchanger”, and 2005-0060162, entitled “Header Pipe Manufacturing Method, Header Pipe, and Heat Exchanger Using the Same”.
The Korean Patent Application No. 2000-29558 has a main aspect to provide a refrigerant evaporator having an improved heat transmission performance and having tubes with sufficiently thin in order to obtain a maximum heat transmission performance. However, in the invention disclosed in the above application, since thicknesses and heights of tubes and corrugated fins are restricted to predetermined thickness and height and other components coupled with the tubes and the corrugated fins of the conventional heat exchanger are applied as they are without special matter, the heat exchanger of the above application has a minute difference in efficiency in comparison to the conventional heat exchanger.
The Korean Patent Application No. 2000-0034886 has a main aspect to provide a refrigerant evaporator having a uniform temperature distribution of blowing air. However, in an upper pipe unit having a plurality of passages by bending a single aluminum thin plate, an inferior bonding may happen in a partition in which both ends of the thin plate are bonded to make the plurality of passages divided into inlets and outlets. Although a lower pipe unit is configured identically to the upper pipe unit and a uniform temperature distribution is attempted by interposing a throttle at a predetermined inner position, since many works are required to fix the throttle to a precise position and to divide the thin plate into two passages, manufacturing costs increase and the inlet and outlet directions of the passages cannot be changed to other side of the heat exchanger.
The Korean Patent Application No. 2001-0036164 has a main aspect to provide a uniform temperature distribution of air cooled by and discharged from an evaporator. The invention of the patent application restricts an aperture ratio of a passage, that is, a value, in which a total transverse sectional area of a refrigerant passage of a single heat exchanging tube is divided by an area corresponding to a single heat exchanging tube of a header chamber partitioned for a refrigerant to enter, or by a horizontal sectional area of apertures of the heat exchanging tube, to be a predetermined percentage.
The Korean Patent Application No. 2001-7016496 has an aspect to provide an evaporator of maintaining a sufficient heat exchanging performance and having a reduced weight and size. According to this invention, although an upper header member and a lower header member are respectively coupled with upper and lower ends of a tube such that the respective header members are divided into covers and plates, a resistance plate is coupled with the upper sides of the header members, and communication holes are punctured in the lower sides of the header members so as to maintain the heat exchanging performance, the number of components rather increases and there is a high possibility of generating inferiority at the coupling position between the components.
The Korean Patent Application No. 2006-7000293 is an invention, without a difference from the above inventions, to achieve a uniform flow of a refrigerant through heat exchanging tube of a tube group and to improve the heat exchanging performance. However, in this invention, like the invention of Korean Patent Application No. 2003-7016496, a header and a tank are partitioned such that a partition is provided only to one side of inlet and outlets of the header, through-holes are punctured in different sizes, and the header and the tank are coupled by grooves and protrusions. It is difficult to manufacture the heat exchanger, manufacturing costs increase due to the increased number of components and man-hour, the grooves and the protrusions that are provided to securely fix the header and the tank are damaged so that the refrigerant leaks and as a result the heat exchanging efficiency is inferior.
The Korean Patent Application No. 2006-0060162 discloses a configuration in which a header is integrally formed with a tank and a baffle is inserted into a middle of a header pipe. However, in order to manufacture a communication means to communicate a plurality of passages formed in the integrated header pipe with each other, a punch and a dice are inserted into the passages in the longitudinal direction of the passages and a pressing device having a pusher must be used. Due to this, it is inconvenient to manufacture the communication means, and all the header pipes must be manufactured again when an inferior good is generated.

DISCLOSURE OF INVENTION

Technical Problem

Therefore, the present invention has been made in view of the above problems, and it is an aspect of the present invention to provide a heat exchanger of a vehicle in which a header pipe is made by making and drawing a plate member containing a clad sheet into a pipe so that it does not need to separate and assemble a header from and with a tank and the clad sheet is not separated from the header pipe during transferring, and a manufacturing method thereof.
Moreover, it is another aspect of the present invention to provide a heat exchanger of a vehicle in which a pair of header pipes have flat surfaces to bring into surface contact with each other such that a plurality of independent header pipes are assembled to closely contact each other to make rows of header pipes, a plurality of same type and same number of communication means are configured at the opposite sides where the heat-exchanging fluid enters and is discharged such that the heat-exchanging fluid flows therethrough, and an end cap and a separator are used such that the header pipes are tightly and securely assembled to easily manufacture and to reduce investment cost, and a method of manufacturing the heat exchanger, and a manufacturing method thereof.

