WO2023051829A1 - 换热器和换热器加工方法 - Google Patents

换热器和换热器加工方法 Download PDF

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Publication number
WO2023051829A1
WO2023051829A1 PCT/CN2022/123596 CN2022123596W WO2023051829A1 WO 2023051829 A1 WO2023051829 A1 WO 2023051829A1 CN 2022123596 W CN2022123596 W CN 2022123596W WO 2023051829 A1 WO2023051829 A1 WO 2023051829A1
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WO
WIPO (PCT)
Prior art keywords
wall
tube
heat exchanger
header
heat exchange
Prior art date
Application number
PCT/CN2022/123596
Other languages
English (en)
French (fr)
Inventor
王东
童仲尧
钟笑鸣
Original Assignee
杭州三花微通道换热器有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Priority claimed from CN202111165535.0A external-priority patent/CN115876024A/zh
Priority claimed from CN202122411190.4U external-priority patent/CN216282894U/zh
Application filed by 杭州三花微通道换热器有限公司 filed Critical 杭州三花微通道换热器有限公司
Publication of WO2023051829A1 publication Critical patent/WO2023051829A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D7/16—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation

Definitions

  • the present application relates to the technical field of heat exchange, in particular to a heat exchanger and a heat exchanger processing method.
  • the heat exchanger includes a header and a heat exchange tube, the heat exchange tube is a folded flat tube, and the folded flat tube is formed by folding a plate, and the two ends of the folded flat tube are respectively connected to the header, and the heat exchanger is Among them, the header and multiple heat exchange tubes are fixed by welding, and the heat exchanger is prone to local stress concentration due to temperature changes and distribution differences during the welding process, resulting in deformation or even leakage of the heat exchange tubes. affect the reliability of the heat exchanger.
  • the present application provides a heat exchanger and a processing method for the heat exchanger, which are beneficial to reducing the stress concentration during the processing of the heat exchange tubes and improving the reliability and service life of the heat exchanger.
  • the first aspect of the present application provides a heat exchanger comprising: a first header and a second header; a heat exchange tube, the heat exchange tube communicates with the first header and the second header;
  • the The heat exchange tube includes a folded pipe section, which is formed by folding and welding an alloy plate, and the folded pipe section includes one or more channels extending along its length; there are multiple folded pipe sections, and the folded pipe sections are formed along the The length direction of the first header is arranged at intervals;
  • the folded pipe section includes a pipe wall, and the pipe wall includes a first seam, and the first seam extends along the length direction of the folded pipe section;
  • the pipe wall includes a pipe wall along the The first wall and the second wall arranged in the thickness direction of the folded pipe section, the second wall includes the first slit; one end in the length direction of the first header includes a first end surface, and the first header includes a first end surface.
  • the other end in the length direction includes a second end surface;
  • the heat exchanger includes X folded pipe sections, any one of the X folded pipe sections is between the first wall of the folded pipe section and the first end surface
  • the minimum distance is smaller than the minimum distance between the second wall of the folded pipe section and the first end surface, and the minimum distance between the first wall of the folded pipe section and the first end surface is smaller than the minimum distance between the first wall and the first end surface
  • the heat exchanger also includes Y folded tube sections, and the first wall of any one of the Y folded tube sections is connected to the second
  • the minimum distance between the end surfaces is smaller than the minimum distance between the second wall of the folded pipe section and the first end surface, and the minimum distance between the first wall of the folded pipe section and the second end surface is less than The distance between it and the first end face is Y ⁇ 1.
  • the first walls of the X folded tube sections are closer to the first end surface than the second walls of the folded tube sections, and the X folded tube sections are closer to the first end surface than the second end surface , X ⁇ 1, that is to say, among the folded pipe sections near the first end surface, at least one folded pipe section has its second wall away from the first end surface;
  • the wall is closer to the second end surface, and the Y folded pipe sections are closer to the second end surface than the first end surface, Y ⁇ 1, that is, among the folded pipe sections close to the second end surface, at least one of the folded pipe sections has the first
  • the second wall is away from the second end surface.
  • this structure makes the heat exchanger have two kinds of folded pipe sections with different orientations of the weld seams.
  • the temperature difference between the inside and outside is large, so that the folded pipe sections have the first seam Compared with the first wall, the second wall is easier to concentrate thermal stress.
  • the orientation of the first slit it is beneficial to reduce the local stress concentration of the heat exchanger, thereby improving the reliability and corrosion resistance of the heat exchanger.
  • the section of the heat exchange tube is a flat tube
  • the first header includes a third wall and a first channel surrounded by the third wall
  • the heat exchanger satisfies the following relationship:
  • D is the hydraulic diameter of the first header
  • d is the thickness of the third wall
  • H is the distance between two adjacent folded pipe sections in the length direction of the first header
  • h is The thickness of the alloy plate.
  • the heat exchanger further includes fins, part of the fins is located between the adjacent folded tube sections in the length direction of the first header, and the part of the fins is The height is H1, and the heat exchanger satisfies the following relationship:
  • D is the hydraulic diameter of the first header
  • d is the thickness of the third wall
  • h is the thickness of the alloy plate
  • indicates rounding.
  • the first header includes a third wall and a first channel surrounded by the third wall, and the heat exchanger satisfies the following relationship:
  • D is the hydraulic diameter of the first header
  • d is the thickness of the third wall
  • H is the distance between two adjacent folded pipe sections in the length direction of the first header
  • h is the The thickness of the above alloy plate.
  • the thickness of the tube wall is less than or equal to 0.5mm
  • the thickness dimension of the tube wall is less than or equal to the thickness dimension of the alloy plate
  • the first header includes a third wall and the third The wall surrounds the first channel formed, and the heat exchanger satisfies the following relationship:
  • D is the hydraulic diameter of the first header
  • d is the thickness of the third wall
  • H is the distance between two adjacent folded pipe sections in the length direction of the first header
  • h is The thickness of the alloy plate.
  • the number of channels contained in the folded tube section is greater than 8
  • the first header includes a third wall and a first channel surrounded by the third wall
  • the heat exchanger satisfies the following relation:
  • D is the hydraulic diameter of the first header
  • d is the thickness of the third wall
  • H is the distance between two adjacent folded pipe sections in the length direction of the first header
  • h is The thickness of the alloy plate.
  • the folded pipe section includes a main body and a bent part, at least part of the bent part has a length direction that is not parallel to the length direction of the main body.
  • the first header, the bent part and the main body part are arranged in sequence; at least part of the first wall of the bent part is compared with The first wall of the main body portion is closer to the first end surface, and the second wall of the partially bent portion is farther away from the second end surface than the second wall of the main body portion.
  • the heat exchange tubes include a plurality of straight parts and bent parts
  • the straight parts include folded tube sections
  • one end of the bent part communicates with one straight part
  • the other end of the bent part communicates with the other
  • One straight portion is connected
  • the length direction of one straight portion is parallel to or angled to the length direction of the other straight portion, and there are one or more bent portions.
  • the first seam is filled with solder.
  • the second aspect of the present application provides a heat exchanger manufacturing method.
  • the heat exchanger manufacturing method includes the following steps: preparing a plurality of heat exchange tube semi-finished products, and the heat exchange tube semi-finished products include the first a first wall and a second wall, the heat exchange tube semi-finished product has a first gap, the first gap penetrates the second wall along the thickness direction, or the first gap is formed at the end of the first wall part and the end of the second wall; arrange N semi-finished heat exchange tubes along the first direction at predetermined intervals, N>4, and the thickness direction of the semi-finished heat exchange tubes is the same as that of the first The directions are parallel or at an angle.
  • the semi-finished products of the heat exchange tubes placed by definition are the first tube, the second tube, ...
  • pipe so that in the first direction, the minimum distance between the second wall of the first pipe and the first wall of the second pipe is L1, and the first wall of the first pipe and the first wall of the first pipe 2
  • the minimum distance between the first wall of the tube is L2, L1 is smaller than L2;
  • the second wall of the Nth tube is placed towards the N-1th tube, so that the second wall of the Nth tube
  • the wall is closer to the N-1th tube in the first direction than the first wall of the Nth tube, so that in the first direction, the Nth tube
  • the minimum distance between the second wall and the first wall of the N-1th tube is smaller than the minimum distance between the first wall of the N-th tube and the first wall of the N-1th tube.
  • the second walls of the heat exchange tube semi-finished products at the two edges face the inner side of the heat exchanger, since the second wall of the heat exchange tube semi-finished product has a first gap,
  • the heat exchanger expands with heat and contracts with cold during the welding process, which makes the second wall of the semi-finished heat exchange tube more easily deformed than the first wall.
  • the first gap faces the inner side of the heat exchanger , which is beneficial to reduce the local stress concentration of the heat exchanger, thereby improving the reliability and service life of the heat exchanger.
  • the heat exchanger processing method further includes the step of placing the second wall of the second tube facing the third tube, and the second wall of the second tube is compared to the second wall of the second tube.
  • the first wall of the second tube is closer to the third tube in the first direction, so that in the first direction, the second wall of the second tube is closer to the first wall of the third tube.
  • the minimum distance of a wall is smaller than the minimum distance between the first wall of the second tube and the first wall of the third tube;
  • the second wall of the N-1 tube is placed towards the N-2 tube , the second wall of the N-1-th tube is closer to the N-2-th tube in the first direction than the first wall of the N-1-th tube, so that in the first direction, the minimum distance between the second wall of the N-1-th tube and the first wall of the N-2-th tube is smaller than the distance between the first wall of the N-1-th tube and the N-2-th tube
  • the minimum distance to the first wall is smaller than the minimum distance between the first wall of the second tube and
  • the heat exchanger processing method further includes the step of placing the second wall of the Mth tube facing the M+1th tube, 2 ⁇ M ⁇ N/2, and the second wall of the Mth tube is The second wall of the M tube is closer to the M+1th tube in the first direction than the first wall of the Mth tube, so that in the first direction, the Mth tube
  • the minimum distance between the second wall of the tube and the first wall of the M+1-th tube is smaller than the minimum distance between the first wall of the M-th tube and the first wall of the M+1-th tube.
  • the heat exchanger processing method further includes the step of placing the second wall of the L-th tube toward the L-1-th tube, N/2 ⁇ L ⁇ N, and the L-th tube
  • the second wall of the L tube is closer to the L-1-th tube in the first direction than the first wall of the L-th tube, so that in the first direction, the L-th tube
  • the minimum distance between the second wall of the L-1th tube and the first wall of the L-1-th tube is smaller than the minimum distance between the first wall of the L-th tube and the first wall of the L-1-th tube.
  • the heat exchanger processing method further includes the step of placing the second wall of the third tube facing the fourth tube, and the second wall of the third tube is compared to the second wall of the third tube.
  • the first wall of the third tube is closer to the fourth tube in the first direction, so that in the first direction, the second wall of the third tube is closer to the first wall of the fourth tube.
