US20160361749A1 - Heat exchanger manufacturing method and diameter enlargement tool - Google Patents

Heat exchanger manufacturing method and diameter enlargement tool Download PDF

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Publication number
US20160361749A1
US20160361749A1 US15/115,069 US201415115069A US2016361749A1 US 20160361749 A1 US20160361749 A1 US 20160361749A1 US 201415115069 A US201415115069 A US 201415115069A US 2016361749 A1 US2016361749 A1 US 2016361749A1
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United States
Prior art keywords
tube
diameter
shaped body
metal sheet
main body
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Abandoned
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US15/115,069
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English (en)
Inventor
Naoya Goto
Takuma Endo
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Sanoh Industrial Co Ltd
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Sanoh Industrial Co Ltd
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Assigned to SANOH INDUSTRIAL CO., LTD. reassignment SANOH INDUSTRIAL CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ENDO, TAKUMA, GOTO, NAOYA
Publication of US20160361749A1 publication Critical patent/US20160361749A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/08—Tube expanders
    • B21D39/20—Tube expanders with mandrels, e.g. expandable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/08—Making tubes with welded or soldered seams
    • B21C37/09—Making tubes with welded or soldered seams of coated strip material ; Making multi-wall tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B21C37/20—Making helical or similar guides in or on tubes without removing material, e.g. by drawing same over mandrels, by pushing same through dies ; Making tubes with angled walls, ribbed tubes and tubes with decorated walls
    • B21C37/202—Making helical or similar guides in or on tubes without removing material, e.g. by drawing same over mandrels, by pushing same through dies ; Making tubes with angled walls, ribbed tubes and tubes with decorated walls with guides parallel to the tube axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
    • B21D53/08—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of both metal tubes and sheet metal
    • B21D53/085—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of both metal tubes and sheet metal with fins places on zig-zag tubes or parallel tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/14—Soldering, e.g. brazing, or unsoldering specially adapted for soldering seams
    • B23K1/16—Soldering, e.g. brazing, or unsoldering specially adapted for soldering seams longitudinal seams, e.g. of shells
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00—Tubular elements; Assemblies of tubular elements
    • F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
    • F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
    • F28F1/24—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element and extending transversely
    • F28F1/30—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element and extending transversely the means being attachable to the element

Definitions

  • the present invention relates to a heat exchanger manufacturing method and a diameter enlargement tool.
  • JP-A Japanese Patent Application Laid-Open (JP-A) No. 2011-257084 describes a method of inserting a tube-shaped body (heat transfer tube) formed by extruding aluminum in a tube shape through insertion holes formed in fins, and then inserting a diameter enlargement tool (pipe enlargement tool) inside the tube-shaped body to enlarge the external diameter of the tube-shaped body.
  • a tube-shaped body heat transfer tube
  • a diameter enlargement tool pipe enlargement tool
  • the diameter enlargement tool is used to stretch the tube-shaped body in the circumferential direction (stretch around the perimeter) in order to enlarge the external diameter, and so a large load is required to enlarge the diameter of the tube-shaped body.
  • an object of the present invention is to provide a heat exchanger manufacturing method and a diameter enlargement tool enabling a reduction in the load required to enlarge the diameter of the tube-shaped body.
  • a heat exchanger manufacturing method of a first aspect of the present invention includes a forming process of rolling a metal sheet into a roll shape to form a tube-shaped body, a diameter enlargement process of inserting the tube-shaped body through a through hole formed at a metal fin, and loosening the metal sheet that has been rolled into a roll shape to enlarge the diameter of the tube-shaped body and place an outer peripheral face of the tube-shaped body in contact with a hole wall of the through hole, and a joining process of, after the diameter enlargement process, joining together a roll-overlap portion of the metal sheet that has been rolled into a roll shape.
  • the metal sheet is rolled up into a roll shape to form the tube-shaped body, and the metal sheet rolled up into a roll shape is loosened to enlarge the diameter of the tube-shaped body.
  • This enables the load required to enlarge the diameter of the tube-shaped body to be reduced compared to a configuration where an extrusion-formed heat transfer tube is stretched in the circumferential direction (stretched around the perimeter) to enlarge the diameter.
  • a heat exchanger manufacturing method of a second aspect of the present invention is the heat exchanger manufacturing method of the first aspect in which, in the diameter enlargement process, a diameter enlargement tool, with an external diameter that is larger than an internal diameter of the tube-shaped body prior to diameter enlargement, is inserted inside the tube-shaped body to forcibly loosen the metal sheet that has been rolled into a roll shape and enlarge the diameter of the tube-shaped body.
