Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
  • F28F9/02—Header boxes; End plates
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
  • F28F9/02—Header boxes; End plates
  • F28F9/04—Arrangements for sealing elements into header boxes or end plates
  • F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
  • F28F9/22—Arrangements for directing heat-exchange media into successive compartments, e.g. arrangements of guide plates

Definitions

• This disclosure relates to a distributor, a heat exchanger, a method for manufacturing a distributor, and a method for manufacturing a heat exchanger.
• Some distributors have an inner tube housed inside an outer tube, with orifices on the outer surface that allow the refrigerant to flow out, to distribute the refrigerant evenly.
• Patent Document 1 discloses a distributor that includes a cylindrical inner tube with an orifice and a cylindrical outer tube that houses the inner tube.
• Patent Document 2 discloses a distributor that includes two cylindrical inner tubes with orifices and a rectangular outer tube that houses the two inner tubes.
• the distributor parts are assembled and then brazed to join them together.
• the inner tube is sufficiently long, the center of the inner tube's axial direction may bend and come into contact with the inner wall of the outer tube.
• the outer tube is made by joining two components, the part of the inner tube that is in contact with the inner wall of the outer tube may come into contact with the brazing material used at the joint. As a result, the orifice may become clogged with the brazing material.
• This disclosure has been made to solve the above-mentioned problems, and aims to provide a distributor, a heat exchanger, a method for manufacturing a distributor, and a method for manufacturing a heat exchanger in which the orifice is prevented from being blocked by brazing material.
• the distributor according to the present disclosure comprises an inner pipe having an orifice on its outer peripheral surface from which the refrigerant flows, and an outer pipe having an inner diameter larger than the outer diameter of the inner pipe and containing the inner pipe with its inner peripheral surface surrounding the outer peripheral surface of the inner pipe in the internal space formed by the inner peripheral surface.
• a plurality of refrigerant pipes are connected to the outer pipe, joined with brazing material, and through which the refrigerant is distributed.
• the portion of the inner peripheral surface of the outer pipe facing the orifice is made of a material with a higher melting point than the brazing material.
• the portion of the inner surface of the outer tube facing the orifice is made of a material with a higher melting point than the brazing material. Therefore, the facing portion does not melt during brazing, and the material of the facing portion does not function as brazing material. As a result, even if the inner tube bends and the orifice comes into contact with the facing portion, the orifice is prevented from being blocked by the brazing material.
• FIG. 1 is a perspective view of a heat exchanger including a distributor according to a first embodiment of the present disclosure
• FIG. 1 is an enlarged front view of a portion of a distributor according to a first embodiment of the present disclosure.
• 3 is a cross-sectional view taken along the line III-III shown in FIG. 2.
• 4 is a cross-sectional view taken along the line IV-IV shown in FIG. 2.
• FIG. 10 is a cross-sectional view of a main body portion of an outer tube when assembling heat transfer tubes, fins, and an inner tube in a manufacturing method of a heat exchanger including a distributor according to the first embodiment of the present disclosure.
• FIG. 10 is a cross-sectional view of a main body portion of an outer tube when assembling heat transfer tubes, fins, and an inner tube in a manufacturing method of a heat exchanger including a distributor according to the first embodiment of the present disclosure.
• 10 is a cross-sectional view of a main body portion of an outer tube when a cover portion is lightly press-fitted in a method for manufacturing a heat exchanger including a distributor according to a first embodiment of the present disclosure.
• 10 is a cross-sectional view of a distributor according to a second embodiment of the present disclosure.
• 10 is a cross-sectional view of a modified example of a distributor according to the second embodiment of the present disclosure.
• 10 is a cross-sectional view of another modified example of the distributor according to the second embodiment of the present disclosure.
• 10 is a cross-sectional view of a distributor according to a third embodiment of the present disclosure.
• 13 is a cross-sectional view of a modified example of a distributor according to the third embodiment of the present disclosure.
• FIG. 13 is a cross-sectional view of another modified example of the distributor according to the third embodiment of the present disclosure.
• FIG. 10 is a cross-sectional view of yet another modified example of the distributor according to the third embodiment of the present disclosure.
• FIG. 10 is an enlarged front view of a modified example of a dowel included in the distributor according to the first embodiment of the present disclosure.