  • the minimum distance of one wall is less than the minimum distance between the first wall of the third tube and the first wall of the fourth tube; the second wall of the fourth tube is placed towards the fifth tube, and the first 4.
  • the second wall of the fourth tube is closer to the fifth tube in the first direction than the first wall of the fourth tube, so that in the first direction, the first wall of the fourth tube.
  • the minimum distance between the second wall and the first wall of the fifth pipe is less than the minimum distance between the first wall of the fourth pipe and the first wall of the fifth pipe; wall is placed towards the 6th tube, the second wall of the 5th tube is closer to the 6th tube in the first direction than the first wall of the 5th tube, so that in the first Directionally, the minimum distance between the second wall of the fifth tube and the first wall of the sixth tube is smaller than the minimum distance between the first wall of the fifth tube and the first wall of the sixth tube.
  • the heat exchanger processing method further includes the step of placing the second walls of the first to N/2th tubes facing the Nth tube, and the first The second wall of the pipe to the N/2th pipe is closer to the Nth pipe in the first direction than the first wall of the N/2th pipe, so that in the first direction upward, the minimum distance between the first pipe to the second wall of the N/2th pipe and the first wall of the Nth pipe is smaller than the first wall from the first pipe to the N/2th pipe
  • the minimum distance from the first wall of the Nth tube; the second wall of the N/2+1th tube to the Nth tube is placed towards the first tube, and the N/2+th tube
  • the second wall of the first tube to the Nth tube is closer to the first tube in the first direction than the first wall of the N/2+1th tube, so that in the first direction Upward, the minimum distance between the N/2+1th pipe and the second wall of the Nth pipe and the first wall of the first pipe is smaller than the N/2+1th pipe to the Nth pipe.
  • the heat exchanger processing method further includes the following steps: providing a first header and a second header, and connecting the first header with a plurality of heat exchange tube semi-finished products in the length direction One end is directly or indirectly connected, and the other end of the plurality of semi-finished heat exchange tubes in the length direction is directly or indirectly connected to the second header.
  • the heat exchanger processing method further includes the step of providing fins, and placing the fins between two semi-finished heat exchange tubes adjacent in the first direction; Or fins are provided, and part of the fins is placed between two adjacent heat exchange tube semi-finished products in the first direction.
  • the heat exchange tube semi-finished product, the first header, the second header and the fins together form a core assembly
  • the heat exchanger processing method further includes the following steps, The core assembly is installed with other accessories, and the core assembly is brazed so that the heat exchange tube semi-finished product is fixedly connected with the first header and the second header, so that the heat exchange tube semi-finished product It is fixedly connected with the fins, and the heat exchange tube semi-finished product is brazed to become a heat exchange tube.
  • the third aspect of the present application provides a heat exchanger produced by the heat exchanger processing method described in any one of the above embodiments.
  • Fig. 1 is a flow chart of a heat exchanger processing method provided in the embodiment of the present application
  • Fig. 2 is a flow chart of another heat exchanger processing method provided by the embodiment of the present application.
  • Fig. 3 is a flow chart of another heat exchanger processing method provided by the embodiment of the present application.
  • Fig. 4 is a flowchart of another heat exchanger processing method provided by the embodiment of the present application.
  • Fig. 5 is a flowchart of another heat exchanger processing method provided by the embodiment of the present application.
  • Fig. 6 is a flow chart of another heat exchanger processing method provided by the embodiment of the present application.
  • Fig. 7 is a schematic structural view of a heat exchanger according to an embodiment of the present application.
  • Fig. 8 is a partial structural schematic diagram of the heat exchanger shown in Fig. 7;
  • Fig. 9 is a structural schematic diagram of a folded pipe section according to an embodiment of the present application.
  • Fig. 10 is a schematic cross-sectional structure diagram of the folded pipe section shown in Fig. 9;
  • Fig. 11 is a structural schematic diagram of a folded pipe section according to another embodiment of the present application.
  • Fig. 12 is a schematic cross-sectional structural view of the folded pipe section shown in Fig. 11;
  • Fig. 13 is a schematic structural view of a heat exchanger according to another embodiment of the present application, wherein the fins are not shown;
  • Fig. 14 is a schematic structural view of the folded pipe section in the heat exchanger shown in Fig. 13;
  • Fig. 15 is a schematic structural view of a heat exchanger according to yet another embodiment of the present application, wherein the fins are not shown;
  • Fig. 16 is a schematic structural view of the folded pipe section in the heat exchanger shown in Fig. 15;
  • Fig. 17 is a schematic structural view of a heat exchanger according to yet another embodiment of the present application.
  • Fig. 18 is a schematic structural view of a heat exchanger according to yet another embodiment of the present application.
  • Figure 19 is the relationship between the thickness and reliability of the heat exchanger alloy plate provided by the embodiment of the present application.
  • Fig. 20 is the relationship between heat exchangers X, Y and reliability according to an embodiment of the present application.
  • the embodiment of the present application provides a heat exchanger processing method, which includes the following steps: step S10, preparing a plurality of heat exchange tube semi-finished products, and the heat exchange tube semi-finished products are made of The alloy plate is folded and formed. Compared with the heat exchange tube obtained after processing, the semi-finished heat exchange tube has roughly the same shape and structure, but the parts of the folded plate have not been fixedly connected by welding.
  • the heat exchange tube semi-finished product includes one or more channels extending along its length direction, the heat exchange tube semi-finished product includes a first wall and a second wall arranged along its thickness direction, the heat exchange tube semi-finished product has a first gap, and the first gap is along the thickness direction.
  • the direction runs through the second wall, or the first gap is formed between the end of the first wall and the end of the second wall, in other words, the end of the first wall is the first bend and the end of the second wall is
  • the first bending part is sleeved on the outer peripheral surface of the second bending part, and the first bending part and the second bending part are arranged at intervals to form a first gap; step S20, N
  • the semi-finished heat exchange tubes are arranged at predetermined intervals along the first direction, N>4, and the thickness direction of the semi-finished heat exchange tubes is parallel to or at an angle to the first direction.
  • the direction can be from top to bottom, and the first direction can also be from bottom to top), and the semi-finished heat exchange tubes placed in the definition are the first tube, the second tube, ... the N-1 tube, the N-1 tube N tubes; step S30, adjusting the orientation of the second wall of some of the heat exchange tube semi-finished products, so that the first gaps of all the heat exchange tube semi-finished products included in the heat exchanger have two different orientations, because the second heat exchange tube semi-finished products
  • the wall has a first gap, and the temperature change and distribution difference of the heat exchanger during the welding process make the second wall of the heat exchange tube semi-finished product more likely to be deformed relative to the first wall or the first gap is poorly welded.
  • the orientation of the gap is beneficial to reduce the local stress concentration of the heat exchanger, thereby improving the reliability and service life of the heat exchanger.
  • the first gap is filled with molten solder, and the first gap will be welded to form a joint weld (ie, the first seam 44 hereinafter), so that the heat exchange tube semi-finished product will form Sealed heat exchange tube sections.
  • the solder in the first gap is heated and melted, and when the temperature drops, the melted solder condenses again, thereby realizing the sealing of the first gap.
  • the first gap existing on the surface of the heat exchange tube semi-finished product during the welding process of the heat exchanger, the first gap will be welded to form a joint weld, but the deformation of the heat exchange tube is unfavorable to the welding of the first gap Influenced by the influence, the first gaps of all the heat exchange tube semi-finished products of the heat exchanger provided in the embodiment of the present application have two different orientations. Since the second wall of the heat exchange tube semi-finished products has the first gap, the heat exchanger is welded during the welding process.
  • the second wall of the semi-finished heat exchange tube is more likely to deform than the first wall, and by changing the orientation of the first seam, it is beneficial to reduce the local stress concentration of the heat exchanger, thereby improving the reliability of the heat exchanger and service life.
  • the heat exchanger processing method provided in the embodiment of the present application further includes step S40: providing a first header and a second header, both of the first header and the second header extend along the first direction;
  • the tube is directly or indirectly connected to one end of the plurality of heat exchange tube semi-finished products in the length direction, and the other end of the plurality of heat exchange tube semi-finished products in the length direction is directly or indirectly connected to the second header.
  • the heat exchanger processing method provided in the embodiment of the present application further includes step S50: providing fins, placing the fins between two semi-finished heat exchange tubes adjacent in the first direction; or providing fins, placing Part of the fins is placed between two adjacent semi-finished heat exchange tubes in the first direction.
  • the heat exchange tube semi-finished product, the first header, the second header and the fins together form the core assembly
  • the heat exchanger processing method provided in the embodiment of the present application further includes step S60: installing the core assembly with other accessories , brazing the core assembly, so that the semi-finished heat exchange tube is fixedly connected with the first header and the second header, and the semi-finished heat exchange tube is fixedly connected with the fins, and the semi-finished heat exchange tube is brazed to become a heat exchange tube .
  • step S30 includes step S31.
  • Step S31 specifically includes: placing the second wall of the first tube toward the second tube, the second wall of the first tube is closer to the second tube in the first direction than the first wall of the first tube, so that In the first direction, the minimum distance between the second wall of the first tube and the first wall of the second tube is smaller than that of the first wall of the first tube, which is closer to the first wall of the second tube in the first direction.
  • the second wall of the Nth tube is placed towards the N-1th tube, the second wall of the Nth tube is closer to the N-1th tube in the first direction than the first wall of the Nth tube, so that in the first direction, the minimum distance between the second wall of the Nth tube and the first wall of the N-1th tube is smaller than the minimum distance between the first wall of the Nth tube and the first wall of the N-1th tube It is closer to the N-1th tube in the first direction than the first wall of the Nth tube.
  • the second wall of the heat exchange tube semi-finished product on the two edges of the heat exchanger faces the inner side of the heat exchanger.
  • the heat exchanger is welded during the welding process.
  • Medium heat expansion and cold contraction make the second wall of the heat exchange tube semi-finished product easier to deform than the first wall.
  • the first gap faces the inner side of the heat exchanger, which is beneficial to reduce the heat exchanger. Local stress concentration, thereby improving the reliability and service life of the heat exchanger.
  • step S30 further includes step S32, that is, step S30 includes step S31 and step S32.
  • Step S32 specifically includes: placing the second wall of the second tube toward the third tube, the second wall of the second tube is closer to the third tube in the first direction than the first wall of the second tube, so that In the first direction, the minimum distance between the second wall of the second tube and the first wall of the third tube is smaller than the minimum distance between the first wall of the second tube and the first wall of the third tube;
  • the second wall is placed towards the N-2th tube, and the second wall of the N-1th tube is closer to the N-2th tube in the first direction than the first wall of the tube, so that in the first direction,
  • the minimum distance between the second wall of the N-1 th tube and the first wall of the N-2 th tube is smaller than the minimum distance between the first wall of the N-1 th tube and the first wall of the N-2 th tube.
  • the inner side of the heat exchanger further reduces the local stress concentration of the heat exchanger, thereby improving the reliability and service life of the heat exchanger.