  • the diameter enlargement tool in the diameter enlargement process, the diameter enlargement tool, with an external diameter that is larger than the internal diameter of the tube-shaped body prior to diameter enlargement, is inserted inside the tube-shaped body pre-diameter enlargement to forcibly loosen the metal sheet rolled up into a roll shape and enlarge the diameter of the tube-shaped body.
  • employing the diameter enlargement tool with an external diameter larger than the internal diameter of the tube-shaped body pre-diameter enlargement enables the diameter of the tube-shaped body to be enlarged in a simple manner.
  • a heat exchanger manufacturing method of a third aspect of the present invention is the heat exchanger manufacturing method of the second aspect in which, the metal sheet has an undulating portion formed on one sheet face and, in the forming process, the metal sheet is rolled into a roll shape to form the tube-shaped body with the undulating portion at an inner side thereof.
  • the metal sheet is rolled up into a roll shape with the undulating portion formed on the one face on the inside to form the tube-shaped body with the undulating portion at an inner peripheral face.
  • Forming the undulating portion in this manner increases the surface area of the inner peripheral face of the tube-shaped body, improving heat transfer efficiency between the tube-shaped body and fluid passing through inside the tube-shaped body.
  • the heat exchanger manufacturing method described above enables a reduction in the load required to enlarge the diameter of the tube-shaped body, thereby enabling deformation (squashing deformation) of the undulating portion formed at the inner peripheral face of the tube-shaped body to be suppressed when using the diameter enlargement tool to enlarge the diameter of the tube-shaped body.
  • This enables heat transfer efficiency to be secured between the tube-shaped body and the fluid passing through inside the tube-shaped body.
  • a heat exchanger manufacturing method of a fourth aspect of the present invention is the heat exchanger manufacturing method of either the second aspect or the third aspect in which the metal sheet is configured by aluminum.
  • the metal sheet rolled up into a roll shape to form the tube-shaped body is configured by aluminum, thereby enabling a reduction in weight and a reduction in costs, while securing heat transfer efficiency between the tube-shaped body and the fluid passing through inside the tube-shaped body.
  • configuring the metal sheet by aluminum enables the load required to enlarge the diameter of the tube-shaped body to be reduced compared to cases in which the metal sheet is configured by a material that deforms less readily, such as a steel sheet. Deformation (squashing deformation) of an undulating portion formed at the inner peripheral face of the tube-shaped body can accordingly be further suppressed when enlarging the diameter of the tube-shaped body with the diameter enlargement tool.
  • a heat exchanger manufacturing method of a fifth aspect of the present invention is the heat exchanger manufacturing method of any one of the second aspect to the fourth aspect in which the diameter enlargement tool includes a circular column-shaped main body that is inserted inside the tube-shaped body, ribs that are provided at intervals in a circumferential direction around an outer peripheral face of the main body, that project outward from the main body outer peripheral face, that extend from an end portion of the main body at an insertion direction side toward an opposite side to the insertion direction, and that contact an inner peripheral face of the tube-shaped body, and inclined portions that are formed at insertion direction leading end portions of the ribs, and that have a projection height from the main body outer peripheral face that gradually increases toward the opposite side to the insertion direction.
  • the ribs of the diameter enlargement tool contact the inner peripheral face of the tube-shaped body, thereby enabling a reduction in the contact surface area between the diameter enlargement tool and the inner peripheral face of the tube-shaped body, enabling a reduction in resistance from deformation of the tube-shaped body when inserting the diameter enlargement tool into the tube-shaped body.
  • the load required to insert the diameter enlargement tool into the tube-shaped body can accordingly be reduced.
  • the leading end portions of the ribs in the insertion direction are formed with the inclined portions whose projection height from the outer peripheral face of the main body gradually increases on progression toward the opposite side to the insertion direction.
  • the inclined portions accordingly act as guides for enlarging the diameter of the tube-shaped body when the diameter enlargement tool is inserted into the tube-shaped body pre-diameter enlargement. This enables smoother insertion of the diameter enlargement tool into the tube-shaped body than a rib configuration that does not include the inclined portions.
  • a heat exchanger manufacturing method of a sixth aspect of the present invention is the heat exchanger manufacturing method of the fifth aspect in which the ribs extend in a spiral shape toward the opposite side of the main body to the insertion direction, with the direction of the spiral being set as an opposite direction to a roll-up direction of the metal sheet that has been rolled into a roll shape.
  • the ribs extend in a spiral shape toward the side of the main body opposite to the insertion direction, with the direction of the spiral set as the opposite direction to the roll-up direction of the metal sheet rolled up into a roll shape.
  • the metal sheet rolled up into a roll shape is accordingly imparted with force from the ribs in the opposite direction to the roll-up direction and is loosened when the diameter enlargement tool is inserted into the tube-shaped body.
  • the load required to enlarge the diameter of the tube-shaped body can accordingly be reduced.