• 10 is a cross-sectional view of a modified example of an outer tube included in the distributor according to the first embodiment of the present disclosure;
• FIG. 10 is a cross-sectional view of a brazing jig used in a brazing step provided in a modified example of the distributor manufacturing method according to the first embodiment of the present disclosure, and a main body portion and a cover portion fixed by the brazing jig.
• FIG. 10 is an enlarged front view showing an example of an attachment position of a brazing jig used in a brazing step included in a modified example of the manufacturing method of the distributor according to the first embodiment of the present disclosure.
• FIG. 10 is an enlarged front view showing another example of an attachment position of a brazing jig used in a brazing step included in the modified example of the manufacturing method of the distributor according to the first embodiment of the present disclosure.
• FIG. 10 is an enlarged front view showing an example of a brazing jig used in a brazing step included in the manufacturing method of a modified example of the distributor according to the first embodiment of the present disclosure.
• FIG. 10 is an enlarged front view showing an example of a brazing jig used in a brazing step included in the manufacturing method of a modified example of the distributor according to the first embodiment of the present disclosure.
• FIG. 10 is an enlarged front view showing another example of a brazing jig used in a brazing step included in the manufacturing method of the modified example of the distributor according to the first embodiment of the present disclosure.
• FIG. 10 is an enlarged front view showing yet another example of a brazing jig used in a brazing step included in the manufacturing method of the modified distributor according to the first embodiment of the present disclosure.
• the distributor according to the first embodiment is a distributor in which an inner pipe having an orifice for allowing the refrigerant to flow out is housed in an outer pipe connected to a heat transfer pipe.
• this distributor in order to prevent the orifice from being clogged with brazing material during brazing during manufacturing, the inner peripheral surface of the outer pipe is formed of a material that does not melt when heated during brazing.
• FIG. 1 is a perspective view of a heat exchanger 100 equipped with a distributor 1A according to embodiment 1. To facilitate understanding, FIG. 1 shows only the heat transfer tubes 3 and fins 4 in a portion of the heat exchanger 100, and omits the heat transfer tubes 3 and fins 4 in other portions.
• the heat exchanger 100 comprises distributors 1A and 2A for distributing and collecting the refrigerant, a plurality of heat transfer tubes 3 connected to the distributors 1A and 2A and through which the refrigerant flows, and a plurality of fins 4 attached to the heat transfer tubes 3.
• Distributors 1A and 2A are formed in the shape of a square tube with rounded corners. Although not shown in Figure 1, the internal space of the square tube of distributors 1A and 2A forms a flow path for the refrigerant to flow. Distributors 1A and 2A also have cylindrical connection parts 5 and 6 shown in Figure 1, to which connection pipes of external equipment (not shown) that supply and discharge the refrigerant are connected. When external equipment is connected to distributors 1A and 2A, the refrigerant flows through the flow path in the internal space.
• distributors 1A and 2A are arranged spaced apart from each other in the vertical direction, with their tube axes A1 and A2 oriented horizontally.
• Multiple heat transfer tubes 3 are connected to distributors 1A and 2A to allow refrigerant to circulate between them.
• Each heat transfer tube 3 is formed in a tubular shape to allow the refrigerant to flow through it.
• the heat transfer tubes 3 extend in the vertical direction. Furthermore, the upper and lower ends of the heat transfer tubes 3 are inserted into insertion holes (not shown) in the cylindrical walls of distributors 1A and 2A. Furthermore, these upper and lower ends are joined to distributors 1A and 2A with brazing material. In this way, the heat transfer tubes 3 are connected to distributors 1A and 2A. As a result, the refrigerant flows through the heat transfer tubes 3 when it is flowed through distributors 1A and 2A.
• each heat transfer tube 3 is made of a metal with high thermal conductivity, such as pure aluminum or an aluminum alloy, to facilitate the transfer of heat from the refrigerant flowing through it. Furthermore, the heat transfer tubes 3 are formed with a flat cross section to facilitate the transfer of heat from the refrigerant. In other words, the heat transfer tubes 3 are flattened tubes. As shown in Figure 1, the heat transfer tubes 3 are arranged at a constant pitch in the direction of the tube axes A1 and A2 of the distributors 1A and 2A. This also leaves gaps between the heat transfer tubes 3. Fins 4 are provided in these gaps to release the heat transferred to the heat transfer tubes 3 into the surrounding air.