Technical Solution

In accordance with an aspect of the present invention, the above and other aspects can be accomplished by the provision of a heat exchange of a vehicle comprises a plurality of tubes (7), through which a heat exchanging fluid (90) flows, spaced apart from each other, an upper header pipe unit (3) coupled with upper ends of the tubes (7) to communicate with, a lower header pipe unit (6) coupled with lower ends of the tubes (7) to communicate with, and the upper header pipe unit (3) includes a first header pipe (1) through which the heat exchanging fluid (90) enters, a second header pipe (2) through which the heat exchanging fluid (90) is discharged, a plurality of separators to control flowing directions of the heat exchanging fluids (90) of the first and second header pipes (1 and 2), and the lower header pipe unit (6) includes a third header pipe (4) to make the heat exchanging fluid (90) flow to a side, a fourth header pipe (5) to make the heat exchanging fluid (90) flow in a direction opposite to the third header pipe (4), and the upper header pipe unit (3) and the lower header pipe unit (6) to comprise a pair of header pipes in which a header and a tank are integrally formed with each other.
According to another embodiment of the present invention, there are provided the present invention provides a heat exchange of a vehicle comprises a plurality of tubes (7), through which a heat exchanging fluid (90) flows, spaced apart from each other, an upper header pipe unit (3) coupled with upper ends of the tubes (7) to communicate with, a lower header pipe unit (6) coupled with lower ends of the tubes (7) to communicate with, and the upper header pipe unit (3) includes a first header pipe (1) through which the heat exchanging fluid (90) enters, a second header pipe (2) through which the heat exchanging fluid (90) is discharged, a plurality of separators and a plurality of end caps (20) to control flowing directions of the heat exchanging fluids (90) of the first and second header pipes (1 and 2), and the lower header pipe unit (6) includes a third header pipe (4) to make the heat exchanging fluid (90) flow to a side, a fourth header pipe (5) to make the heat exchanging fluid (90) flow in a direction opposite to the third header pipe (4), and the upper header pipe unit (3) and the lower header pipe unit (6) to comprise a pair of header pipes in which a header and a tank are integrally formed with each other.
According to still another embodiment of the present invention, there are provided the present invention provides a heat exchange of a vehicle comprises a plurality of tubes (7), through which a heat exchanging fluid (90) flows, spaced apart from each other, an upper header pipe unit (3) coupled with upper ends of the tubes (7) to communicate with, a lower header pipe unit (6) coupled with lower ends of the tubes (7) to communicate with, and the upper header pipe unit (3) includes a first header pipe (1) coupled with an inlet manifold (11) through which the heat exchanging fluid (90) enters, a second header pipe (2) coupled with a discharging manifold (12) through which the heat exchanging fluid (90) is discharged, a separator and a plurality of end caps (20′) to control flowing directions of the heat exchanging fluids (90) of the first and second header pipes (1 and 2) and the lower header pipe unit (6) includes a third header pipe (4) to make the heat exchanging fluid (90) flow to a side, a fourth header pipe (5) to make the heat exchanging fluid (90) flow in a direction opposite to the third header pipe (4), and the upper header pipe unit (3) and the lower header pipe unit (6) to comprise a pair of header pipes in which a header and a tank are integrally formed with each other.
The plurality of separators may comprise control separators (32) and end separators (33) respectively inserted into insertion groove (40) formed in the middle and both ends of the first and second header pipes (1 and 2) to control the flowing direction of the heat exchanging fluid, and inlet and outlet separators (31) inserted into insertion grooves (40) formed in the other ends of the first and second header pipes (1 and 2) to form an inlet (50) and an outlet (51) for the heat exchanging fluid.
End separators (33) may be inserted into respective insertion grooves (40) formed in both ends of the third and fourth header pipes (4 and 5) such that the third and fourth header pipes (4 and 5) closely contact each other and the both ends of the third and fourth header pipes (4 and 5) are closed.
The first and second header pipes (1 and 2) may closely contact each other due to the control separators (32) and the inlet and outlet separators (31).
The end caps (20) may comprise inlet and outlet end caps (21) to form the inlet (50) and the outlet (51) for the heat exchanging fluid (90) and coupled with end sides of the first and second header pipes (1 and 2), a plurality of control end caps (22) coupled with both ends of the first and second header pipes (1 and 2) and both ends of the third and fourth header pipes (4 and 5) to control the flow of the heat exchanging fluid (90).
The first and second header pipes (I and 2) may be closely coupled with each other by control separators (32) inserted into insertion grooves (40) formed in the middle of the first and second header pipes (1 and 2) to control the flow of the heat exchanging fluid (90) and by inlet and outlet end caps (21) and control end caps (22 respectively coupled with both ends of the first and second header pipes (1 and 2).
The end caps (20′) may comprise inlet end caps (23) coupled with sides of the first and second header pipes (1 and 2) to form an inlet (50) for the heat exchanging fluid (90), and a plurality of control end caps (22) coupled with the other sides of the first and second header pipes (1 and 2) and both ends of the third and fourth header pipes (4 and 5) to control the flow of the heat exchanging fluid (90).
The first and second header pipes (1 and 2) may be closely coupled with each other by control separators (32) inserted into insertion grooves (40) formed in the middle of the first and second header pipes (1 and 2) to control the flow of the heat exchanging fluid (90) and by inlet end caps (23) and control end caps (22) respectively coupled with both ends of the first and second header pipes (1 and 2).
The third and fourth header pipes (4 and 5) may closely contact each other and the both ends of the third and fourth header pipes (4 and 5) are closed by a plurality of control end caps 22 coupled with both ends of the third and fourth header pipes (4 and 5).
The first and second header pipes (1 and 2) may have the same shape and number of a plurality of communication means (41) to face each other from opposite sides through which the heat exchanging fluid (90) enters and is discharged in order to communicate the heat exchanging fluid (90) between the first and second header pipes (1 and 2).
The inlet manifold (11) may form an inlet hole (81) communicated with the inlet (50), and is coupled with an inlet end cap (23) such that the heat exchanging fluid (90) enters.
The discharging manifold (12) may be inserted into a coupling hole (80) formed in a side opposite to communication means (41) about control separators (32) such that the heat exchanging fluid (90) is discharged out.
The first and second header pipes (1 and 2) and the third and fourth header pipes (4 and 5) respectively may have flat surfaces to bring into surface contact with each other in the longitudinal direction.
The upper header pipe unit (3) and the lower header pipe unit (6) may be made by making a plate member into a circular shape pipe and drawing the circular plat member proper to shapes of the header pipes.
The upper header pipe unit (3) and the lower header pipe unit (6) may be made of a plate member containing a clad sheet.
The communication means (41) may have a communication area gradually increased or decreased in the direction where a refrigerant flows.
The communication means (41) may be concentrated to end separators (33) or a side of the upper header pipe unit (3).
According to another aspect of the present invention, there are provided the present invention provides a method of manufacturing a heat exchanger of a vehicle comprises a plurality of tubes (7), through which a heat exchanging fluid (90) flows, spaced apart from each other, an upper header pipe unit (3) coupled with upper ends of the tubes (7) to communicate with, a lower header pipe unit (6) coupled with lower ends of the tubes (7) to communicate with, and the method comprises forming the upper header pipe unit (3) and the lower header pipe unit (6) respectively including a pair of header pipes in which a header and a tank are integrally formed with each other, forming the upper header pipe unit (3) with a first header pipe (1) and a second header pipe (2) such the heat exchanging fluid (90) enters and is discharged, forming flat surfaces in sides of the first and second header pipes (1 and 2) in the longitudinal direction to correspond to each other and to bring into surface contact with each other, forming the same shapes and numbers of communication means (41) at the positions where the flat surfaces are formed in order to communicate the heat exchanging fluid (90) between the first and second header pipes (1 and 2), selectively coupling one of an inlet and outlet end cap (21) and a control end cap (22), an inlet end cap (23) and a control end cap (22), or an inlet and outlet separator (31) and an end separator (33) with both ends of the first and second header pipes (1 and 2) in order to closely contact the first and second header pipes (1 and 2) with each other, coupling the control separator (32) with insertion grooves (40) formed in the middle of the upper header pipe unit (3) to control the flow of the heat exchanging fluid (90), forming the lower header pipe unit (6) with a third header pipe (4) and a fourth header pipe (5), forming flat surfaces in sides of the third and fourth header pipes (4 and 5) in the longitudinal direction to correspond to each other and to bring into surface contact with each other, coupling the end caps (22) or the end separators (33) with both ends of the third and fourth header pipes (4 and 5) in order to closely contact the third and fourth header pipes (4 and 5) with each other; and coupling the upper header pipe unit (3) and the lower header pipe unit (6) with both ends of the tubes (7) to communicate with.