  • step S30 further includes step S33 , that is, step S30 includes step S31 , step S32 and step S33 .
  • Step S33 specifically includes: placing the second wall of the Mth tube towards the M+1th tube, 2 ⁇ M ⁇ N/2, the second wall of the Mth tube is at the first side compared to the first wall of the Mth tube Upwards closer to the M+1th tube, so that in the first direction, the minimum distance between the second wall of the Mth tube and the first wall of the M+1th tube is smaller than the first wall of the Mth tube and the M+1th tube The minimum distance from the first wall of the tube.
  • step S30 further includes step S34 , that is, step S30 includes step S31 , step S32 , step S33 and step S34 .
  • Step S34 specifically includes: placing the second wall of the L-th tube toward the L-1-th tube, N/2 ⁇ L ⁇ N, and the second wall of the L-th tube is at the first The direction is closer to the L-1th tube, so that in the first direction, the minimum distance between the second wall of the L-th tube and the first wall of the L-1th tube is smaller than the first wall of the L-th tube and the L-th tube. 1 Minimum distance from the first wall of the pipe.
  • step S33 may specifically include: placing the second wall of the third tube toward the fourth tube, and the second wall of the third tube is compared to the first wall of the third tube.
  • One wall is closer to the 4th tube in the first direction, so that in the first direction, the minimum distance between the second wall of the 3rd tube and the first wall of the 4th tube is smaller than the first wall of the 3rd tube and the 4th tube.
  • Minimum distance from the first wall of the tube place the second wall of the 4th tube towards the 5th tube, the second wall of the 4th tube is closer to the 5th tube in the first direction than the first wall of the 4th tube , so that in the first direction, the minimum distance between the second wall of the 4th pipe and the first wall of the 5th pipe is smaller than the minimum distance between the first wall of the 4th pipe and the first wall of the 5th pipe;
  • the second wall of the tube is placed towards the sixth tube, the second wall of the fifth tube is closer to the sixth tube in the first direction than the first wall of the fifth tube, so that in the first direction, the fifth tube
  • the minimum distance between the second wall of the first tube and the first wall of the sixth tube is smaller than the minimum distance between the first wall of the fifth tube and the first wall of the sixth tube.
  • step S30 includes step S31 and step S35.
  • Step S35 specifically includes: placing the second walls of the first tube to the N/2th tube facing the Nth tube, and the second walls of the first tube to the N/2th tube are compared with the first walls of the N/2th tube. The wall is closer to the Nth tube in the first direction, so that in the first direction, the minimum distance between the second wall of the first tube to the N/2th tube and the first wall of the Nth tube is smaller than that of the first tube to the Nth tube.
  • the second wall to the Nth tube is closer to the first tube in the first direction than the first wall of the N/2+1th tube, so that in the first direction, the N/2+1th tube to the first tube
  • the minimum distance between the second wall of the N tube and the first wall of the first tube is smaller than the minimum distance between the first wall of the N/2+1 tube and the first wall of the N tube and the first wall of the first tube; so that all heat transfer
  • the first gaps of the tube semi-finished products all face the inner side of the heat exchanger, so as to reduce the local stress concentration of the heat exchanger as much as possible, thereby improving the reliability and service life of the heat exchanger.
  • the embodiment of the present application provides a heat exchanger 100, the heat exchanger 100 includes a first header 1, a second header 2 and a heat exchange tube 4, the heat exchange tube 4 communicates First header 1 and second header 2.
  • the heat exchange tube 4 only includes a folded pipe section, which is formed by folding and welding an alloy sheet, and the folded pipe section includes one or more channels extending along its length direction; there are multiple folded pipe sections, and the folded pipe sections are formed along the The length direction of the pipe 1 is arranged at intervals; the folded pipe section includes a pipe wall, and the pipe wall includes a first slit 44, and the first slit 44 extends along the length direction of the folded pipe section; the pipe wall includes a first wall 40 arranged along the thickness direction of the folded pipe section and The second wall 42, the second wall 42 includes a first slit 44; one end in the length direction of the first header 1 includes a first end face 10, and the other end in the length direction of the first header 1 includes a second end face 12; X
  • the first wall 40 of each folded pipe section is closer to the first end surface 10 than the second wall 42 of the folded pipe section, and the X folded pipe sections are closer to the first end surface 10 than the second end surface 12, X ⁇ 1, That is to say, among
  • This structure makes the first slits 44 of all the folded tube sections included in the heat exchanger 100 have two different orientations. Since the second wall of the heat exchange tube has the first slits, the temperature difference between the inside and outside of the heat exchanger 100 is relatively large during operation. , so that the second wall 42 of the folded pipe section is more likely to generate local stress concentration relative to the first wall 40, and by changing the orientation of the first slit 44, it is beneficial to reduce the local stress concentration of the heat exchanger 100, thereby improving the reliability of the heat exchanger 100 and corrosion resistance.
  • the heat exchanger 100 when the heat exchanger 100 is working, there is a temperature difference between the working temperature of the heat exchanger 100 and the ambient temperature, and the heat exchanger 100 generates localized thermal stress concentration and deforms the heat exchange tubes, resulting in damage and leakage of the heat exchanger 100 , affecting the reliability, corrosion resistance and service life of the heat exchanger 100 .
  • the second wall 42 with welds is more prone to local stress concentration than the first wall 40 without welds.
  • the outer side of the heat exchanger 100 provided by the embodiment of the present application
  • the first slits 44 of the folded tube sections at both ends have two different orientations.
  • the second wall 42 of the heat exchange tube has the first slit 44, the temperature difference between the inside and outside of the heat exchanger 100 during operation, the second wall 42 of the folded tube section Compared with the first wall 40 , it is easier to generate stress concentration.
  • By changing the orientation of the first slit 44 it is beneficial to reduce the local stress concentration of the heat exchanger, thereby improving the reliability and service life of the heat exchanger 100 .
  • first walls 40 of the X folded pipe sections are closer to the first end surface 10 than the second walls 42 of the folded pipe sections, and among all the folded pipe sections, the X folded pipe sections are arranged by the wall closest to the first end surface 10
  • the positions are arranged in order to the position close to the second end surface 12; the first wall 40 of the Y folded pipe section is closer to the second end surface 12 than the second wall 42 of the folded pipe section, and among all the folded pipe sections, the Y folded pipe sections
  • the pipe sections are arranged sequentially from the position closest to the second end surface 12 to the position close to the first end surface 10 .
  • the first slit 44 may be located at the center of the second wall 42 ; as shown in FIG. 5 and FIG. 6 , the first slit 44 may be located at the edge of the second wall 42 .
  • the first seam 44 is filled with solder.
  • solder When the heat exchanger 100 is in the welding process, after the solder on the surface of the folded pipe section is heated and melted, part of the solder will accumulate in the first seam 44, which is beneficial to improve the folding process. pipe reliability.
  • the heat exchanger 100 also includes fins 5, which can improve the corrosion resistance and reliability of the heat exchanger, and also affect the distribution of thermal stress on the heat exchanger.
  • the fins 5 may be corrugated fins, and the fins 5 are located between adjacent folded tube sections in the length direction of the first header, and one or more corrugated fins may be arranged between adjacent heat exchange tubes.
  • the height of the fin 5 is H1, which refers to the maximum height dimension of the fin;
  • the fin 5 can also be a horizontally inserted fin, and the horizontally inserted fin is arranged at intervals along the length direction of the folded pipe section , part of the cross-inserted fins is located between two adjacent folded pipe sections in the length direction of the first header 1, when the fins 5 are cross-inserted fins, the height H1 of the fins 5 refers to the height of the first header The maximum height dimension of some fins located between adjacent heat exchange tubes in the length direction.
  • the cross section of the heat exchange tube 4 is a flat tube
  • the first header 1 includes a third wall 14 and a first passage 16
  • the walls surrounding the first passage 16 include a third wall 14, and the heat exchanger 100 satisfies the following relationship:
  • D is the hydraulic diameter of the first header 1
  • d is the thickness of the third wall 14
  • H is the distance between two adjacent heat exchange tubes 4 along the length direction of the first header 1
  • h is the alloy plate thickness,
  • indicates rounding.
  • the folded pipe sections are processed in different welding terminals, and the time of welding processing is different, which also has a certain relationship with the setting of the first seam on the folded pipe section, and the heat exchanger 100 has an optimal welding process during the welding process. In this range, it is beneficial to reduce the local stress concentration of the heat exchanger 100, thereby improving the reliability of the heat exchanger 100.
  • the welding temperature difference refers to the difference between the highest welding temperature and the temperature at which the composite layer starts to melt, and t is the time during the welding process that the welding temperature is higher than the melting temperature of the composite layer.
  • Tw,t is related to many parameters such as the material of the heat exchange tube 4, the structure of the heat exchange tube 4, and the welding process.
  • the overall furnace welding processing method Generally greater than or equal to 2.
  • the first header 1 includes the third wall 14 and the first channel 16
  • the wall surrounding the first channel 16 includes the third wall 14, and the heat exchanger 100 satisfies the following relationship:
  • D is the hydraulic diameter of the first header 1
  • d is the thickness of the third wall 14
  • H is the distance between two adjacent heat exchange tubes 4 in the length direction of the first header 1
  • h is the alloy The thickness of the plate,
  • indicates rounding.
  • the first header 1 includes a third wall 14 and a first channel 16, which surrounds the first channel 16
  • the walls include a third wall 14, and the heat exchanger 100 satisfies the following relationship:
  • D is the hydraulic diameter of the first header 1
  • d is the tube wall thickness of the first header 1
  • H is the distance between two adjacent heat exchange tubes 4 in the length direction of the first header 1
  • h is the thickness of the alloy plate,
  • indicates rounding.
  • the strength and reliability of the heat exchange tube 4 are related to the number of channels in the heat exchange tube 4.
  • the heat exchange tube 4 includes a plurality of channels arranged at intervals along its width direction, the number of channels included in the heat exchange tube 4 is greater than 8, and the first header 1 includes a third wall 14 and a first channel 16, enclosing a first
  • the walls of the channel 16 include a third wall 14, and the heat exchanger 100 satisfies the following relationship:
  • D is the hydraulic diameter of the first header 1
  • d is the thickness of the third wall 14
  • H is the distance between two adjacent heat exchange tubes 4 along the length direction of the first header 1
  • h is the alloy plate thickness,
  • indicates rounding.
  • the number of heat exchange tubes with weld seams facing inward is 3-5, distributed on one or both sides of the flat tube group of the heat exchanger The outermost side is better for improving the thermal stress distribution of the heat exchanger, which is conducive to improving corrosion resistance.
  • the heat exchange tube 4 includes a main body portion 46 and a bent portion 48. At least part of the bent portion 48 has a length direction that is not parallel to the length direction of the main body portion 46. By arranging the bent portion 48, it is beneficial to further reduce heat transfer. The stress generated by the tube 4 during the welding process improves the reliability of the heat exchanger 100 . In addition, the provision of the bent portion 48 can also play a role in distinguishing the direction, preventing the direction of the first wall 40 and the second wall 42 from being reversed when the heat exchange tube 4 is installed.