  • a heat exchanger manufacturing method of a seventh aspect of the present invention is the heat exchanger manufacturing method of the fifth aspect in which the ribs extend in straight line shapes toward the opposite side of the main body to the insertion direction, and an interval between respective contact portions, at which two of the ribs disposed on either side of a peripheral inside edge portion of the metal sheet that has been rolled into a roll shape contact the inner peripheral face of the tube-shaped body, widens toward the opposite side to the insertion direction.
  • the separation between respective contact portions where two of the ribs disposed on each side of a peripheral inside end portion of the metal sheet rolled up into a roll shape contact the inner peripheral face of the tube-shaped body widens on progression toward the opposite side to the insertion direction.
  • the peripheral inside edge portion of the metal sheet rolled up into a roll shape is accordingly imparted with force from the two ribs in the opposite direction to the roll-up direction, and moves in the circumferential direction of the tube-shaped body, thereby loosening the metal sheet rolled up into a roll shape. This enables the load required to enlarge the diameter of the tube-shaped body to be reduced.
  • a diameter enlargement tool of an eighth aspect of the present invention is a diameter enlargement tool to enlarge the diameter of a tube-shaped body formed by rolling a metal sheet into a roll shape, the diameter enlargement tool including a circular column-shaped main body that is inserted inside the tube-shaped body, ribs that are provided at intervals in a circumferential direction around an outer peripheral face of the main body, that project outward from the main body outer peripheral face, that extend from an end portion of the main body at an insertion direction side toward an opposite side to the insertion direction, and that contact an inner peripheral face of the tube-shaped body, and inclined portions that are formed at insertion direction leading end portions of the ribs, and that have a projection height from the main body outer peripheral face that gradually increases toward the opposite side to the insertion direction, wherein an external diameter of the diameter enlargement tool is larger than an internal diameter of the tube-shaped body.
  • the external diameter of the diameter enlargement tool is larger than the internal diameter of the tube-shaped body, such that inserting the diameter enlargement tool into the tube-shaped body forcibly loosens the metal sheet rolled up into a roll shape and enlarges the diameter of the tube-shaped body.
  • the ribs contact the inner peripheral face of the tube-shaped body, thereby enabling a reduction in the contact surface area between the diameter enlargement tool and the inner peripheral face of the tube-shaped body. Resistance due to deformation of the tube-shaped body when inserting the diameter enlargement tool into the tube-shaped body can accordingly be reduced. This enables a reduction in the load required to insert the diameter enlargement tool into the tube-shaped body. The load required to enlarge the diameter of the tube-shaped body can be reduced as a result.
  • the heat exchanger manufacturing method and the diameter enlargement tool of the present invention enable a reduction in the load required to enlarge the diameter of a tube-shaped body.
  • FIG. 1 is a cross-section taken along the axial direction of a tube-shaped body to explain a diameter enlargement process of a heat exchanger manufacturing method of a first exemplary embodiment.
  • FIG. 2 is a cross-section taken along line 2 X- 2 X in FIG. 1 .
  • FIG. 3 is a cross-section taken along line 3 X- 3 X in FIG. 1 .
  • FIG. 4A is a perspective view illustrating a diameter enlargement tool employed in a heat exchanger manufacturing method of the first exemplary embodiment.
  • FIG. 4B is a front view of the diameter enlargement tool illustrated in FIG. 4A .
  • FIG. 4C is a side view of the diameter enlargement tool illustrated in FIG. 4A .
  • FIG. 5 is a cross-section taken along the axial direction of a tube-shaped body of a heat exchanger manufactured using a heat exchanger manufacturing method of the first exemplary embodiment.
  • FIG. 6A is a perspective view illustrating a first modified example of a diameter enlargement tool employed in the first exemplary embodiment.
  • FIG. 6B is a front view of the diameter enlargement tool of the first modified example illustrated in FIG. 6A .
  • FIG. 6C is a side view of the diameter enlargement tool of the first modified example illustrated in FIG. 6A .
  • FIG. 7A is a perspective view illustrating a second modified example of a diameter enlargement tool employed in the first exemplary embodiment.
  • FIG. 7B is a front view of the diameter enlargement tool of the second modified example illustrated in FIG. 7A .
  • FIG. 7C is a side view of the diameter enlargement tool of the second modified example illustrated in FIG. 7A .
  • FIG. 8A is a perspective view illustrating a third modified example of a diameter enlargement tool employed in the first exemplary embodiment.
  • FIG. 8B is a front view of the diameter enlargement tool of the third modified example illustrated in FIG. 8A .
  • FIG. 8C is a side view of the diameter enlargement tool of the third modified example illustrated in FIG. 8A .
  • FIG. 9 is a cross-section taken along an axis-orthogonal direction of a tube-shaped body employed in a heat exchanger of a heat exchanger manufacturing method of a second exemplary embodiment.