• the fins 4 are made of a metal with high thermal conductivity, for example, the same metal material as the heat transfer tubes 3, to facilitate the transfer of heat from the heat transfer tubes 3. Furthermore, the fins 4 are formed in the shape of a plate (not shown) to facilitate the release of heat into the surrounding air. The plate is folded into a corrugated shape. The fins 4 are sandwiched between adjacent heat transfer tubes 3, with the peaks and valleys of the corrugation facing the flat surfaces of the heat transfer tubes 3. The peaks and valleys of the fins 4's corrugations are then joined to the heat transfer tubes 3 with brazing material. In this way, the fins 4 are attached to the heat transfer tubes 3. As a result, the fins 4 release the heat transferred from the heat transfer tubes 3 into the air from the surface of the corrugated plate.
• distributor 1A employs a double-pipe structure with an inner pipe having multiple orifices for the refrigerant to flow out and an outer pipe that houses the inner pipe, in order to distribute the refrigerant more evenly.
• Figure 2 is an enlarged front view of a portion of distributor 1A.
• Figure 3 is a cross-sectional view taken along the III-III cutting line shown in Figure 2.
• Figure 4 is a cross-sectional view taken along the IV-IV cutting line shown in Figure 2. Note that, for ease of understanding, the heat transfer tubes 3 connected to distributor 1A are not shown in Figure 2.
• the distributor 1A has an inner tube 10A and an outer tube 20A that houses the inner tube 10A.
• the inner pipe 10A is cylindrical, as shown in Figures 3 and 4, to allow the refrigerant to flow through it.
• the end of the cylinder is connected to the refrigerant inlet of the distributor 1A, and the refrigerant is supplied into it.
• the inner pipe 10A has multiple orifices 11 formed in its cylindrical surface, as shown in Figures 3 and 4.
• the cylindrical axis of the inner pipe 10A is oriented in the direction of the pipe axis A1 described using Figure 1.
• the orifices 11 are arranged at equal intervals in the direction of the pipe axis A1. As a result, the orifices 11 discharge the refrigerant evenly in the direction of the pipe axis A1, thereby distributing the refrigerant evenly.
• the inner tube 10A is made of a material with a higher melting point than the brazing material to prevent the orifice 11 from being blocked during the brazing process in the manufacture of the heat exchanger 100.
• the inner tube 10A is made of an Al-Mn aluminum alloy, specifically, an A3003 alloy. This prevents the inner tube 10A from melting when heated during the brazing process, and as a result, the inner tube 10A prevents the orifice 11 from being blocked by the molten material.
• the inner tube 10A is then housed in the outer tube 20A.
• the outer tube 20A is formed by combining two components to accommodate the inner tube 10A. That is, as shown in Figures 2-4, the outer tube 20A is formed by combining a main body portion 21A and a cover portion 22A.
• the main body 21A is formed in the shape of a gutter extending in the direction of the pipe axis A1, i.e., a U-shaped cross section.
• the inner diameter R1 of the main body 21A in the front-to-rear direction, i.e., the Y direction, of the U-shaped cross section is larger than the outer diameter R2 of the inner pipe 10A.
• the main body 21A accommodates the inner pipe 10A by inserting it through the opening of the U-shaped cross section.
• the inner pipe 10A is located in the center of the internal space of the U-shaped cross section. In other words, the cylindrical axis of the inner pipe 10A is coaxial with the pipe axis A1.
• the inner surface of the main body 21A surrounds the outer surface of the inner pipe 10A, leaving a space between the inner surface of the main body 21A and the outer surface of the inner pipe 10A.
• the inner surface of the main body 21A does not block the opening of the orifice 11, allowing the refrigerant to flow from the orifice 11 into the internal space of the main body 21A.
• the main body 21A spreads the refrigerant throughout the entire pipe.
• the main body 21A has the same number of through holes formed, each with the same shape as the cross-sectional shape of the heat transfer tubes 3.
• the ends of the heat transfer tubes 3 are inserted into the through holes and joined with brazing material, thereby connecting the heat transfer tubes 3 to the main body 21A.
• the refrigerant flows through the tubes in the main body 21A, the refrigerant is distributed to the heat transfer tubes 3.
• the cover portion 22A is formed with an inverted U-shape in cross section that is smaller than the main body portion 21A.
• the width of the cover portion 22A in the Y direction is larger than the Y direction width W1 of the opening of the U-shape in cross section of the main body portion 21A, to the extent that it can be lightly press-fitted.