  • the first header 1, the bent portion 48 and the main body portion 46 are sequentially arranged, and at least part of the first wall 40 of the bent portion 48 is compared with the first wall of the main body portion 46.
  • 40 is closer to the first end surface 10
  • the second wall 42 of this part of the bent portion 48 is farther away from the second end surface 12 than the second wall 42 of the main body portion 46, that is, the bent portion 48 is arranged on the folded pipe section.
  • the bending part 48 can be close to the first header 1.
  • the bending part 48 plays a role of blocking flow, preventing the heat exchanger 100 from first collecting during the processing process.
  • the molten solder on the wall of tube 1 or on the surface of heat exchange tube 4 flows into the first seam 44.
  • solder may affect the reliability or heat transfer performance of the heat exchange tube.
  • the bending portion 48 at the end of the folded pipe section the accumulation of solder in the first seam 44 can be reduced, which is conducive to improving the reliability of the heat exchange tube and improving the heat exchange performance.
  • the present application provides another heat exchanger 100, which includes a first header 1, a second header 2, and a heat exchange tube 4, and the heat exchange tube 4 communicates with the first header 1 and the second header.
  • Two headers 2 The difference between this heat exchanger 100 and Embodiment 1 is that the heat exchange tube 4 includes a sleeve 8 and at least two heat exchange tube sections, the heat exchange tube section is formed by welding semi-finished heat exchange tubes, and at least two heat exchange tube sections are formed along the heat exchange tube section.
  • the length direction of the tubes 3 is arranged in sequence, and the adjacent two heat exchange tube sections contained in the same heat exchange tube 3 are connected by a sleeve 8, that is to say, one end of the heat exchange tube section along its length direction is connected to the first The header 1 or the second header 2 is directly connected, and the other end of the heat exchange tube section along its length direction is indirectly connected with the second header 2 or the first header 1 .
  • the present application provides another heat exchanger 100, which includes a first header 1, a second header 2, and a heat exchange tube 4, and the heat exchange tube 4 communicates with the first header 1 and the second header.
  • Two headers 2 The difference between the heat exchanger 100 and the first embodiment is that the heat exchange tube 4 includes a plurality of straight parts 6 and curved parts 7 .
  • the straight part 6 includes a heat exchange tube section, and the heat exchange tube section is formed by welding a heat exchange tube semi-finished product.
  • One end of the bent part 7 communicates with one straight part 6, and the other end of the bent part 7 communicates with another straight part 6.
  • the length direction of the part 6 is parallel to or at an angle to the length direction of the other straight part 6, and there are one or more bent parts 7, that is to say, one end of the heat exchange tube segment along its length direction is connected to the first header 1 or the first
  • the two headers 2 are directly connected, and the other end of the heat exchange tube section along its length direction is indirectly connected with the second header 2 or the first header 1 .
  • first and second are used for descriptive purposes only, and cannot be interpreted as indicating or implying relative importance or implicitly specifying the quantity of indicated technical features.
  • the features defined as “first” and “second” may explicitly or implicitly include at least one of these features.
  • “plurality” means at least two, such as two, three, etc., unless otherwise clearly and specifically defined.
  • a first feature being “on” or “under” a second feature may mean that the first and second features are in direct contact, or that the first and second features are indirect through an intermediary. touch.
  • “above”, “above” and “above” the first feature on the second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature.
  • “Below”, “beneath” and “beneath” the first feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is less horizontally than the second feature.

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Abstract

一种换热器（100）加工方法及换热器（100），换热器（100）加工方法包括以下步骤：准备多个换热管（4）半成品，所述换热管（4）半成品包括沿其厚度方向设置的第一壁（40）和第二壁（42），所述第二壁（42）具有第一间隙，所述第一间隙沿所述厚度方向贯穿所述第二壁（42）；将N个所述换热管（4）半成品沿第一方向按预定距离间隔设置，N>4，所述换热管（4）半成品的厚度方向与所述第一方向平行或成角度，沿所述第一方向，定义排列的所述换热管（4）半成品依次为第1管，第2管，……第N-1管，第N管；将所述第1管的所述第二壁（42）朝向所述第2管放置；将所述第N管的所述第二壁（42）朝向所述第N-1管放置；有利于减少换热器（100）的应力集中，提高换热器（100）的可靠性和使用寿命。

Description

换热器和换热器加工方法
相关申请的交叉引用
本公开要求申请号为202111165535.0、申请日为2021年09月30日的中国专利申请、申请号为202122411190.4且申请日为2021年09月30日的中国专利申请的优先权和权益，上述中国专利申请的全部内容在此通过引用并入本公开。
技术领域
本申请涉及热交换技术领域，尤其涉及一种换热器及换热器加工方法。
背景技术
相关技术中，换热器包括集流管和换热管，换热管为折叠扁管，折叠扁管由板材折叠形成，折叠扁管两端分别与集流管连接，换热器在制造过程中，集流管和多个换热管通过焊接加工固定，而换热器在焊接加工过程中由于加工温度变化和分布差异，容易造成换热器局部应力集中，导致换热管变形甚至泄露，影响换热器的可靠性。
发明内容
本申请提供了一种换热器及换热器加工方法，有利于减少换热管加工过程中的应力集中，提高换热器的可靠性和使用寿命。