  • FIG. 10 is a cross-section taken along an axis-orthogonal direction (corresponding to a cross-section taken along line 2 X- 2 X of FIG. 1 ) of a tube-shaped body pre-diameter enlargement to explain a diameter enlargement process of a heat exchanger manufacturing method of the second exemplary embodiment.
  • FIG. 11 is a cross-section taken along an axis-orthogonal direction (corresponding to a cross-section taken along line 3 X- 3 X of FIG. 1 ) of a tube-shaped body after diameter enlargement to explain a diameter enlargement process of the heat exchanger manufacturing method illustrated in FIG. 10 .
  • FIG. 5 illustrates a heat exchanger 20 manufactured by a heat exchanger manufacturing method of a first exemplary embodiment.
  • the heat exchanger 20 of the present exemplary embodiment is installed in an air conditioner, and is employed in heat exchange with a fluid employed in a heat exchange section of the air conditioner.
  • the present invention is not limited to such a configuration, and the heat exchanger 20 may be installed in a refrigerator and employed to cool a coolant (an example of a fluid) employed in a cooling section of the refrigerator, or may be installed to a vehicle and employed to cool coolant water (an example of a fluid) in an engine cooling device.
  • the heat exchanger 20 of the present exemplary embodiment may be applied to any equipment that performs heat exchange with a fluid.
  • the heat exchanger 20 of the present exemplary embodiment includes a heat transfer tube 30 and fins 40 .
  • the heat transfer tube 30 is an example of a tube-shaped body of the present invention.
  • the heat transfer tube 30 is formed by bending a single metal sheet 31 .
  • the heat transfer tube 30 is formed by rolling up the single metal sheet 31 into a roll shape and joining together at a roll-overlap portion.
  • the heat transfer tube 30 of the present exemplary embodiment is a double-walled rolled tube configured by rolling the metal sheet 31 around twice.
  • part of an inner face 31 B of the metal sheet 31 rolled up into a roll shape configures a tube inner face 30 B
  • part of an outer face 31 A of the metal sheet 31 rolled up into a roll shape configures a tube outer face 30 A.
  • the tube outer face 30 A indicates the outer peripheral face of the heat transfer tube 30
  • the tube inner face 30 B indicates the inner peripheral face of the heat transfer tube 30 .
  • the axial direction of the heat transfer tube 30 is indicated by the direction of arrow A.
  • the inner face 31 B of the metal sheet 31 rolled up into a roll shape is formed with an inside stepped face 32 B between a peripheral inside edge portion 31 C and a peripheral outside edge portion 31 D.
  • the edge portion 31 C of the metal sheet 31 rolled up into a roll shape is joined to the inside stepped face 32 B.
  • the outer face 31 A of the metal sheet 31 rolled up into a roll shape is formed with an outside stepped face 32 A between the edge portion 31 C and the edge portion 31 D.
  • the edge portion 31 D of the metal sheet 31 rolled up into a roll shape is joined to the outside stepped face 32 A.
  • an intermediate portion (roll-up direction intermediate portion) between the edge portion 31 C and the edge portion 31 D of the metal sheet 31 rolled up into a roll shape is bent into a substantially crank shape, forming a stepped portion 32 .
  • One face (the face configuring the inner face 31 B) of the thus formed stepped portion 32 configures the inside stepped face 32 B, and the other face (the face configuring the outer face 31 A) configures the outside stepped face 32 A.
  • the metal sheet 31 forming the heat transfer tube 30 is a metal sheet with a core formed from a metal material affixed with a covering member formed from a metal material with a lower melting point than the core, namely a clad sheet.
  • the metal sheet 31 is configured by aluminum.
  • the metal sheet 31 is formed by affixing a covering member formed from an aluminum alloy (for example, aluminum impregnated with silicon) to a core formed from pure aluminum.
  • the covering member forms the outer face 31 A of the metal sheet 31 rolled up into a roll shape.
  • the covering member is moreover employed as a joining material (brazing filler) for joining together the roll-overlap portion of the metal sheet 31 rolled up into a roll shape.
  • the core forms the inner face 31 B of the metal sheet 31 rolled up into a roll shape.
  • the metal sheet 31 is configured by aluminum, however the present invention is not limited to such a configuration, and the metal sheet 31 may be configured from a metal material such as copper or iron.
  • the fins 40 are configured by forming a metal material (for example aluminum) into plate shapes.
  • the fins 40 are formed with through holes 42 penetrating in the plate thickness direction. Specifically, the through holes 42 are formed in the fins 40 by burring.