• the cover portion 22A is fitted into the opening of the main body portion 21A with the side with the opening of the inverted U-shape in cross section facing the side with the opening of the main body portion 21A, that is, with the -Z surface side of the cover portion 22A facing the +Z surface side of the main body portion 21A. More specifically, the cover portion 22A is lightly press-fitted. As a result, the cover portion 22A blocks the opening of the main body portion 21A.
• the main body 21A is provided with dowels 211 that protrude inward from the inner peripheral surface. More specifically, dowels 211 are provided on each of the two opposing sidewalls of the main body 21A. The dowels 211 are located a fixed distance away from the +Z end of each of the two sidewalls. As a result, the dowels 211 are located a fixed distance inward from the opening end of the main body 21A. Furthermore, each dowel 211 is formed using the half-pierce method, resulting in a shape in which the sidewalls of the main body 21A locally protrude inward.
• the cover 22A is lightly press-fitted into the opening of the main body 21A, and the -Z end of the cover 22A abuts against the dowels 211, thereby determining its position relative to the opening end of the main body 21A.
• multiple dowels 211 are formed at a constant pitch across the entire body portion 21A in the direction of the tube axis A1.
• the -Z end of the cover portion 22A abuts against each of the dowels 211, thereby determining its position across the entire body portion, and as a result, completely covering the opening of the body portion 21A.
• the main body 21A is provided with a plurality of claws 212 on the +Z side that are bent along the outer peripheral surface of the cover part 22A.
• the claws 212 extend from the +Z end of the opening of the main body 21A toward the +Z side and the inside of the opening. As a result, the claws 212 extend along the +Z side surface of the cover part 22A.
• the claws 212 hold the cover part 22A by extending along the +Z side surface of the cover part 22A. As a result, the claws 212 firmly secure the cover part 22A to the main body 21A.
• multiple claw portions 212 are formed at a constant pitch across the entire body portion 21A in the direction of the tube axis A1.
• the cover portion 22A is firmly fixed to the body portion 21A across its entire length.
• the main body 21A and cover 22A are formed by molding a plate of clad material covered with brazing material.
• the main body portion 21A is formed from a clad material plate having a plate-shaped core material 213 and a coating layer 214 covering one side of the core material 213.
• the core material 213 is formed from a material with a higher melting point than the brazing material, for example, an Al-Mn aluminum alloy, specifically, A3003 alloy.
• the coating layer 214 is formed from a brazing material, for example, an Al-Si aluminum alloy, specifically, A4343 alloy.
• the main body portion 21A is formed by bending the coating layer 214 outward and the core material 213 inward. As a result, the inner peripheral surface of the main body portion 21A, which is U-shaped in cross section, is formed from the core material 213.
• the inner peripheral surface of the main body portion 21A does not melt during the brazing process, and if it comes into contact with the outer peripheral surface of the inner tube 10A, molten material will not adhere to the outer peripheral surface of the inner tube 10A. This prevents the orifice 11 from becoming blocked.
• the cover portion 22A is formed from a clad plate having a plate-shaped core material 223 and a coating layer 224 that covers one side of the core material 223.
• the materials and bending direction of the core material 223 and coating layer 224 are the same as those of the core material 213 and coating layer 214 of the main body portion 21A.
• the cover portion 22A is lightly press-fitted into the U-shaped cross-sectional opening of the main body portion 21A with the coating layer 224 facing outward. As a result, both ends of the inverted U-shaped cross-section of the coating layer 224 of the cover portion 22A contact the inner circumferential surface of the main body portion 21A.
• the portion of the coating layer 224 connecting both ends of the inverted U-shaped cross-section contacts the inner circumferential surface of the claw portion 212.
• the contacting portions of the coating layer 224 are melted during the brazing process, thereby joining the cover portion 22A to the main body portion 21A.
• the core material 223 forms the inner circumferential surface of the cover portion 22A.
• the inner circumferential surface of the cover portion 22A does not melt during the brazing process, and if the outer circumferential surface of the inner tube 10A comes into contact with it, the orifice 11 is prevented from being blocked by molten material.
• the main body portion 21A and cover portion 22A of outer tube 20A have inner circumferential surface portions formed of a material with a higher melting point than the brazing material, so the inner circumferential surface portions do not melt during the brazing process.
• the orifice 11 is prevented from being blocked by molten material adhering to the outer circumferential surface portion of inner tube 10A.
• Figure 5 is a flowchart of the manufacturing method for the heat exchanger 100.