本申请第一方面提供了一种换热器包括：第一集管和第二集管；换热管，所述换热管连通所述第一集管和所述第二集管；所述换热管包括折叠管段，所述折叠管段由合金板折叠后焊接形成，所述折叠管段包括沿其长度延伸的一个或多个通道；所述折叠管段为多个，多个折叠管段沿所述第一集管的长度方向间隔设置；所述折叠管段包括管壁，所述管壁包括第一缝，所述第一缝沿所述折叠管段的长度方向延伸；所述管壁包括沿所述折叠管段厚度方向设置的第一壁和第二壁，所述第二壁包括所述第一缝；所述第一集管的长度方向上的一端包括第一端面，所述第一集管的长度方向上的另一端包括第二端面；所述换热器包括X个折叠管段，所述X个折叠管段中的任一个所述折叠管段的所述第一壁与所述第一端面之间的最小距离小于该所述折叠管段的第二壁与所述第一端面之间的最小距离，并且该所述折叠管段的第一壁与所述第一端面之间的最小距离小于其与所述第二端面之间的距离，X≥1；所述换热器还包括Y个所述折叠管段，所述Y个折叠管段中的任一个折叠管段的所述第一壁与所述第二端面之间的最小距离小于该所述折叠管段的第二壁与所述第一端面之间的最小距离，并且该所述折叠管段的第一壁与所述第二端面之间的最小距离小于其与所述第一端面之间的距离，Y≥1。
根据本申请提供的热交换器，X个折叠管段的第一壁相较于该折叠管段的第二壁更靠近第一端面，并且该X个折叠管段相较于第二端面更靠近第一端面，X≥1，也就是说，在 靠近第一端面的折叠管段中，至少有一个折叠管段的第二壁背离第一端面；Y个折叠管段的第一壁相较于该折叠管段的第二壁更靠近第二端面，并且该Y个折叠管段相较于第一端面更靠近第二端面，Y≥1，也就是说，在靠近第二端面的折叠管段中，至少有一个折叠管段的第二壁背离第二端面。由于换热管的第二壁具有第一缝，这种结构使得热交换器具有焊缝不同朝向的两种折叠管段，热交换器在工作时内外温度差异较大，使得折叠管段具有第一缝的第二壁相对于第一壁更容易热应力集中，通过改变第一缝的朝向，有利于减少热交换器局部应力集中，从而提高热交换器的可靠性和耐腐蚀性。
在一些实施例中，所述换热管的截面为扁平管，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
Figure PCTCN2022123596-appb-000001
和/或
Figure PCTCN2022123596-appb-000002
其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向上相邻两个折叠管段之间的距离，h为所述合金板的厚度。
在一些实施例中，所述换热器还包括翅片，部分所述翅片在所述第一集管的长度方向上位于相邻的所述折叠管段之间，该部分所述翅片的高度为H1,所述换热器满足如下关系:
Figure PCTCN2022123596-appb-000003
和/或
Figure PCTCN2022123596-appb-000004
其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，h为所述合金板的厚度,||表示取整。
在一些实施例中，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
Figure PCTCN2022123596-appb-000005
和/或
Figure PCTCN2022123596-appb-000006
其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向相邻两个折叠管段之间的距离，h为所述合金板的厚度。
在一些实施例中，所述管壁的厚度小于等于0.5mm，所述管壁的厚度尺寸小于等于所述合金板的厚度尺寸，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
Figure PCTCN2022123596-appb-000007
和/或
Figure PCTCN2022123596-appb-000008
其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向上相邻两个折叠管段之间的距离，h为所述合金板的厚度。
在一些实施例中，所述折叠管段包含的所述通道数量大于8，所述第一集管包括第三 壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
Figure PCTCN2022123596-appb-000009
和/或
Figure PCTCN2022123596-appb-000010
其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向上相邻两个折叠管段之间的距离，h为所述合金板的厚度。
在一些实施例中，3≤X≤5，和/或3≤Y≤5。
在一些实施例中，在所述第一集管的长度方向设置的所述换热管为N个，所述换热器满足如下关系：X＝Y＝N/2。
在一些实施例中，所述折叠管段包括主体部和折弯部，至少部分所述折弯部的长度方向与所述主体部的长度方向不平行。
在一些实施例中，在所述主体部的长度方向上，所述第一集管、所述折弯部和所述主体部依次设置；至少部分所述折弯部的第一壁相较于所述主体部的第一壁更靠近所述第一端面，该部分折弯部的第二壁相较于所述主体部的第二壁更远离所述第二端面。
在一些实施例中，所述换热管包括多个直部和弯曲部，所述直部包括折叠管段，所述弯曲部的一端与一个直部连通，该所述弯曲部的另一端与另一个直部连通，一个所述直部的长度方向与另一个所述直部的长度方向平行或者成角度，所述弯曲部为1个或者多个。
在一些实施例中，所述第一缝内填充有焊料。
本申请第二方面提供了一种换热器加工制造方法，所述换热器加工制造方法包括以下步骤：准备多个换热管半成品，所述换热管半成品包括沿其厚度方向设置的第一壁和第二壁，所述换热管半成品具有第一间隙，所述第一间隙沿所述厚度方向贯穿所述第二壁，或所述第一间隙形成在所述第一壁的端部和所述第二壁的端部之间；将N个所述换热管半成品沿第一方向按预定距离间隔设置，N>4，所述换热管半成品的厚度方向与所述第一方向平行或成角度，沿所述第一方向，定义放置的所述换热管半成品依次为第1管，第2管，……第N-1管，第N管；将所述第1管的所述第二壁朝向所述第2管放置，所述第1管的第二壁相较于所述第1管的所述第一壁在所述第一方向上更靠近所述第2管，以使在所述第一方向上，所述第1管的第二壁与所述第2管的第一壁的最小距离为L1，所述第1管的第一壁与所述第2管的第一壁的最小距离为L2，L1小于L2；将所述第N管的所述第二壁朝向所述第N-1管放置，以使所述第N管的所述第二壁相较于所述第N管的所述第一壁在所述第一方向上更靠近所述第N-1管，以使在所述第一方向上，所述第N管的所述第二壁与所述第N-1管的第一壁的最小距离小于所述第N管的第一壁与所述第N-1管的第一壁的最小距离。
根据本申请提供的换热器加工方法制成的换热器，两个边缘的换热管半成品的第二壁朝向换热器的内侧，由于换热管半成品的第二壁具有第一间隙，换热器在焊接加工过程中热胀冷缩，使得换热管半成品的第二壁相对于第一壁更容易产生变形，通过改变第一间隙 的朝向，使第一间隙朝向换热器的内侧，有利于减少换热器局部应力集中，从而提高换热器的可靠性和使用寿命。
在一些实施例中，所述的换热器加工方法还包括以下步骤，将所述第2管的所述第二壁朝向第3管放置，所述第2管的第二壁相较于所述第2管的第一壁在所述第一方向上更靠近所述第3管，以使在所述第一方向上，所述第2管的第二壁与所述第3管的第一壁的最小距离小于所述第2管的第一壁与所述第3管的第一壁的最小距离；将所述第N-1管的所述第二壁朝向第N-2管放置，所述第N-1管的第二壁相较于所述第N-1管的第一壁在所述第一方向上更靠近所述第N-2管，以使在所述第一方向上，所述第N-1管的第二壁与所述第N-2管的第一壁的最小距离小于所述第N-1管的第一壁与所述第N-2管的第一壁的最小距离。
在一些实施例中，所述的换热器加工方法还包括以下步骤，将第M管的所述第二壁朝向所述第M+1管放置，2<M<N/2，所述第M管的第二壁相较于所述第M管述第一壁在所述第一方向上更靠近所述第M+1管，以使在所述第一方向上，所述第M管的第二壁与所述第M+1管的第一壁的最小距离小于所述第M管的第一壁与所述第M+1管的第一壁的最小距离。
在一些实施例中，所述的换热器加工方法还包括以下步骤，将第L管的所述第二壁朝向所述第L-1管放置，N/2<L<N，所述第L管的第二壁相较于所述第L管的第一壁在所述第一方向上更靠近所述第L-1管,以使在所述第一方向上，所述第L管的第二壁与所述第L-1管的第一壁的最小距离小于所述第L管的第一壁与所述第L-1管的第一壁的最小距离。
在一些实施例中，所述的换热器加工方法还包括以下步骤，将所述第3管的所述第二壁朝向第4管放置，所述第3管的第二壁相较于所述第3管的第一壁在所述第一方向上更靠近所述第4管，以使在所述第一方向上，所述第3管的第二壁与所述第4管的第一壁的最小距离小于所述第3管的第一壁与所述第4管的第一壁的最小距离；将所述第4管的所述第二壁朝向第5管放置，所述第4管的第二壁相较于所述第4管的第一壁在所述第一方向上更靠近所述第5管，以使在所述第一方向上，所述第4管的第二壁与所述第5管的第一壁的最小距离小于所述第4管的第一壁与所述第5管的第一壁的最小距离；将所述第5管的所述第二壁朝向第6管放置，所述第5管的第二壁相较于所述第5管的第一壁在所述第一方向上更靠近所述第6管，以使在所述第一方向上，所述第5管的第二壁与所述第6管的第一壁的最小距离小于所述第5管的第一壁与所述第6管的第一壁的最小距离。
在一些实施例中，所述的换热器加工方法还包括以下步骤，将所述第1管至第N/2管的所述第二壁均朝向所述第N管放置，所述第1管至所述第N/2管的第二壁相较于所述第N/2管的第一壁在所述第一方向上更靠近所述第N管，以使在所述第一方向上，所述第1管至所述第N/2管的第二壁与所述第N管的第一壁的最小距离小于所述第1管至所述第N/2管的第一壁与所述第N管的第一壁的最小距离；将所述第N/2+1管至第N管的所述第二壁 均朝向所述第1管放置，所述第N/2+1管至所述第N管的第二壁相较于该第N/2+1管的第一壁在所述第一方向上更靠近所述第1管，以使在所述第一方向上，所述第N/2+1管至所述第N管的第二壁与所述第1管的第一壁的最小距离小于第N/2+1管至所述第N管的第一壁与所述第1管的第一壁的最小距离。
在一些实施例中，所述的换热器加工方法还包括以下步骤，提供第一集管及第二集管，将所述第一集管与多个所述换热管半成品长度方向上的一端直接连接或间接连接，将多个所述换热管半成品长度方向上的另一端与所述第二集管直接连接或间接连接。
在一些实施例中，所述的换热器加工方法还包括以下步骤，提供翅片，将所述翅片放置于在所述第一方向上相邻两个所述换热管半成品之间；或提供翅片，将部分所述翅片放置于在所述第一方向上相邻两个所述换热管半成品之间。
在一些实施例中，所述换热管半成品、所述第一集管、所述第二集管和所述翅片共同组成芯体组件，所述换热器加工方法还包括以下步骤，将所述芯体组件与其他配件安装，对芯体组件进行钎焊，以使所述换热管半成品与所述第一集管和所述第二集管固定连接，使所述换热管半成品与所述翅片固定连接，所述换热管半成品经过钎焊成为换热管。
本申请第三方面提供了一种换热器换热器由上述实施例中任一项所述的换热器加工方法制得的换热器。
附图说明
图1为本申请实施例提供的一种换热器加工方法的流程图；
图2为本申请实施例提供的另一种换热器加工方法的流程图；
图3为本申请实施例提供的又一种换热器加工方法的流程图；
图4为本申请实施例提供的再一种换热器加工方法的流程图；
图5为本申请实施例提供的又一种换热器加工方法的流程图；
图6为本申请实施例提供的再一种换热器加工方法的流程图；
图7是根据本申请一个实施例的换热器的结构示意图；
图8是根据图7所示换热器的部分结构示意图；
图9是根据本申请一个实施例的折叠管段的结构示意图；
图10是根据图9的所示折叠管段的剖面结构示意图；
图11是根据本申请另一个实施例的折叠管段的结构示意图；
图12是根据图11所示折叠管段的剖面结构示意图；
图13是根据本申请另一个实施例的换热器的结构示意图，其中翅片未示出；
图14是根据图13所示换热器中折叠管段的结构示意图；
图15是根据本申请再一个实施例的换热器的结构示意图，其中翅片未示出；
图16是根据图15所示换热器中折叠管段的结构示意图；
图17是根据本申请又一个实施例的换热器的结构示意图；
图18是根据本申请再一个实施例的换热器的结构示意图；
图19为本申请实施例提供的换热器合金板厚度与可靠性的关系；
图20是根据本申请实施例的换热器X、Y与可靠性的关系。
附图标记：
100-换热器；
1-第一集管；10-第一端面；12-第二端面；14-第三壁；16-第一通道；
2-第二集管；4-换热管；
40-第一壁；42-第二壁；44-第一缝；46-主体部；48-折弯部；
5-翅片；6-直部；7-弯曲部；8-套管。
具体实施方式