ADVANTAGEOUS EFFECTS

As described above, according to the present invention, a header pipe is made by making and drawing a plate member containing a clad sheet into a pipe so that it does not need to separate and assemble a header from and with a tank and the clad sheet is not separated from the header pipe during transferring.
Moreover, a pair of header pipes have flat surfaces to bring into surface contact with each other such that a plurality of independent header pipes are assembled to closely contact each other to make rows of header pipes, a plurality of same type and same number of communication means are configured at both opposite sides where the heat-exchanging fluid enters and is discharged such that the heat-exchanging fluid flows therethrough, and an end cap and a separator are used such that the header pipes are tightly and securely assembled, so that the header pipes can more closely contact each other and be assembled. Thus, the heat exchanger is easily manufactured and investment cost is reduced.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating a heat exchange of a vehicle according to an embodiment of the present invention;

FIG. 2 is a perspective view illustrating a heat exchange of a vehicle according to another embodiment of the present invention;

FIG. 3 is a perspective view illustrating a heat exchange of a vehicle according to still another embodiment of the present invention;

FIG. 4 is a view illustrating a flow of a heat exchanging fluid of FIGS. 1 and 2;

FIG. 5 is a view illustrating a flow of a heat exchanging fluid of FIG. 3;

FIG. 6 is a perspective view illustrating a first example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention;

FIG. 7 is a perspective view illustrating a second example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention;

FIG. 8 is a perspective view illustrating a third example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention; and

FIG. 9 is a perspective view illustrating a fourth example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention.

EXPLANATION ON ESSENTIAL ELEMENTS OF DRAWINGS

1: first header pipe 2: second header pipe
3: upper header pipe unit 4: third header pipe
5: fourth header pipe 6: lower header pipe unit
7: tube 11: inlet manifold
12: discharging manifold 20, 20′: end cap
21: outlet end cap 22: control end cap
23: inlet end cap 31: outlet separator
32: control separator 33: end separator
40: insertion groove 41: communication means
42: tube hole 60: separation recess
80: coupling hole 81: inlet hole