• Figure 6 is a cross-sectional view of the main body portion 21A of the outer tube 20A when the heat transfer tubes 3, fins 4, and inner tube 10A are assembled in the manufacturing method for the heat exchanger 100.
• Figure 7 is a cross-sectional view of the main body portion 21A of the outer tube 20A when the cover portion 22A is lightly press-fitted.
• the heat transfer tube 3, fins 4, main body 21A and cover 22A of the inner tube 10A and outer tube 20A, each having the above-described shape are fabricated (step S1).
• the heat transfer tube 3 is fabricated by extruding a metal material of the above-described material.
• the outer surface of the heat transfer tube 3 may be coated with brazing material to make it easier to join the heat transfer tube 3 to the outer tube 20A, although this is not necessarily desirable compared to leaving the opening of the orifice 11 intact without contacting the molten brazing material with the inner tube 10A.
• the fins 4, main body 21A and cover 22A of the inner tube 10A and outer tube 20A, each having the above-described shape are fabricated by pressing a metal plate of the above-described material.
• the heat transfer tube 3, fins 4, and inner tube 10A are attached to the main body 21A of the outer tube 20A (step S2).
• the fins 4 are attached to the heat transfer tube 3, and the end of the heat transfer tube 3 in this state is inserted into the through-hole 215 formed in the main body 21A, as shown in Figure 6.
• the inner tube 10A is inserted into the internal space of the main body 21A.
• the inner tube 10A is positioned coaxially with the main body 21A.
• the orifice 11 is oriented, for example, toward the side wall portions that face each other in the vertical direction of the U-shaped cross section of the main body 21A.
• the cover portion 22A is lightly press-fitted into the main body portion 21A of the outer tube 20A (step S3).
• the width W2 of the cover portion 22A is larger than the width W1 of the U-shaped cross-sectional opening of the main body portion 21A to the extent that light press-fitting is possible.
• the cover portion 22A is pressed into the main body portion 21A.
• the claws 212 provided on the main body 21A are bent so that the claws 212 are aligned with the outer peripheral surface of the cover 22A. This causes the claws 212 to crimp the cover 22A. As a result, the cover 22A is held by the claws 212.
• brazing is performed (step S4). Specifically, the main body portion 21A, into which the cover portion 22A was lightly press-fit in step S3, is heated to melt the brazing material. At this time, as shown in FIGS. 6 and 7, because the cylindrical axis of the inner tube 10A is oriented horizontally, gravity can cause the inner tube 10A to bend and come into contact with the inner surface of the main body portion 21A. However, the inner surfaces of the main body portion 21A and cover portion 22A of the outer tube 20A are formed from core materials 213 and 223, which do not melt at the temperature at which the brazing material melts.
• the inner tube 10A is surrounded by these inner surfaces, molten material does not adhere to the inner surface even if it bends and comes into contact with these inner surfaces. As a result, the orifice 11 formed in the inner tube 10A is prevented from being blocked by the brazing material.
• the main body portion 21A is heated until it reaches a temperature at which the brazing material in the coating layers 214, 224 melts.
• the outer peripheral surface of the heat transfer tube 3 is coated with brazing material, it is heated until it reaches a temperature at which the brazing material in the heat transfer tube 3 melts, in addition to the brazing material in the coating layers 214, 224.
• the molten brazing material is solidified by cooling. This completes the brazing in step S4.
• the heat transfer tube 3 is joined to the main body portion 21A by the brazing material in the coating layer 214 of the main body portion 21A of the outer tube 20A.
• the heat transfer tube 3 is joined to the main body portion 21A by the brazing material in the heat transfer tube 3.
• the cover portion 22A is joined to the main body portion 21A by the brazing material in the coating layer 224 of the cover portion 22A of the outer tube 20A.
• the distributor 1A is completed through the above steps.
• the heat transfer tubes 3 and fins 4 are also assembled and brazed for the distributor 2A, completing the heat exchanger 100 with the distributor 2A attached as well as the distributor 1A. This completes the manufacturing method for the heat exchanger 100.
• the cover portion 22A is lightly press-fitted into the main body portion 21A of the outer tube 20A, but in embodiment 1, it is sufficient that the cover portion 22A is fitted into the main body portion 21A of the outer tube 20A. Therefore, the cover portion 22A may be fitted into the main body portion 21A of the outer tube 20A by an interference fit, for example, by press fitting or strong press fitting. The cover portion 22A may also be fitted into the main body portion 21A of the outer tube 20A by an intermediate fit, for example, by hammering. This is because these methods also allow the cover portion 22A and the main body portion 21A to be joined with sufficient bonding strength.