下面详细描述本公开的实施例，所述实施例的示例在附图中示出。下面通过参考附图描述的实施例是示例性的，旨在用于解释本公开，而不能理解为对本公开的限制。在本公开的描述中，需要理解的是，术语“中心”、“纵向”、“横向”、“长度”、“宽度”、“厚度”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”“内”、“外”、“顺时针”、“逆时针”、“轴向”、“径向”、“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本公开和简化描述，而不是指示或暗示所指的装置或元夹具必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本公开的限制。
下面参考附图描述根据本公开实施例的具有换热器加工方法。
根据本公开实施例的如图1-图6所示，本申请实施例提供了一种换热器加工方法，其包括以下步骤：步骤S10，准备多个换热管半成品，换热管半成品由合金板材折叠形成，换热管半成品与加工后得到的换热管相比，形状结构大致相同，只是折叠板材的各部分还没有通过焊接固定连接。换热管半成品包括沿其长度方向延伸的一个或多个通道，换热管半成品包括沿其厚度方向设置的第一壁和第二壁，换热管半成品具有第一间隙，第一间隙沿厚度方向贯穿第二壁，或第一间隙形成在第一壁的端部和第二壁的端部之间，换言之，第一壁的端部为第一折弯部和第二壁的端部为第二折弯部，第一折弯部套设在第二折弯部的外周面，且第一折弯部和第二折弯部沿间隔设置以形成第一间隙；步骤S20，将N个换热管半成品沿第一方向按预定距离间隔设置，N>4，换热管半成品的厚度方向与第一方向平行或成角度，沿第一方向(第一方向为上下方向，换言之，第一方向可以为从上到下的方向，第一方向也可以为从下到上的方向)，定义放置的换热管半成品依次为第1管，第2管，……第N-1管，第N管；步骤S30，调整其中一部分换热管半成品的第二壁的朝向，使得换热器包括的所有换热管半成品的第一间隙具有两种不同的朝向，由于换热管半成品的第二壁具有第一间隙，换热器在焊接加工过程中加工温度变化和分布差异，使得换热管 半成品的第二壁相对于第一壁更容易产生变形或者第一间隙焊接不良，通过改变第一间隙的朝向，有利于减少换热器局部应力集中，从而提高换热器的可靠性和使用寿命。
其中，当换热器在焊接加工过程时，第一间隙内被融化的焊料填充，第一间隙会焊接形成接合焊缝(即下文中的第一缝44)，从而使换热管半成品会形成密封的换热管段。具体来说，第一间隙内焊料受热熔化，当温度降低之后，熔化的焊料再次凝结，从而实现第一间隙的密封。
具体地，当换热器在焊接加工过程时，换热器的加工温度存在分布差异，换热器在加热和冷却过程中产生的热应力而使换热管发生形变，两者叠加的影响导致换热器容易产生应力集中，影响换热器的可靠性和使用寿命。尤其是换热管半成品的表面上存在的第一间隙，在换热器的焊接加工过程中，第一间隙会焊接形成接合焊缝，然而换热管发生的形变对第一间隙的焊接有不利的影响，本申请实施例提供的换热器的所有换热管半成品的第一间隙具有两种不同的朝向，由于换热管半成品的第二壁具有第一间隙，换热器在焊接加工过程中热胀冷缩，换热管半成品的第二壁相对于第一壁更容易产生变形，通过改变第一缝的朝向，有利于减少换热器局部应力集中，从而提高换热器的可靠性和使用寿命。
进一步地，本申请实施例提供的换热器加工方法还包括步骤S40：提供第一集管及第二集管，第一集管和第二集管均沿第一方向延伸；将第一集管与多个换热管半成品长度方向上的一端直接连接或间接连接，将多个换热管半成品长度方向上的另一端与第二集管直接连接或间接连接。
进一步地，本申请实施例提供的换热器加工方法还包括步骤S50：提供翅片，将翅片放置于在第一方向上相邻两个换热管半成品之间；或提供翅片，将部分翅片放置于在第一方向上相邻两个换热管半成品之间。
进一步地，换热管半成品、第一集管、第二集管和翅片共同组成芯体组件，本申请实施例提供的换热器加工方法还包括步骤S60：将芯体组件与其他配件安装，对芯体组件进行钎焊，以使换热管半成品与第一集管和第二集管固定连接，使换热管半成品与翅片固定连接，换热管半成品经过钎焊成为换热管。
如图2所示，步骤S30包括步骤S31。步骤S31具体包括：将第1管的第二壁朝向第2管放置，第1管的第二壁相较于第1管的第一壁在第一方向上更靠近第2管，以使在第一方向上，第1管的第二壁与第2管的第一壁的最小距离小于相较于该第1管的第一壁在第一方向上更靠近与第2管的第一壁的最小距离；将第N管的第二壁朝向第N-1管放置，第N管的第二壁相较于第N管的第一壁在第一方向上更靠近第N-1管，以使在第一方向上， 第N管的第二壁与第N-1管的第一壁的最小距离小于第N管的第一壁与第N-1管的第一壁的最小距离相较于该第N管的第一壁在第一方向上更靠近第N-1管。采用这种加工方法使换热器的两个边缘的换热管半成品的第二壁朝向换热器的内侧，由于换热管半成品的第二壁具有第一间隙，换热器在焊接加工过程中热胀冷缩，使得换热管半成品的第二壁相对于第一壁更容易产生变形，通过改变第一间隙的朝向，使第一间隙朝向换热器的内侧，有利于减少换热器局部应力集中，从而提高换热器的可靠性和使用寿命。
进一步地，如图3所示，步骤S30还包括步骤S32，也就是说，步骤S30包括步骤S31和步骤S32。步骤S32具体包括：将第2管的第二壁朝向第3管放置，第2管的第二壁相较于第2管的第一壁在第一方向上更靠近第3管，以使在第一方向上，第2管的第二壁与第3管的第一壁的最小距离小于第2管的第一壁与第3管的第一壁的最小距离；将第N-1管的第二壁朝向第N-2管放置，第N-1管的第二壁相较于该管的第一壁在第一方向上更靠近第N-2管，以使在第一方向上，第N-1管的第二壁与第N-2管的第一壁的最小距离小于第N-1管的第一壁与第N-2管的第一壁的最小距离。也就是说，使换热器的两个边缘处，分别有两个换热管半成品的第二壁朝向换热管的内侧，通过使更多的换热管半成品的第一间隙朝向换热器的内侧，进一步减少换热器的局部应力集中，从而提高换热器的可靠性和使用寿命。
进一步地，如图4所示，步骤S30还包括步骤S33，也就是说，步骤S30包括步骤S31、步骤S32和步骤S33。步骤S33具体包括：将第M管的第二壁朝向第M+1管放置，2<M<N/2，第M管的第二壁相较于第M管的第一壁在第一方向上更靠近第M+1管，以使在第一方向上，第M管的第二壁与第M+1管的第一壁的最小距离小于第M管的第一壁与第M+1管的第一壁的最小距离。
进一步地，继续参考图4，步骤S30还包括步骤S34，也就是说，步骤S30包括步骤S31、步骤S32、步骤S33和步骤S34。步骤S34具体包括：将第L管的第二壁朝向第L-1管放置，N/2<L<N，第L管的第二壁相较于该第L管的第一壁在第一方向上更靠近第L-1管,以使在第一方向上，第L管的第二壁与第L-1管的第一壁的最小距离小于第L管的第一壁与第L-1管的第一壁的最小距离。
如图5所示，在一种具体的实施例中，步骤S33具体可以包括：将第3管的第二壁朝向第4管放置，第3管的第二壁相较于第3管的第一壁在第一方向上更靠近第4管，以使在第一方向上，第3管的第二壁与第4管的第一壁的最小距离小于第3管的第一壁与第4管的第一壁的最小距离；将第4管的第二壁朝向第5管放置，第4管的第二壁相较于第4 管的第一壁在第一方向上更靠近第5管，以使在第一方向上，第4管的第二壁与第5管的第一壁的最小距离小于第4管的第一壁与第5管的第一壁的最小距离；将第5管的第二壁朝向第6管放置，第5管的第二壁相较于第5管的第一壁在第一方向上更靠近第6管，以使在第一方向上，第5管的第二壁与第6管的第一壁的最小距离小于第5管的第一壁与第6管的第一壁的最小距离。
如图6所示，步骤S30包括步骤S31和步骤S35。步骤S35具体包括：将第1管至第N/2管的第二壁均朝向第N管放置，第1管至第N/2管的第二壁相较于第N/2管的第一壁在第一方向上更靠近第N管，以使在第一方向上，第1管至第N/2管的第二壁与第N管的第一壁的最小距离小于第1管至第N/2管的第一壁与第N管的第一壁的最小距离；将第N/2+1管至第N管的第二壁均朝向第1管放置，第N/2+1管至第N管的第二壁相较于第N/2+1管的第一壁在第一方向上更靠近第1管，以使在第一方向上，第N/2+1管至第N管的第二壁与第1管的第一壁的最小距离小于第N/2+1管至第N管的第一壁与第1管的第一壁的最小距离；从而使所有换热管半成品的第一间隙均朝向换热器的内侧，尽最大可能减少换热器的局部应力集中，从而提高换热器的可靠性和使用寿命。需要说明的是，N为偶数时，N/2可以取到整数；N为奇数时，N/2不是整数，可以取小于N/2的最大整数，也可以取大于N/2的最小整数。
如图7-图16所示，本申请实施例提供了一种换热器100，该换热器100包括第一集管1、第二集管2和换热管4，换热管4连通第一集管1和第二集管2。
其中，换热管4仅包括折叠管段，折叠管段由合金板材折叠后焊接形成，折叠管段包括沿其长度方向延伸的一个或多个通道；折叠管段为多个，多个折叠管段沿第一集管1的长度方向间隔设置；折叠管段包括管壁，管壁包括第一缝44，第一缝44沿折叠管段的长度方向延伸；管壁包括沿折叠管段的厚度方向设置的第一壁40和第二壁42，第二壁42包括第一缝44；第一集管1的长度方向上的一端包括第一端面10，第一集管1的长度方向的另一端包括第二端面12；X个折叠管段的第一壁40相较于该折叠管段的第二壁42更靠近第一端面10，并且该X个折叠管段相较于第二端面12更靠近第一端面10，X≥1，也就是说，在靠近第一端面10的折叠管段中，至少有一个折叠管段的第二壁42背离第一端面10；Y个折叠管段的第一壁40相较于该折叠管段的第二壁42更靠近第二端面12，并且该Y个折叠管段相较于第一端面10更靠近第二端面12，Y≥1，也就是说，在靠近第二端面12的折叠管段中，至少有一个折叠管段的第二壁42背离第二端面12。这种结构使得热交换器100包括的所有折叠管段的第一缝44具有两种不同的朝向，由于换热管的第二壁具有第一缝，热交换器100在工作时内外温度差异较大，使得折叠管段的第二壁42相对于第一壁40更容易产生局部应力集中，通过改变第一缝44的朝向，有利于减少热交换器100局部 应力集中，从而提高热交换器100的可靠性和耐腐蚀性。
具体来说，当热交换器100在工作时，热交换器100的工作温度和环境温度存在温差，热交换器100产生局部热应力集中而使换热管发生形变，导致热交换器100破损泄露，影响热交换器100的可靠性，耐腐蚀性和使用寿命。尤其是折叠管段的表面存在的接合焊缝，具有焊缝的第二壁42相比不具有焊缝的第一壁40，更容易产生局部应力集中本申请实施例提供的热交换器100的外侧两端的折叠管段的第一缝44具有两种不同的朝向，由于换热管的第二壁42具有第一缝44，热交换器100在工作过程中内外温度差异，折叠管段的第二壁42相对于第一壁40更容易产生应力集中，通过改变第一缝44的朝向，有利于减少换热器局部应力集中，从而提高热交换器100的可靠性和使用寿命。
进一步地，X个折叠管段的第一壁40相较于该折叠管段的第二壁42更靠近第一端面10，并且在所有折叠管段中，该X个折叠管段由最靠近第一端面10的位置向靠近第二端面12的位置依次排列；Y个折叠管段的第一壁40相较于该折叠管段的第二壁42更靠近第二端面12，并且在所有折叠管段中，该Y个折叠管段由最靠近第二端面12的位置向靠近第一端面10的位置依次排列。
其中，第一缝44可以位于第二壁42的中央；如图5和图6所示，第一缝44可以位于第二壁42的边缘。
在一些实施例中，第一缝44内填充有焊料，当热交换器100在焊接加工过程时，折叠管段表面的焊料受热融化后，部分焊料堆积会在第一缝44内，有利于提高折叠管段的可靠性。
进一步地，热交换器100还包括翅片5，翅片5可以提供换热器的耐腐蚀性和可靠性，同时也影响热应力在换热器上的分布情况。翅片5可以是波纹翅片，翅片5在第一集管的长度方向上位于相邻折叠管段之间，相邻换热管之间可以布置一个或者多个波纹翅片，当相邻换热管之间只有一个波纹翅片时，翅片5的高度为H1是指翅片的最大高度尺寸；翅片5还可以是横插翅片，横插翅片沿折叠管段的长度方向间隔布置，部分横插翅片在第一集管1的长度方向位于相邻两个折叠管段之间，当翅片5为横插翅片时，翅片5的高度H1是指在第一集管的长度方向上位于相邻换热管之间的部分翅片的最大高度尺寸。
进一步地，换热管4的截面为扁平管，第一集管1包括第三壁14第一通道16，围成第一通道16的壁包括第三壁14，换热器100满足如下关系：
Figure PCTCN2022123596-appb-000011
和/或
Figure PCTCN2022123596-appb-000012
当X或Y的数量满足该关系时，有利于减少换热器局部应力集中，从而提高换热器100的可靠性和使用寿命。
其中，D为第一集管1的水力直径，d为第三壁14的厚度，H为沿第一集管1的长度方向相邻两个换热管4之间的距离，h为合金板的厚度，||表示取整。