  • the heat transfer tube 30 is inserted through the through holes 42 , and the tube outer face 30 A, that is the outer peripheral face of the heat transfer tube 30 , is joined to hole walls 42 A. Note that in the present exemplary embodiment, the tube outer face 30 A of the heat transfer tube 30 is joined to hole walls 42 A configuring inner walls of ring shaped stand-out portions 44 formed by burring the fins 40 .
  • the heat exchanger 20 plural of the heat transfer tubes 30 are arranged parallel to each other in a row, and end portions of adjacent heat transfer tubes 30 are coupled together by U-shaped tube connectors. Each of the heat transfer tubes 30 is inserted through respective through holes 42 of the plural fins 40 , and the respective tube outer faces 30 A are joined to the respective hole walls 42 A.
  • the flat plate shaped metal sheet 31 is prepared, with the covering member affixed to the core.
  • the metal sheet 31 is rolled up into a roll shape to form the heat transfer tube 30 (pre-diameter enlargement heat transfer tube) that is an example of a tube-shaped body (see FIG. 2 ).
  • the metal sheet 31 is rolled up into a roll shape using a roll forming machine, namely by roll forming, to form the heat transfer tube 30 .
  • the metal sheet 31 is rolled up into a roll shape such that the external diameter of the heat transfer tube 30 is smaller than the diameter of the through holes 42 formed in the fins 40 (see FIG. 1 ).
  • the metal sheet 31 rolled up into a roll shape is inserted through the through holes 42 formed in the fins 40 .
  • the metal sheet 31 rolled up into a roll shape is then loosened to enlarge the diameter of the heat transfer tube 30 , placing the tube outer face 30 A of the heat transfer tube 30 in contact with the hole walls 42 A of the through holes 42 of the fins 40 .
  • a diameter enlargement tool 50 with a larger external diameter than the internal diameter of the heat transfer tube 30 pre-diameter enlargement is inserted inside the pre-diameter enlargement heat transfer tube 30 , forcibly loosening the metal sheet 31 rolled up into a roll shape to enlarge the diameter of the heat transfer tube 30 .
  • the external diameter of the diameter enlargement tool 50 is set at a size to enlarge the diameter of the heat transfer tube 30 far enough for the tube outer face 30 A to contact the hole walls 42 A.
  • the stepped portion 32 is formed between the edge portion 31 C and the edge portion 31 D of the metal sheet 31 rolled up into a roll shape.
  • the edge portion 31 C is disposed facing the inside stepped face 32 B of the stepped portion 32
  • the edge portion 31 D is disposed facing the outside stepped face 32 A of the stepped portion 32 .
  • the metal sheet 31 rolled up into a roll shape is heated together with the fins 40 , melting the covering member, and then the covering member is cooled and hardened in a close contact state of the roll-overlap portion of the metal sheet 31 rolled up into a roll shape, thereby joining (brazing) the roll-overlap portion of the metal sheet 31 rolled up into a roll shape.
  • the covering member forming the outer periphery of the metal sheet 31 rolled up into a roll shape is also joined to the hole walls 42 A of the through holes 42 .
  • the heat exchanger 20 is thereby formed.
  • the diameter enlargement tool 50 is configured including a circular column-shaped main body 52 that is inserted inside the heat transfer tube 30 , ribs 54 provided at an outer peripheral face 52 A of the main body 52 , and inclined portions 56 formed at insertion direction leading end portions of the ribs 54 .
  • the insertion direction of the main body 52 is the same direction as the insertion direction of the diameter enlargement tool 50 , and the insertion direction of the main body 52 is indicated by the direction of arrow B in the drawings.
  • the ribs 54 project out from the outer peripheral face 52 A of the main body 52 , and extend from the insertion direction leading end side of the main body 52 toward the opposite side to the insertion direction. Plural of the ribs 54 are provided at intervals around the circumferential direction of the main body 52 (the direction indicated by arrow C in the drawings). Apex portions 54 A of the ribs 54 are configured so as to contact the tube inner face 30 B of the heat transfer tube 30 .
  • the external diameter of the diameter enlargement tool 50 refers to the external diameter of a circle that passes through the locations of the ribs 54 most distant from the axial center of the main body 52 (portions of the apex portions 54 A).
  • the ribs 54 extend in straight line shapes toward the opposite side to the insertion direction of the main body 52 .
  • a separation L between respective contact portions where two of the ribs 54 , disposed on each side of the edge portion 31 C of the metal sheet 31 rolled up into a roll shape, contact the tube inner face 30 B of the heat transfer tube 30 widens on progression toward the opposite side to the insertion direction of the main body 52 .
  • the inclined portions 56 are configured such that their projection height from the outer peripheral face 52 A of the main body 52 becomes gradually higher on progression toward the opposite side to the insertion direction of the main body 52 .