BEST MODE FOR CARRYING OUT THE INVENTION

These and/or other aspects and advantages of the present invention will become apparent and more readily appreciated from the following description of the embodiments. Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is a perspective view illustrating a heat exchange of a vehicle according to an embodiment of the present invention, FIG. 2 is a perspective view illustrating a heat exchange of a vehicle according to another embodiment of the present invention, FIG. 3 is a perspective view illustrating a heat exchange of a vehicle according to still another embodiment of the present invention, FIG. 4 is a view illustrating a flow of a heat exchanging fluid of FIGS. 1 and 2, FIG. 5 is a view illustrating a flow of a heat exchanging fluid of FIG. 3, FIG. 6 is a perspective view illustrating a first example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention, FIG. 7 is a perspective view illustrating a second example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention, FIG. 8 is a perspective view illustrating a third example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention, and FIG. 9 is a perspective view illustrating a fourth example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention.
As illustrated in the drawings, in a heat exchanger of a vehicle according to an embodiment of the present invention and a manufacturing method thereof, a plurality of header pipes, in which a header and a tank are integrally formed with each other, are closely assembled with each other to form two row header pipes so that it does not need to assemble the tank and the header, a flow of a heat exchanging fluid is controlled by an end cap and a separator, and various types of a communication means is provided to make the heat exchanging fluid smoothly flow between the header pipes to form upper and lower header pipe unit. The heat exchanger includes an upper header pipe unit 3, a separator, a lower header pipe unit 6, end caps 20 and 20′ and a communication means 41.
The upper header pipe unit 3 includes a first header pipe 1 and a second header pipe 2. The first and second header pipes 1 and 2 are hollow cylinders, and have lower sides with a curve gentler than upper sides to form tube holes 42. Sides of tubes 7 are coupled with the tube holes 42 to communicate. Moreover, the upper header pipe unit 3 has insertion grooves 40 respectively formed in both ends and middle upper sides, includes a plurality of communication means 41 provided to sides of the upper header pipe unit 3 by a predetermined distance in the longitudinal direction. The communication means 41 of the first and second header pipes 1 and 2 face each other such that a heat exchanging fluid communicates between the first and second header pipes 1 and 2.
The separator includes a separation recess 60 formed in the lower side and is inserted into the insertion grooves 40 of the first and second header pipes 1 and 2, that is, a side of the separator is inserted into the first header pipe 1 and the other side thereof is inserted into the second header pipe 2 when the separation recess 60 is a reference position. Due to this, the first and second header pipes 1 and 2 are closely coupled with each other. Moreover, the separator includes a control separator 32, an inlet and outlet separator 31, and an end separator 33. The inlet and outlet separator 31 is inserted into the insertion grooves 40 formed in the sides of the first and second header pipes 1 and 2 to form an inlet 50 and an outlet 51 such that the heat exchanging fluid 90 enters the first header pipe 1 and is discharged from the second header pipe 2.
Moreover, the control separator 32 and the end separator 33 are respectively inserted into the insertion grooves 40 formed the middle and the other sides of the first and second header pipes 1 and 2 to serve as a thin film and to prevent the heat exchanging fluid from flowing. In addition, due to the separator, the first and second header pipes 1 and 2 make the heat exchanging fluid 90 communicate through the communication means 41 assembled to face each other.
The upper header pipe unit 6 includes third and fourth header pipes 4 and 5 having tube holes 42, with which the other sides of the tubes 7 are coupled, formed in the upper sides thereof at a predetermined distance. The third and fourth header pipes 4 and 5 have insertion holes 40 formed in the lower sides of both ends into which the end separators 33 are inserted. Due to this, the third and fourth header pipes 4 and 5 are closely coupled with each other like the first and second header pipes 1 and 2, and have both ends closed by the end separators 33.
The end cap 20 includes an inlet and outlet end cap 21 and a control end cap 22, and the end cap 20 includes an inlet end cap 23 and a control end cap 22. According to another embodiment of the present invention, the inlet and outlet separator 31 having the inlet 50 and the outlet 51 is coupled with the first and second header pipes 1 and 2 by the inlet and outlet end cap 21 having the inlet 50 and the outlet 51, and the end separator 33, inserted into the sides of the header pipes to control the flow of the heat exchanging fluid 90, is coupled with the control end cap 22 to control the flow.
In other words, the inlet and outlet end cap 21 and the control end cap 22 are used so that the insertion grooves 40 formed in the ends of the first and second header pipes 1 and 2 become needless.
Moreover, the configuration that both ends of the third and fourth header pipes 4 and 5 are closed by inserting the end separator 33 into the insertion grooves 40 of the ends of the third and fourth header pipe 4 and 5 is replaced with a configuration that the control end cap 22 closes the ends of the third and fourth header pipes 4 and 5 without the insertion grooves 40, so that the third and fourth header pipes 4 and 5 are more closely coupled with each other and are more precisely assembled.
In an inlet manifold 11 and a discharging manifold 12 according to still another embodiment of the present invention, the control separator 32 is inserted into the insertion grooves 40 formed in the middle of the first and second header pipes 1 and 2 to control the flow of the heat exchanging fluid 90, the control end cap 22 is coupled with the sides of the first and second header pipes 1 and 2 to block the flow of the heat exchanging fluid 90, and the inlet end cap 23 having the inlet 50 formed in a side thereof is coupled with the other sides of the first and second header pipes 1 and 2 such that the heat exchanging fluid 90 enters the first header pipe 1. The inlet manifold 11 has an inlet hole 81 formed in an outer circumference of an end to communicate with the inlet 50, and is coupled with the other side of the inlet end cap 23 having an end with which the first and second header pipes 1 and 2 are coupled to make the heat exchanging fluid 90 enter the first header pipe 1.
Moreover, the second header pipe 2 without the communication means 41 has a coupling hole 80 such that the discharging manifold 12 is inserted into the coupling hole 80 to discharge the heat exchanging fluid 90.
Hereinafter, the above-mentioned structures will be described in detail with reference to FIGS. 1 to 9.
FIG. 1 is a perspective view illustrating a heat exchange of a vehicle according to an embodiment of the present invention. As illustrated in the drawing, both ends of the tubes 7 are coupled and communicate with the upper header pipe unit 3 and the lower header pipe unit 6.