进一步地，折叠管段在不同焊接终端里面加工，焊接加工的时间不同，跟折叠管段上 的第一缝的设置也存在一定的关联关系，而热交换器100在焊接加工过程中，存在一个最佳的区间范围，在该范围内有利于降低热交换器100的局部应力集中，从而提高热交换器100的可靠性，X个折叠管段和Y个折叠管段与焊接温差TW及焊接时长t也存在一定关系如下关系，
Figure PCTCN2022123596-appb-000013
Tw单位为摄氏度，t单位为S秒，结果无量纲化，取其整数值，X和Y应大于该整数值。焊接温差是指最高焊接温度与复合层开始融化的温度之间的差值，t是焊接过程中，焊接温度高于复合层融化的温度之上的时间。Tw,t和换热管4的材料，换热管4的结构，焊接工艺过程等诸多参数相关。对于铝合金的换热器100，整体炉焊的加工方式来说，
Figure PCTCN2022123596-appb-000014
一般大于等于2。
由此可知，第一集管1包括第三壁14和第一通道16，围成第一通道16的壁包括第三壁14，换热器100满足如下关系：
Figure PCTCN2022123596-appb-000015
和/或
Figure PCTCN2022123596-appb-000016
其中，D为第一集管1的水力直径，d为第三壁14的厚度，H为在第一集管1的长度方向上相邻两个换热管4之间的距离，h为合金板的厚度，||表示取整。
进一步地，参考图19，管壁的厚度小于0.5mm，管壁的厚度尺寸小于合金板的厚度尺寸，第一集管1包括第三壁14和第一通道16，围成第一通道16的壁包括第三壁14，换热器100满足如下关系：
Figure PCTCN2022123596-appb-000017
和/或
Figure PCTCN2022123596-appb-000018
其中，D为第一集管1的水力直径，d为第一集管1的管壁厚度，H为在第一集管1的长度方向上相邻两个换热管4之间的距离，h为合金板的厚度，||表示取整。
进一步地，参考图20，换热管4的强度和可靠性与换热管4中通道的数量相关，通道数量越多，越有利于换热管4的强度和可靠性；另一方面通道的数量影响换热管的宽度和第一缝44的焊接质量，通道数量越多，换热管的焊点越多，不利于接合缝的焊接，影响焊接质量。因此，随着通道数量的增多，需要改变换热器100的结构，提高换热器100的可靠性。
具体地，换热管4包括沿其宽度方向间隔设置的多个通道，换热管4包含的通道数量大于8，第一集管1包括第三壁14和第一通道16，围成第一通道16的壁包括第三壁14，换热器100满足如下关系：
Figure PCTCN2022123596-appb-000019
和/或
Figure PCTCN2022123596-appb-000020
其中，D为第一集管1的水力直径，d为第三壁14的厚度，H为沿第一集管1的长度方向相邻两个换热管4之间的距离，h为合金板的厚度，||表示取整。
在一种实施例中，3≤X≤5，和/或3≤Y≤5，例如，X为3、4或5，Y为3、4或5。考虑到换热器工作过程中不同的内外温差以及换热器的尺寸差异，焊缝朝内的换热管数量为3-5根，分布于换热器扁管组的一侧或者两侧的最外侧，对于换热器热应力分布情况的改善较好，有利于提高耐腐蚀性。
在另一种实施例中，沿第一集管1长度方向设置的换热管4为N个，换热器100满足如下关系：X＝Y＝N/2。也就是说，所有靠近第一端面10的换热管4，第一壁40相较于该换热管4的第二壁42更靠近第一端面10；所有靠近第二端面12的换热管4，第一壁40相较于该换热管4的第二壁42更靠近第二端面12。
进一步地，换热管4包括主体部46和折弯部48，至少部分折弯部48的长度方向与主体部46的长度方向不平行，通过设置折弯部48，有利于进一步减小换热管4在焊接加工过程中产生的应力，提高换热器100可靠性。此外，通过设置折弯部48还能够起到辨别方向的作用，防止换热管4在安装时第一壁40和第二壁42的方向装反。
进一步地，在主体部46的长度方向上，第一集管1、折弯部48和主体部46依次设置，至少部分折弯部48的第一壁40相较于主体部46的第一壁40更靠近第一端面10，该部分折弯部48的第二壁42相较于主体部46的第二壁42更远离第二端面12，也就是说，折弯部48设置于折叠管段的两端，使折弯部48能够靠近第一集管1，在换热器整体焊接的过程中，通过折弯部48起到阻流的作用，防止热交换器100在加工过程中第一集管1管壁上的或者换热管4表面上的融化焊料流入第一缝44，当越来越多的焊料积聚在第一焊缝内时，可能影响换热管的可靠性或换热性能，通过在折叠管段端部设置折弯部48，可以减少焊料积聚在第一缝44内，有利于提升换热管的可靠性，提高换热性能。
如图17所示，本申请实施提供了另一种换热器100，其包括第一集管1、第二集管2和换热管4，换热管4连通第一集管1和第二集管2。该换热器100与实施例一的区别在于，换热管4包括套管8和至少两个换热管段，换热管段由换热管半成品焊接形成，至少两个换热管段沿着换热管3的长度方向依次排列，并且同一个换热管3所包含的相邻两个换热管段之间通过套管8相连接，也就是说，换热管段沿其长度方向的一端与第一集管1或第二集管2直接连接，该换热管段沿其长度方向的另一端与第二集管2或第一集管1间接连接。
如图18所示，本申请实施提供了另一种换热器100，其包括第一集管1、第二集管2和换热管4，换热管4连通第一集管1和第二集管2。该换热器100与实施例一的区别在于，换热管4包括多个直部6和弯曲部7。其中，直部6包括换热管段，换热管段由换热管半成品焊接形成，弯曲部7的一端与一个直部6连通，该弯曲部7的另一端与另一个直部6连通，一个直部6的长度方向与另一个直部6的长度方向平行或者成角度，弯曲部7为1 个或者多个，也就是说，换热管段沿其长度方向的一端与第一集管1或第二集管2直接连接，该换热管段沿其长度方向的另一端与第二集管2或第一集管1间接连接。
以上仅为本申请的优选实施例而已，并不用于限制本申请，对于本领域的技术人员来说，本申请可以有各种更改和变化。凡在本申请的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本申请的保护范围之内。
在本公开的描述中，需要理解的是，术语“中心”、“纵向”、“横向”、“长度”、“宽度”、“厚度”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”“内”、“外”、“顺时针”、“逆时针”、“轴向”、“径向”、“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本公开和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本公开的限制。
此外，术语“第一”、“第二”仅用于描述目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。在本公开的描述中，“多个”的含义是至少两个，例如两个，三个等，除非另有明确具体地限定。
在本公开中，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”、“固定”等术语应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或成一体；可以是机械连接，也可以是电连接或彼此可通讯；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系，除非另有明确的限定。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本公开中的具体含义。
在本公开中，除非另有明确的规定和限定，第一特征在第二特征“上”或“下”可以是第一和第二特征直接接触，或第一和第二特征通过中间媒介间接接触。而且，第一特征在第二特征“之上”、“上方”和“上面”可是第一特征在第二特征正上方或斜上方，或仅仅表示第一特征水平高度高于第二特征。第一特征在第二特征“之下”、“下方”和“下面”可以是第一特征在第二特征正下方或斜下方，或仅仅表示第一特征水平高度小于第二特征。
在本说明书的描述中，参考术语“一个实施例”、“一些实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本公开的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不必须针对的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特点可以在任一个或多个实施例或示例中以合适的方式结合。此外，在不相互矛盾的情况下，本领域的技术人员可以将本说明书中描述的不同实施例或示例以及不同实施例或示例的特征进行结合和组合。
尽管上面已经示出和描述了本公开的实施例，可以理解的是，上述实施例是示例性的，不能理解为对本公开的限制，本领域的普通技术人员在本公开的范围内可以对上述实施例进行变化、修改、替换和变型。

Claims (30)

  1. 一种换热器，其特征在于，包括：
    第一集管和第二集管；
    换热管，所述换热管连通所述第一集管和所述第二集管；
    所述换热管包括折叠管段，所述折叠管段由合金板折叠后焊接形成，所述折叠管段包括沿其长度延伸的一个或多个通道；
    所述折叠管段为多个，多个折叠管段沿所述第一集管的长度方向间隔设置；
    所述折叠管段包括管壁，所述管壁包括第一缝，所述第一缝沿所述折叠管段的长度方向延伸；
    所述管壁包括沿所述折叠管段厚度方向设置的第一壁和第二壁，所述第二壁包括所述第一缝；
    所述第一集管的长度方向上的一端包括第一端面，所述第一集管的长度方向上的另一端包括第二端面；
    所述换热器包括X个折叠管段，所述X个折叠管段中的任一个所述折叠管段的所述第一壁与所述第一端面之间的最小距离小于该所述折叠管段的第二壁与所述第一端面之间的最小距离，并且该所述折叠管段的第一壁与所述第一端面之间的最小距离小于其与所述第二端面之间的距离，X≥1；
    所述换热器还包括Y个所述折叠管段，所述Y个折叠管段中的任一个折叠管段的所述第一壁与所述第二端面之间的最小距离小于该所述折叠管段的第二壁与所述第一端面之间的最小距离，并且该所述折叠管段的第一壁与所述第二端面之间的最小距离小于其与所述第一端面之间的距离，Y≥1。
  2. 根据权利要求1所述的换热器，其特征在于，所述换热管的截面为扁平管，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
    Figure PCTCN2022123596-appb-100001
    和/或
    Figure PCTCN2022123596-appb-100002
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向上相邻两个折叠管段之间的距离，h为所述合金板的厚度。
  3. 根据权利要求2所述的换热器，其特征在于，所述换热器还包括翅片，部分所述翅片在所述第一集管的长度方向上位于相邻的所述折叠管段之间，该部分所述翅片的高度为H1,所述换热器满足如下关系:
    Figure PCTCN2022123596-appb-100003
    和/或
    Figure PCTCN2022123596-appb-100004
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，h为所述合金板的厚度,||表示取整。
  4. 根据权利要求1-3任一项所述的换热器，其特征在于，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
    Figure PCTCN2022123596-appb-100005
    和/或
    Figure PCTCN2022123596-appb-100006
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向相邻两个折叠管段之间的距离，h为所述合金板的厚度。
  5. 根据权利要求4所述的换热器，其特征在于，所述管壁的厚度小于等于0.5mm，所述管壁的厚度尺寸小于等于所述合金板的厚度尺寸，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
    Figure PCTCN2022123596-appb-100007
    和/或