  • a rod 58 extending from a drive device that inserts the main body 52 into the heat transfer tube 30 , is coupled to the diameter enlargement tool 50 .
  • the metal sheet 31 is rolled up into a roll shape to form the heat transfer tube 30 , and then the metal sheet 31 rolled up into a roll shape is loosened to enlarge the diameter of the heat transfer tube 30 .
  • the load required to enlarge the diameter of the heat transfer tube 30 can accordingly be reduced compared to in a configuration where an extrusion-formed extruded heat transfer tube is stretched in the circumferential direction (stretched around the perimeter) to enlarge the diameter.
  • the diameter enlargement tool 50 that has a larger external diameter than the internal diameter of the heat transfer tube 30 pre-diameter enlargement is inserted inside the heat transfer tube 30 , and the metal sheet 31 rolled up into a roll shape is forcibly loosened to enlarge the diameter of the heat transfer tube 30 .
  • employing the diameter enlargement tool 50 with a larger external diameter than the internal diameter of the heat transfer tube 30 pre-diameter enlargement enables simple diameter enlargement in the heat transfer tube 30 .
  • the ribs 54 of the diameter enlargement tool 50 contact the tube inner face 30 B of the heat transfer tube 30 , thereby enabling a reduction in the contact surface area between the diameter enlargement tool 50 and the tube inner face 30 B of the heat transfer tube 30 , and enabling a reduction in resistance due to deformation of the heat transfer tube 30 when the diameter enlargement tool 50 is inserted into the heat transfer tube 30 .
  • the load required to insert the diameter enlargement tool 50 into the heat transfer tube 30 can accordingly be reduced.
  • the leading end portions of the ribs 54 in the insertion direction of the main body 52 are formed with the inclined portions 56 whose projection height from the outer peripheral face 52 A of the main body 52 gradually increases on progression toward the opposite side to the insertion direction. Accordingly, during insertion of the diameter enlargement tool 50 into the heat transfer tube 30 pre-diameter enlargement, the inclined portions 56 act as guides for the diameter enlargement of the heat transfer tube 30 . The diameter enlargement tool 50 can accordingly be inserted smoothly into the heat transfer tube 30 .
  • the separation L between the respective contact portions where the two ribs 54 disposed on each side of the edge portion 31 C of the metal sheet 31 rolled up into a roll shape contact the tube inner face 30 B of the heat transfer tube 30 widens on progression toward the opposite side of the main body 52 to the insertion direction.
  • the edge portion 31 C of the metal sheet 31 rolled up into a roll shape is imparted with force from the two ribs 54 in the opposite direction to the roll-up direction and moves in the heat transfer tube 30 circumferential direction (indicated by the arrow D in the drawings), thereby loosening the metal sheet 31 rolled up into a roll shape.
  • This enables a reduction in the load required for diameter enlargement of the heat transfer tube 30 .
  • the metal sheet 31 rolled up into a roll shape to form the heat transfer tube 30 is configured by aluminum, thereby enabling a reduction in weight and reduction in costs of the heat exchanger 20 while securing heat transfer efficiency between the heat transfer tube 30 and the fluid passing through the heat transfer tube 30 .
  • Configuring the metal sheet 31 by aluminum enables, for example, a reduction in the load required for diameter enlargement of the heat transfer tube 30 in comparison to when the metal sheet 31 is formed from a material that does not deform so readily, such as steel sheet.
  • the diameter enlargement tool 50 is used to enlarge the diameter of the heat transfer tube 30 formed by rolling up the metal sheet 31 into a roll shape, however the present invention is not limited to such a configuration.
  • the diameter of the heat transfer tube 30 may be enlarged using a diameter enlargement tool 60 of a first modified example, a diameter enlargement tool 70 of a second modified example, or a diameter enlargement tool 80 of a third modified example of the diameter enlargement tool 50 , respectively described below.
  • the diameter enlargement tool 60 of the first modified example, the diameter enlargement tool 70 of the second modified example, and the diameter enlargement tool 80 of the third modified example may also be employed in the manufacturing method of a heat exchanger 22 of a second exemplary embodiment, described later.
  • ribs 64 projecting out from the outer peripheral face 52 A of the main body 52 extend in straight line shapes from an end portion of the main body 52 on the insertion direction side toward the opposite side to the insertion direction.
  • Plural of the ribs 64 are provided at uniform separations around the circumferential direction of the main body 52 . Accordingly, during insertion of the diameter enlargement tool 60 into the heat transfer tube 30 pre-diameter enlargement, the diameter enlargement tool 60 can be inserted into the heat transfer tube 30 pre-diameter enlargement without limitation to the position of the ribs 64 of the diameter enlargement tool 60 .
  • the complexity of the heat transfer tube 30 diameter enlargement operation can accordingly be lessened.