The upper header pipe unit 3 includes the first header pipe 1 and the second header pipe 2. The first and second header pipes 1 and 2 respectively have at least one flat surface formed in the longitudinal direction of the first and second header pipes 1 and 2 such that the first and second header pipes 1 and 2 correspond to each other and bring into surface contact with each other. Moreover, in order to make the heat exchanging fluid 90 flow between the first and second header pipes 1 and 2, the communication means 41 are provided in the contact surface and the control separator 32 having the separation recess 60 formed in the middle thereof is inserted into the insertion groove 40. By doing so, the passages for the heat exchanging fluid are not formed in bi-directions but in multiple directions, and the heat exchanging fluid 90 can flow between the first and second header pipes 1 and 2 through only the communication means 41.
The upper header pipe unit 3 includes the insertion grooves 40 formed in the both upper sides such that the inlet and outlet separator 31 is inserted into an insertion groove 40 and the end separator 33 is inserted into the other insertion groove 40. The inlet and outlet separator 31 has the inlet 50 and the outlet through which the heat exchanging fluid 90 enters and is discharged, and the end separator 33 prevents the heat exchanging fluid 90 from leaking. Both of the end separator 33 and the inlet and outlet separator 31 have the separation recesses 60 formed in the middle thereof like the control separator 32.
The lower header pipe unit 6 having the tube holes 42 is coupled with the lower sides of the tubes 7 such that the tubes 7 are coupled and communicate with the lower header pipe unit 6. The lower header pipe unit 6 includes the third header pipe 4 and the fourth header pipe 5, and the third and fourth header pipes 4 and 5 bring into surface contact with each other.
The lower header pipe unit 6 has the insertion grooves 40 formed in both ends of the other sides where the tube holes 42 are formed, and the end separator 33 is inserted into the insertion grooves 40 to close the both ends.
FIG. 2 is a perspective view illustrating a heat exchange of a vehicle according to another embodiment of the present invention. As illustrated in the drawing, the upper header pipe unit 3 is coupled with the upper ends of the tubes 7 and the lower header pipe unit 6 is coupled with the lower ends of the tubes 7 to communicate the upper and lower ends of the tubes 7 with the upper and lower header pipe unit 3 and 6 such that the heat exchanging fluid 90 flows.
The upper header pipe unit 3 includes the first header pipe 1 through which the heat exchanging fluid 90 enters and flows and a second header pipe 2 through which the heat exchanging fluid 90 is discharged. The first and second header pipes 1 and 2 respectively have at least one flat surface to bring outer circumferential surfaces into surface contact with each other in the longitudinal direction.
Furthermore, the first and second header pipes 1 and 2 respectively have the insertion grooves 40 formed in the middle, and a plurality of communication means 41 formed in the opposite sides about the insertion grooves 40 through which the heat exchanging fluid 90 enter and is discharged. The same number and shapes of communication means 41 are provided to surfaces to contact each other such that the heat exchanging fluid 90 flow from the first header pipe 1 to the second header pipe 2.
The first and second header pipes 1 and 2 are bonded to each other to form a pair of header pipes, and the control separator 32 having the separation recess 60 is inserted into the insertion groove 40 formed in the middle of the first and second header pipes 1 and 2 such that the heat exchanging fluid 90 of the first and second header pipes 1 and 2 flows through only the communication means 41.
In addition, portions through which the heat exchanging fluid 90 enter and is discharged, that is, the opposite ends in which the communication means 41 of the upper header pipe unit 3 are not formed, the inlet and outlet end cap 21 having the inlet 50 and the outlet 51 is inserted such that the heat exchanging fluid 90 enters and is discharged and the first and second header pipes 1 and 2 are more securely coupled with each other. Moreover, the control end cap 22 is inserted into the other ends of the first and second header pipes 1 and 2 having the communication means 41 to make the first and second header pipes 1 and 2 more closely contact each other like the inlet and outlet end cap 21.
Like the upper header pipe unit 3, the third and fourth header pipe 4 and 5 bring into surface contact with each other in the lower ends of the tubes 7 and communicate with the lower ends of the tubes 7. In this case, the control end caps 22 are inserted into the both ends of the lower header pipe unit 6 including the third and fourth header pipes 4 and 5 to make the third and fourth header pipes 4 and 5 more closely contact each other and to prevent the heat exchanging fluid 90 from leaking out of the third and fourth header pipes 4 and 5.
The upper header pipe unit 3 and the lower header pipe unit 6 respectively have the tube holes 42 in the portions coupled with the tubes 7 to communicate with the upper and lower sides of the tubes 7.
FIG. 3 is a perspective view illustrating a heat exchange of a vehicle according to still another embodiment of the present invention. As illustrated in the drawing, both ends of the tubes 7 communicate with the upper header pipe unit 3 and the lower header pipe unit 6.
The upper header pipe unit 3 includes the first header pipe 1 and a second header pipe 2. The first and second header pipes 1 and 2 respectively have at least one flat surface to bring outer circumferential surfaces into surface contact with each other in the longitudinal direction. Moreover, in order to make the heat exchanging fluid 90 flow between the first and second header pipes 1 and 2, the communication means 41 are provided in the bonding portions thereof, and the control separator 32 having the separation recess 60 formed in the middle is inserted into the insertion grooves 40. By doing so, the passages for the heat exchanging fluid 90 are not formed in two directions but in the multiple directions, and the heat exchanging fluid 90 can flow between the first and second header pipes 1 and 2 through only the communication means 41.
Although the inlet end cap 23 which has the inlet 50 is formed in the portion through which the heat exchanging fluid 90 of the first header pipe 1 enters, and close a side of the second header pipe 2 is inserted into the side of the upper header pipe unit 3 such that the inlet manifold 11 having the inlet hole 81 to communicate with the inlet 50 of the inlet end cap 23 is coupled with a side of the inlet end cap 23 to make the heat exchanging fluid 90 enter.
Moreover, the control end cap 22 is inserted into the other side of the upper header pipe unit 3 to prevent the heat exchanging fluid 90 from being discharged out, and the second header pipe 2 has the coupling hole 80 formed in the opposite side where the communication means 41 are formed, that is, in the portion where the first header pipe 1 does not bring into surface contact. The discharging manifold 12 is coupled with the coupling hole 80 to discharge the heat exchanging fluid 90.
In the lower sides of the tubes 7, the lower header pipe unit 6 is inserted into the tube holes 42 to communicate therewith. The lower header pipe unit 6 is configured such that the third and fourth header pipes 4 and 5 bring into surface contact with each other at the outer circumferences in the longitudinal direction, and the control end caps 22 are inserted into the ends of the lower header pipe unit 6 such that the third and fourth header pipes 4 and 5 more closely contact each other.