    Figure PCTCN2022123596-appb-100008
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向上相邻两个折叠管段之间的距离，h为所述合金板的厚度。
  6. 根据权利要求1-3任一项所述的换热器，其特征在于，所述折叠管段包含的所述通道数量大于8，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
    Figure PCTCN2022123596-appb-100009
    和/或
    Figure PCTCN2022123596-appb-100010
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向上相邻两个折叠管段之间的距离，h为所述合金板的厚度。
  7. 根据权利要求1-3任一项所述的换热器，其特征在于，3≤X≤5，和/或3≤Y≤5。
  8. 根据权利要求7所述的换热器，其特征在于，在所述第一集管的长度方向设置的所述换热管为N个，所述换热器满足如下关系：
    X＝Y＝N/2。
  9. 根据权利要求8所述的换热器，其特征在于，所述折叠管段包括主体部和折弯部，至少部分所述折弯部的长度方向与所述主体部的长度方向不平行。
  10. 根据权利要求1或2所述的换热器，其特征在于，在所述主体部的长度方向上，所述第一集管、所述折弯部和所述主体部依次设置；至少部分所述折弯部的第一壁相较于所述主体部的第一壁更靠近所述第一端面，该部分折弯部的第二壁相较于所述主体部的第二壁更远离所述第二端面。
  11. 根据权利要求10所述的换热器，其特征在于，所述换热管包括多个直部和弯曲部， 所述直部包括折叠管段，所述弯曲部的一端与一个直部连通，该所述弯曲部的另一端与另一个直部连通，一个所述直部的长度方向与另一个所述直部的长度方向平行或者成角度，所述弯曲部为1个或者多个。
  12. 根据权利要求1所述的热交换器，其特征在于，所述第一缝内填充有焊料。
  13. 一种换热器加工方法，其特征在于，所述换热器加工制造方法包括以下步骤：
    准备多个换热管半成品，所述换热管半成品包括沿其厚度方向设置的第一壁和第二壁，所述换热管半成品具有第一间隙，所述第一间隙沿所述厚度方向贯穿所述第二壁，或所述第一间隙形成在所述第一壁的端部和所述第二壁的端部之间；
    将N个所述换热管半成品沿第一方向按预定距离间隔设置，N>4，所述换热管半成品的厚度方向与所述第一方向平行或成角度，沿所述第一方向，定义放置的所述换热管半成品依次为第1管，第2管，……第N-1管，第N管；
    将所述第1管的所述第二壁朝向所述第2管放置，所述第1管的第二壁相较于所述第1管的所述第一壁在所述第一方向上更靠近所述第2管，以使在所述第一方向上，所述第1管的第二壁与所述第2管的第一壁的最小距离为L1，所述第1管的第一壁与所述第2管的第一壁的最小距离为L2，L1小于L2；
    将所述第N管的所述第二壁朝向所述第N-1管放置，以使所述第N管的所述第二壁相较于所述第N管的所述第一壁在所述第一方向上更靠近所述第N-1管，以使在所述第一方向上，所述第N管的所述第二壁与所述第N-1管的第一壁的最小距离小于所述第N管的第一壁与所述第N-1管的第一壁的最小距离。
  14. 根据权利要求13所述的换热器加工方法，其特征在于，还包括以下步骤，
    将所述第2管的所述第二壁朝向第3管放置，所述第2管的第二壁相较于所述第2管的第一壁在所述第一方向上更靠近所述第3管，以使在所述第一方向上，所述第2管的第二壁与所述第3管的第一壁的最小距离小于所述第2管的第一壁与所述第3管的第一壁的最小距离；
    将所述第N-1管的所述第二壁朝向第N-2管放置，所述第N-1管的第二壁相较于所述第N-1管的第一壁在所述第一方向上更靠近所述第N-2管，以使在所述第一方向上，所述第N-1管的第二壁与所述第N-2管的第一壁的最小距离小于所述第N-1管的第一壁与所述第N-2管的第一壁的最小距离。
  15. 根据权利要求13或14所述的换热器加工方法，其特征在于，还包括以下步骤，
    将第M管的所述第二壁朝向所述第M+1管放置，2<M<N/2，所述第M管的第二壁相较于所述第M管述第一壁在所述第一方向上更靠近所述第M+1管，以使在所述第一方向上，所述第M管的第二壁与所述第M+1管的第一壁的最小距离小于所述第M管的第一壁与所述第M+1管的第一壁的最小距离。
  16. 根据权利要求15所述的换热器加工方法，其特征在于，还包括以下步骤，
    将第L管的所述第二壁朝向所述第L-1管放置，N/2<L<N，所述第L管的第二壁相较于所述第L管的第一壁在所述第一方向上更靠近所述第L-1管,以使在所述第一方向上，所述第L管的第二壁与所述第L-1管的第一壁的最小距离小于所述第L管的第一壁与所述第L-1管的第一壁的最小距离。
  17. 根据权利要求13或14所述的换热器加工方法，其特征在于，还包括以下步骤，
    将所述第3管的所述第二壁朝向第4管放置，所述第3管的第二壁相较于所述第3管的第一壁在所述第一方向上更靠近所述第4管，以使在所述第一方向上，所述第3管的第二壁与所述第4管的第一壁的最小距离小于所述第3管的第一壁与所述第4管的第一壁的最小距离；
    将所述第4管的所述第二壁朝向第5管放置，所述第4管的第二壁相较于所述第4管的第一壁在所述第一方向上更靠近所述第5管，以使在所述第一方向上，所述第4管的第二壁与所述第5管的第一壁的最小距离小于所述第4管的第一壁与所述第5管的第一壁的最小距离；
    将所述第5管的所述第二壁朝向第6管放置，所述第5管的第二壁相较于所述第5管的第一壁在所述第一方向上更靠近所述第6管，以使在所述第一方向上，所述第5管的第二壁与所述第6管的第一壁的最小距离小于所述第5管的第一壁与所述第6管的第一壁的最小距离。
  18. 根据权利要求13或14所述的换热器加工方法，其特征在于，还包括以下步骤，
    将所述第1管至第N/2管的所述第二壁均朝向所述第N管放置，所述第1管至所述第N/2管的第二壁相较于所述第N/2管的第一壁在所述第一方向上更靠近所述第N管，以使在所述第一方向上，所述第1管至所述第N/2管的第二壁与所述第N管的第一壁的最小距离小于所述第1管至所述第N/2管的第一壁与所述第N管的第一壁的最小距离；
    将所述第N/2+1管至第N管的所述第二壁均朝向所述第1管放置，所述第N/2+1管至所述第N管的第二壁相较于该第N/2+1管的第一壁在所述第一方向上更靠近所述第1管，以使在所述第一方向上，所述第N/2+1管至所述第N管的第二壁与所述第1管的第一壁的最小距离小于第N/2+1管至所述第N管的第一壁与所述第1管的第一壁的最小距离。
  19. 根据权利要求13至18任一项所述的换热器加工方法，其特征在于，还包括以下步骤，
    提供第一集管及第二集管，将所述第一集管与多个所述换热管半成品长度方向上的一端直接连接或间接连接，将多个所述换热管半成品长度方向上的另一端与所述第二集管直接连接或间接连接。
  20. 根据权利要求19所述的换热器加工方法，其特征在于，还包括以下步骤，
    提供翅片，将所述翅片放置于在所述第一方向上相邻两个所述换热管半成品之间；
    或提供翅片，将部分所述翅片放置于在所述第一方向上相邻两个所述换热管半成品之 间。
  21. 根据权利要求20所述的换热器加工方法，其特征在于，所述换热管半成品、所述第一集管、所述第二集管和所述翅片共同组成芯体组件，所述换热器加工方法还包括以下步骤，将所述芯体组件与其他配件安装，对芯体组件进行钎焊，以使所述换热管半成品与所述第一集管和所述第二集管固定连接，使所述换热管半成品与所述翅片固定连接，所述换热管半成品经过钎焊成为换热管。
  22. 一种换热器，其特征在于，换热器由权利要求13至21任一项所述的换热器加工方法制得的换热器。
  23. 根据权利要求22所述的换热器，其特征在于，所述换热器包括：
    第一集管和第二集管；
    换热管，所述换热管沿其长度方向的一端与所述第一集管直接或间接连接，所述换热管沿其长度方向的另一端与所述第二集管直接或间接连接，所述换热管包括沿其长度延伸的一个或多个通道，所述换热管为多个，多个所述换热管沿所述第一集管的长度方向间隔设置；所述换热管包括管壁，所述管壁包括第一缝，所述第一缝沿所述换热管的长度方向延伸；所述管壁包括沿所述换热管厚度方向设置的第一壁和第二壁，所述第二壁包括所述第一缝；所述第一集管的长度方向上的一端包括第一端面，所述第一集管的长度方向上的另一端包括第二端面；X个所述换热管的所述第一壁相较于该所述换热管的第二壁更靠近所述第一端面，并且该X个所述换热管相较于所述第二端面更靠近所述第一端面，X≥1；Y个所述换热管的所述第一壁相较于该所述换热管的第二壁更靠近所述第二端面，并且该Y个所述换热管相较于所述第一端面更靠近所述第二端面，Y≥1。
  24. 根据权利要求23所述的换热器，其特征在于，所述换热管的截面为扁平管，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
    Figure PCTCN2022123596-appb-100011
    和/或
    Figure PCTCN2022123596-appb-100012
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向上相邻两个换热管之间的距离，h为所述合金板的厚度。
  25. 根据权利要求24所述的换热器，其特征在于，所述换热器还包括翅片，部分所述翅片在所述第一集管的长度方向上位于相邻的所述换热管之间，该部分所述翅片的高度为H1,所述换热器满足如下关系:
    Figure PCTCN2022123596-appb-100013
    和/或
    Figure PCTCN2022123596-appb-100014
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，h为所述合金板的厚度,||表示取整。
  26. 根据权利要求23-25任一项所述的换热器，其特征在于，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
    Figure PCTCN2022123596-appb-100015
    和/或
    Figure PCTCN2022123596-appb-100016
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向相邻两个换热管之间的距离，h为所述合金板的厚度。
  27. 根据权利要求26所述的换热器，其特征在于，所述管壁的厚度小于等于0.5mm，所述管壁的厚度尺寸小于等于所述合金板的厚度尺寸，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
    Figure PCTCN2022123596-appb-100017
    和/或
    Figure PCTCN2022123596-appb-100018
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向上相邻两个换热管之间的距离，h为所述合金板的厚度。
  28. 根据权利要求23-25任一项所述的换热器，其特征在于，所述换热管包含的所述通道数量大于8，所述第一集管包括第三壁和由所述第三壁包围形成的第一通道，所述换热器满足如下关系：
    Figure PCTCN2022123596-appb-100019
    和/或
    Figure PCTCN2022123596-appb-100020
    其中，D为所述第一集管的水力直径，d为所述第三壁的厚度，H为在所述第一集管的长度方向上相邻两个换热管之间的距离，h为所述合金板的厚度。
  29. 根据权利要求23-25任一项所述的换热器，其特征在于，3≤X≤5，和/或3≤Y≤5，在所述第一集管的长度方向设置的所述换热管为N个，所述换热器满足如下关系：X＝Y＝N/2，所述换热管包括主体部和折弯部，至少部分所述折弯部的长度方向与所述主体部的长度方向不平行。
  30. 根据权利要求29所述的换热器，其特征在于，在所述主体部的长度方向上，所述第一集管、所述折弯部和所述主体部依次设置；至少部分所述折弯部的第一壁相较于所述主体部的第一壁更靠近所述第一端面，该部分折弯部的第二壁相较于所述主体部的第二壁更远离所述第二端面。
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