  • the reference numeral 64 A in FIG. 6A to FIG. 6C indicates the apex portions of the ribs 64 .
  • ribs 74 projecting out from the outer peripheral face 52 A of the main body 52 extend in a spiral shape from an end portion of the main body 52 on the insertion direction side toward the opposite side to the insertion direction (specifically, in a spiral shape around the outer peripheral face 52 A of the main body 52 ).
  • the spiral direction of the ribs 74 is the opposite direction to the roll-up direction of the metal sheet 31 rolled up into a roll shape.
  • Plural of the ribs 74 are provided at uniform separations around the circumferential direction of the main body 52 .
  • the metal sheet 31 rolled up into a roll shape is imparted with force from the spiral shaped ribs 74 in the opposite direction to the roll-up direction and is loosened. This enables a reduction in the load required to enlarge the diameter of the heat transfer tube 30 .
  • the reference numeral 74 A in FIG. 7A to FIG. 7C indicates the apex portions of the ribs 74 .
  • ribs 84 projecting out from the outer peripheral face 52 A of the main body 52 extend in straight line shapes from an end portion of the main body 52 on the insertion direction side toward the opposite side to the insertion direction.
  • the width (the length around the circumferential direction of the main body 52 ) of apex portions 84 A of the ribs 84 becomes gradually wider on progression toward the opposite side to the insertion direction of the main body 52 .
  • narrow-width portions of the apex portions 84 A of the ribs 84 contact the tube inner face 30 B of the heat transfer tube 30 first, enabling resistance due to deformation of the heat transfer tube 30 to be lowered, and enabling a reduction in the load required for insertion.
  • Wider-width portions of the apex portions 84 A then contact the tube outer face 30 A of the heat transfer tube 30 , enabling substantially uniform enlargement around the circumference of the tube inner face 30 B of the heat transfer tube 30 .
  • FIG. 9 illustrates a heat transfer tube 90 of the heat exchanger 22 manufactured by a heat exchanger manufacturing method of a second exemplary embodiment. Note that in the present exemplary embodiment, configuration similar to that of the first exemplary embodiment is allocated the same reference numerals, and further explanation thereof is omitted.
  • the heat exchanger 22 of the present exemplary embodiment is of similar configuration to the heat exchanger 20 of the first exemplary embodiment.
  • an inner peripheral face (referred to below as the “tube inner face 90 B”) of the heat transfer tube 90 is formed with an undulating portion 92 .
  • the undulating portion 92 is formed over substantially the entire tube inner face 90 B.
  • the heat transfer tube 90 of the present exemplary embodiment is an example of a tube-shaped body of the present invention.
  • the heat transfer tube 90 is formed by rolling up a metal sheet 31 formed with the undulating portion 92 into a roll shape, and joining at a roll-overlap portion.
  • the heat transfer tube 90 of the present exemplary embodiment is a double-walled rolled tube configured by rolling the metal sheet 31 around twice.
  • part of an inner face 31 B of the metal sheet 31 rolled up into a roll shape configures the tube inner face 90 B
  • part of an outer face 31 A of the metal sheet 31 rolled up into a roll shape configures a tube outer face 90 A.
  • the metal sheet 31 is of similar configuration to the metal sheet 31 of the first exemplary embodiment.
  • the undulating portion 92 is configured by grooves 92 A indented toward the radial direction outside of the heat transfer tube 90 , formed at intervals around the circumferential direction of the heat transfer tube 90 , and extending in a direction intersecting with the axial direction of the heat transfer tube 90 (a direction at an angle in the present exemplary embodiment), and by ridges 92 B that are formed between adjacent grooves 92 A to form projections toward the radial direction inside of the heat transfer tube 90 .
  • the undulating portion of the present invention is not limited to such a configuration.
  • an undulating portion may be configured by forming plural projections and plural recesses on the tube inner face 90 B.
  • the flat plate shaped metal sheet 31 is prepared with the covering member affixed to the core, and the undulating portion 92 is formed to one face of the metal sheet 31 (the face formed by the core). Note that the undulating portion 92 is formed to the one face of the metal sheet 31 in a range corresponding to the tube inner face 90 B.
  • the metal sheet 31 formed on the one face with the undulating portion 92 is rolled up into a roll shape with the undulating portion 92 on the inside to form the heat transfer tube 90 that is an example of a tube-shaped body (see FIG. 10 ).
  • the diameter enlargement tool 50 is used to perform a diameter enlargement process similar to that of the first exemplary embodiment, thereby enlarging the diameter of the heat transfer tube 90 .
  • a joining process similar to that of the first exemplary embodiment is performed in order to form the heat exchanger 22 of the present exemplary embodiment.
  • the metal sheet 31 is rolled up into a roll shape, with the undulating portion 92 formed to the one face on the inside, thereby forming the heat transfer tube 90 with the undulating portion 92 formed at the tube inner face 90 B.