FIG. 4 is a view illustrating a flow of a heat exchanging fluid of FIGS. 1 and 2. As illustrated in the drawing, the heat exchanging fluid 90 is introduced from 1, passes in the order of sequential numbers, and is discharged from 8.
Hereinafter, the numbers 1 to 8 of FIG. 4 are referred to regions.
Remarks: 1 indicates a first region, 2 indicates a second region, and etc.
With reference to the configuration in FIG. 2, the flow diagram illustrated in FIG. 4 will be described. The heat exchanging fluid 90 entering the first region through the inlet 50 of the inlet and outlet end cap 21 passes through second and third regions, that is, the third header pipe 4 to flow from a fourth region to a fifth region through the communication means 41 of the first header pipe 1, passes through sixth and seventh regions of the fourth header pipe 5 from the fifth region of the second header pipe 2, and is discharged through an eighth region of the second header pipe 2, that is, the outlet 51 of the inlet and outlet end cap 21.
FIG. 5 is a view illustrating a flow of a heat exchanging fluid of FIG. 3. As illustrated in the drawing, the heat exchanging fluid 90 is introduced from 1, passes in the order of sequential numbers, and is discharged from 9.
Hereinafter, the numbers 1 to 9 of FIG. 5 are referred to regions.
Remarks: 1 indicates a first region, 2 indicates a second region, and etc.
With reference to the configuration in FIG. 3, the flow diagram illustrated in FIG. 5 will be described. The heat exchanging fluid 90 entering the second region of the first header pipe 1 through the first region, that is, the inlet manifold 11 via the inlet end cap 23 passes through third and fourth regions of the third header pipe 4 to flow from a fifth region to a sixth region through the communication means 41 of the first header pipe 1, flows to the second header pipe 2 sequentially, passes through seventh and eighth regions of the fourth header pipe 5 via the tubes 7, and is discharged through the discharging manifold 12 formed in ninth region of the second header pipe 2.
FIG. 6 is a perspective view illustrating a first example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention. As illustrated in the drawing, the communication means 41 are formed in a side about the insertion grooves 40. The communication means 41 have a shape whose area is gradually decreased in the direction where the refrigerant flows.
FIG. 7 is a perspective view illustrating a second example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention. As illustrated in the drawing, the communication means 41 are formed in a side about the insertion grooves 40. The communication means 41 have a shape whose area is gradually increased in the direction where the refrigerant flows.
FIG. 8 is a perspective view illustrating a third example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention. As illustrated in the drawing, the communication means 41 are concentrated to the insertion grooves 40 into which the control separator 32 is inserted.
FIG. 9 is a perspective view illustrating a fourth example of a communication means provided in the heat exchanger of a vehicle according to the embodiment of the present invention. As illustrated in the drawing, the communication means 41 are concentrated to a side of the upper header pipe unit 3. When the control end cap 22 is inserted into a side of the upper header pipe unit 3, the communication means 41 are concentrated to the control end cap 22. When the insertion grooves 40 are formed in a side of the upper header pipe unit 3 and the end separator 33 is inserted into the insertion grooves 40 to close the lateral side of the upper header pipe unit 3, the communication means 3 are concentrated to the end separator 33.
Hereinafter, operation and principle of the heat exchanger according to the embodiments of the present invention constructed as described above are described.
The heat exchanger of a vehicle in which the header and the tank are integrally formed with each other, as illustrated in FIG. 4, has a flow diagram in which the heat exchanging fluid 90 is introduced from the number 1 and is discharged through the number 8. This flow diagram is described with reference to FIG. 1. The heat exchanging fluid 90 is introduced through the inlet 50 of the inlet and outlet separator 31, passes through the first header pipe 1, and flows to the third header pipe 4 via the tubes 7 due to the control separator 32. The heat exchanging fluid 90 passing through the third header pipe 4 flows to the first header pipe I again via the tubes 7, and flows to the second header pipe 2 via the communication means 41. Due to the control separator 32 of the second header pipe 2, the heat exchanging fluid 90 flows to the fourth header pipe 5 via the tubes 7, ascends through the tubes 7 to flow to the second header pipe 2, and is discharged through the outlet 51 of the inlet and outlet separator 31.
The heat exchanger of a vehicle in which the header and the tank are integrally formed with each other according to another embodiment of the present invention, as illustrated in FIG. 4, has a flow diagram in which the heat exchanging fluid 90 is introduced from the number 1 and is discharged through the number 8. This flow diagram is described with reference to FIG. 2. The heat exchanging fluid 90 is introduced through the inlet 50 of the inlet and outlet separator 21, passes through the first header pipe 1, and flows to the third header pipe 4 via the tubes 7 due to the control separator 32. The heat exchanging fluid 90 passing through the third header pipe 4 flows to the first header pipe 1 via the tubes 7, and flows to the second header pipe 2 via the communication means 41 formed in the side thereof. Due to the control separator 32 of the second header pipe 2, the heat exchanging fluid 90 flows to the fourth header pipe 5 via the tubes 7, ascends through the tubes 7 to flow to the second header pipe 2, and is discharged through the outlet 51 of the inlet and outlet end cap 21.
The heat exchanger of a vehicle in which the header and the tank are integrally formed with each other according to still another embodiment of the present invention employs the inlet manifold 11 and the discharging manifold 12. As illustrated in FIG. 5, the heat exchanger has a flow diagram in which the heat exchanging fluid 90 is introduced from the number 1 and is discharged through the number 9. This flow diagram is described with reference to FIG. 3. The heat exchanging fluid 90 enters the inlet manifold 11, passes through the first header pipe 1 via the inlet hole 81 of the inlet manifold 11 and the inlet 50 of the inlet end cap 23, and flows to the third header pipe 4 via the tubes 7 due to the control separator 32. The heat exchanging fluid 90 passing through the third header pipe 4 flows to the first header pipe 1 again via the tubes 7, and flows to the second header pipe 2 via the communication means 41 formed in the side thereof. Due to the control separator 32 of the second header pipe 2, the heat exchanging fluid 90 flows to the fourth header pipe 5 via the tubes 7, ascends through the tubes 7 to flow to the second header pipe 2, and is discharged to the discharging manifold 12 inserted into the coupling hole 80 formed in the side of the second header pipe 2.
Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.