  • Forming the undulating portion 92 in this manner increases the surface area of the tube inner face 90 B of the heat transfer tube 90 , raising the heat transfer efficiency between the heat transfer tube 90 and the fluid passing through inside the heat transfer tube 90 .
  • the manufacturing method of the heat exchanger 22 enables a reduction in the load required to enlarge the diameter of the heat transfer tube 90 , similarly to in the first exemplary embodiment, deformation (squashing deformation) of the undulating portion 92 formed to the tube inner face 90 B can be suppressed when using the diameter enlargement tool 50 to enlarge the diameter of the heat transfer tube 90 . Heat transfer efficiency between the heat transfer tube 90 and the fluid passing through inside the heat transfer tube 90 can accordingly be secured.
  • the stepped portion 32 is formed to the metal sheet 31 during the diameter enlargement process, however the present invention is not limited to such a configuration.
  • the stepped portion 32 may be formed to the metal sheet 31 in advance, prior to the diameter enlargement process. Note that such a configuration, in which the stepped portion 32 is formed to the metal sheet 31 in advance prior to the diameter enlargement process, may also be applied to the second exemplary embodiment.
  • the metal sheet 31 is a clad sheet configured by the core and the covering member, however the present invention is not limited thereto, and the metal sheet 31 may be a metal sheet configured by the core alone.
  • configuration may be made such that molten joining material (brazing filler) is injected into a gap at the roll-overlap portion of the metal sheet 31 of the heat transfer tube 30 after diameter enlargement to join together the roll-overlap portion of the metal sheet 31 .
  • one or both faces of the fins 40 may be formed from an aluminum alloy (brazing filler), and heated together with the heat transfer tube 30 after diameter enlargement such that the roll-overlap portion of the metal sheet 31 is joined by the melted aluminum alloy.
  • Such a configuration may also be applied to the second exemplary embodiment.
  • the heat transfer tube 30 is a double-walled rolled tube configured by rolling the metal sheet 31 around twice, however the present invention is not limited to such a configuration, and the metal sheet 31 may be rolled around more than twice to configure a multi-ply rolled tube. Such a configuration may also be applied to the heat transfer tube 90 of the second exemplary embodiment.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
  • Details Of Heat-Exchange And Heat-Transfer (AREA)
US15/115,069 2014-01-29 2014-10-15 Heat exchanger manufacturing method and diameter enlargement tool Abandoned US20160361749A1 (en)

Applications Claiming Priority (3)

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JP2014-014650 2014-01-29
JP2014014650A JP6327868B2 (ja) 2014-01-29 2014-01-29 熱交換器の製造方法
PCT/JP2014/077473 WO2015114888A1 (ja) 2014-01-29 2014-10-15 熱交換器の製造方法及び拡径治具

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JP (1) JP6327868B2 (ja)
CN (1) CN105939797A (ja)
AR (1) AR099736A1 (ja)
DE (1) DE112014006290T5 (ja)
WO (1) WO2015114888A1 (ja)

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US20210190442A1 (en) * 2017-10-27 2021-06-24 China Petroleum & Chemical Corporation Heat transfer enhancement pipe as well as cracking furnace and atmospheric and vacuum heating furnace including the same
CN114871532A (zh) * 2022-07-11 2022-08-09 四川空分设备(集团)有限责任公司 一种换热管与管板手工深孔焊方法
US20220282936A1 (en) * 2021-03-03 2022-09-08 Rheem Manufacturing Company Finned tube heat exchangers and methods for manufacturing same

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CN106040904B (zh) * 2016-07-28 2018-03-30 海信（广东）空调有限公司 一种管翅式换热器的生产方法及管翅式换热器
CN108067562B (zh) * 2016-11-14 2019-06-07 丹佛斯微通道换热器（嘉兴）有限公司 换热器的组装方法
JP7154747B2 (ja) * 2016-11-25 2022-10-18 株式会社デンソーエアクール 熱交換器および熱交換器の製造方法
JP6913657B2 (ja) * 2018-07-26 2021-08-04 三桜工業株式会社 多重巻管の成形装置及び多重巻管の成形方法
JP7243104B2 (ja) * 2018-09-27 2023-03-22 株式会社ノーリツ 熱交換器およびその製造方法

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CN114871532A (zh) * 2022-07-11 2022-08-09 四川空分设备(集团)有限责任公司 一种换热管与管板手工深孔焊方法

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JP6327868B2 (ja) 2018-05-23
JP2015139811A (ja) 2015-08-03
DE112014006290T5 (de) 2016-11-03
CN105939797A (zh) 2016-09-14
AR099736A1 (es) 2016-08-17

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