Claims

1-20. (canceled)

21. A heat exchange of a vehicle comprising:

a plurality of tubes (7), through which a heat exchanging fluid (90) flows, spaced apart from each other;

an upper header pipe unit (3) coupled with upper ends of the tubes (7) to communicate with;

a lower header pipe unit (6) coupled with lower ends of the tubes (7) to communicate with;

the upper header pipe unit (3) including:

a first header pipe (1) through which the heat exchanging fluid (90) enters;

a second header pipe (2) through which the heat exchanging fluid (90) is discharged; and

a plurality of separators to control flowing directions of the heat exchanging fluids (90) of the first and second header pipes (1 and 2);

the lower header pipe unit (6) including:

a third header pipe (4) to make the heat exchanging fluid (90) flow to a side; and

a fourth header pipe (5) to make the heat exchanging fluid (90) flow in a direction opposite to the third header pipe (4); and

the upper header pipe unit (3) and the lower header pipe unit (6) to comprise a pair of header pipes in which a header and a tank are integrally formed with each other,

wherein the plurality of separators comprise:

control separator (32) and end separator (33) respectively inserted into insertion groove (40) formed in the middle and one ends of the first and second header pipes (1 and 2) to control the flowing direction of the heat exchanging fluid; and

inlet and outlet separator (31) inserted into insertion grooves (40) formed in the other ends of the first and second header pipes (1 and 2) to form an inlet (50) and an outlet (51) for the heat exchanging fluid,

wherein the first and second header pipes (1 and 2) closely contact with each other due to the control separator (32), the end separator (33) and the inlet and outlet separator (31).

22. A heat exchange of a vehicle comprising:

the upper header pipe unit (3) including:

a first header pipe (1) through which the heat exchanging fluid (90) enters;

a separator and a plurality of end caps (20) to control flowing directions of the heat exchanging fluids (90) of the first and second header pipes (1 and 2);

the lower header pipe unit (6) including:

wherein the end caps (20) comprise:

inlet and outlet end cap (21) to form the inlet (50) and the outlet (51) for the heat exchanging fluid (90) and coupled with one end sides of the first and second header pipes (1 and 2); and

a plurality of control end caps (22) coupled with the other end sides of the first and second header pipes (1 and 2) and both ends of the third and fourth header pipes (4 and 5) to control the flow of the heat exchanging fluid (90), wherein the first and second header pipes (1 and 2) are closely coupled with each other by control separator (32) inserted into insertion grooves (40) formed in the middle of the first and second header pipes (1 and 2) to control the flow of the heat exchanging fluid (90) and by inlet and outlet end cap (21) and control end cap (22) respectively coupled with both ends of the first and second header pipes (1 and 2).

23. A heat exchange of a vehicle comprising:

the upper header pipe unit (3) including:

a first header pipe (1) coupled with an inlet manifold (11) through which the heat exchanging fluid (90) enters;

a second header pipe (2) coupled with an outlet manifold (12) through which the heat exchanging fluid (90) is discharged; and

a separator and a plurality of end caps (20′) to control flowing directions of the heat exchanging fluids (90) of the first and second header pipes (1 and 2); the lower header pipe unit (6) including:

wherein the first and second header pipes (1 and 2) are closely coupled with each other by control separator (32) inserted into insertion grooves (40) formed in the middle of the first and second header pipes (1 and 2) to control the flow of the heat exchanging fluid (90) and by inlet end cap (23) and control end cap (22) respectively coupled with both ends of the first and second header pipes (1 and 2).

24. The heat exchange of a vehicle according to claim 21, wherein end separators (33) are inserted into respective insertion grooves (40) formed in both ends of the third and fourth header pipes (4 and 5) such that the third and fourth header pipes (4 and 5) closely contact each other and the both ends of the third and fourth header pipes (4 and 5) are closed.

25. The heat exchange of a vehicle according to claim 23, wherein the end caps (20′) comprise:

inlet end cap (23) coupled with one end sides of the first and second header pipes (1 and 2) to form an inlet (50) for the heat exchanging fluid (90); and

a plurality of control end caps (22) coupled with the other end sides of the first and second header pipes (1 and 2) and both ends of the third and fourth header pipes (4 and 5) to control the flow of the heat exchanging fluid (90).

26. The heat exchange of a vehicle according to claim 25, wherein the inlet manifold (11) forms an inlet hole (81) communicated with the inlet (50), and is coupled with an inlet end cap (23) such that the heat exchanging fluid (90) enters.

27. The heat exchange of a vehicle according to claim 23, wherein the outlet manifold (12) is inserted into a coupling hole (80) formed in a side opposite to communication means (41) about control separator (32) such that the heat exchanging fluid (90) is discharged out.

28. The heat exchange of a vehicle according to claim 22, wherein the third and fourth header pipes (4 and 5) closely contact each other and the both ends of the third and fourth header pipes (4 and 5) are closed by a plurality of control end caps (22) coupled with both ends of the third and fourth header pipes (4 and 5).

29. The heat exchange of a vehicle according to claim 23, wherein the third and fourth header pipes (4 and 5) closely contact each other and the both ends of the third and fourth header pipes (4 and 5) are closed by a plurality of control end caps (22) coupled with both ends of the third and fourth header pipes (4 and 5).

30. The heat exchange of a vehicle according to claim 21, wherein the first and second header pipes (1 and 2) have the same shape and number of a plurality of communication means (41) to face each other from opposite sides through which the heat exchanging fluid (90) enters and is discharged in order to communicate the heat exchanging fluid (90) between the first and second header pipes (1 and 2),

wherein the communication means (41) have a communication area gradually increased or decreased in the direction where a refrigerant flows.

31. The heat exchange of a vehicle according to claim 22, wherein the first and second header pipes (1 and 2) have the same shape and number of a plurality of communication means (41) to face each other from opposite sides through which the heat exchanging fluid (90) enters and is discharged in order to communicate the heat exchanging fluid (90) between the first and second header pipes (1 and 2),

32. The heat exchange of a vehicle according to claim 23, wherein the first and second header pipes (1 and 2) have the same shape and number of a plurality of communication means (41) to face each other from opposite sides through which the heat exchanging fluid (90) enters and is discharged in order to communicate the heat exchanging fluid (90) between the first and second header pipes (1 and 2),

33. The heat exchange of a vehicle according to claim 21, wherein the first and second header pipes (1 and 2) and the third and fourth header pipes (4 and 5) respectively have flat surfaces to bring into surface contact with each other in the longitudinal direction.

34. The heat exchange of a vehicle according to claim 22, wherein the first and second header pipes (1 and 2) and the third and fourth header pipes (4 and 5) respectively have flat surfaces to bring into surface contact with each other in the longitudinal direction.

35. The heat exchange of a vehicle according to claim 23, wherein the first and second header pipes (1 and 2) and the third and fourth header pipes (4 and 5) respectively have flat surfaces to bring into surface contact with each other in the longitudinal direction.

36. The heat exchange of a vehicle according to claim 30, wherein the communication means (41) are concentrated to end separator (33) or a side of the upper header pipe unit (3).

37. The heat exchange of a vehicle according to claim 31, wherein the communication means (41) are concentrated to end separator (33) or a side of the upper header pipe unit (3).

38. The heat exchange of a vehicle according to claim 32, wherein the communication means (41) are concentrated to end separator (33) or a side of the upper header pipe unit (3).

39. The heat exchange of a vehicle according to claim 21, wherein the upper header pipe unit (3) and the lower header pipe unit (6) are made by making a plate member into a circular shape pipe and drawing the circular plat member proper to shapes of the header pipes,

wherein the upper header pipe unit (3) and the lower header pipe unit (6) are made of a plate member containing a clad sheet.

40. The heat exchange of a vehicle according to claim 22, wherein the upper header pipe unit (3) and the lower header pipe unit (6) are made by making a plate member into a circular shape pipe and drawing the circular plat member proper to shapes of the header pipes,

41. The heat exchange of a vehicle according to claim 23, wherein the upper header pipe unit (3) and the lower header pipe unit (6) are made by making a plate member into a circular shape pipe and drawing the circular plat member proper to shapes of the header pipes,