• the main body portion 21A of the outer pipe 20A described above is an example of a first member as defined in the present disclosure.
• the cover portion 22A of the outer pipe 20A is an example of a second member as defined in the present disclosure.
• the cylindrical portion of the outer pipe 20A which is elliptical in cross section and formed by combining the main body portion 21A, which is U-shaped in cross section, and the cover portion 22A, which is inverted U-shaped in cross section, is an example of a cylindrical portion as defined in the present disclosure.
• the inner surface portion of the outer pipe 20A is an example of a portion facing an orifice as defined in the present disclosure.
• the dowel 211 is an example of a convex portion as defined in the present disclosure.
• the heat transfer tube 3 is an example of a refrigerant tube through which a refrigerant is distributed as defined in the present disclosure.
• steps S2 and S3 are an example of a process for assembling an outer tube having what is referred to in this disclosure as a cylindrical portion, placing an inner tube in the internal space of the cylindrical portion, and aligning an orifice with a portion of the inner circumferential surface.
• the inner circumferential surface portion of the outer tube 20A is constructed from core materials 213, 223 formed from a material with a higher melting point than the brazing material.
• This inner circumferential surface portion faces the orifice 11 of the inner tube 10A. Therefore, the inner circumferential surface portion of the outer tube 20A does not melt during brazing and function as the brazing material. As a result, even if the inner tube 10A bends and the orifice 11 comes into contact with the inner circumferential surface portion of the outer tube 20A, the orifice 11 is prevented from being blocked by the brazing material.
• the outer tube 20A is assembled by lightly press-fitting the cover portion 22A into the main body portion 21A, allowing the main body portion 21A and the cover portion 22A to be firmly joined with a small amount of brazing material. As a result, when brazing the main body portion 21A and the cover portion 22A, the brazing material is prevented from leaking onto the inner surface of the outer tube 20A. As a result, the orifice 11 is less likely to be blocked by the brazing material.
• the main body 21A and the cover 22A of the outer pipe 20A have coating layers 214, 224 formed of a brazing material.
• the outer pipe 20A is not limited to this.
• the outer pipe 20A has an inner diameter larger than the outer diameter of the inner pipe 10A, and the inner pipe 10A is accommodated in the internal space formed by the inner circumferential surface portion so that the inner circumferential surface portion surrounds the outer circumferential surface portion of the inner pipe 10A.
• the inner circumferential surface portion of the outer pipe 20A is formed of a material with a higher melting point than the brazing material, and has a portion facing the orifice 11. Therefore, only the cover 22A of the outer pipe 20A may have the coating layer 224.
• distributor 1B In the distributor 1B according to embodiment 2, only the cover portion 22B has the coating layer 224.
• the configuration of distributor 1B will be described below with reference to Figure 8. The description of embodiment 2 will focus on the configuration that differs from embodiment 1.
• Figure 8 is a cross-sectional view of distributor 1B according to embodiment 2. Note that Figure 8 shows a cross-section taken along the same cutting line as the III-III cutting line shown in Figure 2.
• main body 21B provided on outer tube 20B is formed only by core material 213, without the coating layer 214 described in embodiment 1.
• cover portion 22B like embodiment 1, has core material 223 and coating layer 224.
• the coating layer 224 is disposed facing the outside of outer tube 20B.
• the end of the coating layer 224 of cover portion 22B which is inverted U-shaped in cross section, abuts against the core material 213 of main body portion 21B.
• Cover portion 22B is joined to the core material 213 of main body portion 21B by a brazing material portion formed by melting the end of the coating layer 224. This allows cover portion 22B to be integrated with main body portion 21B.
• the inner surface portion of the outer tube 20B is formed from core materials 213 and 223.
• the inner surface portion of the outer tube 20B is formed from a material with a higher melting point than the brazing material, and does not melt during the brazing process.
• the orifice 11 is prevented from being blocked by the brazing material.
• the cover 22B has a coating layer 224 formed from a brazing material.
• the coating layer 224 faces the outer peripheral surface of the outer tube 20B.
• the inner peripheral surface of the outer tube 20B is formed from core materials 213 and 223 made of a material with a higher melting point than the brazing material. For this reason, the inner peripheral surface of the outer tube 20B does not melt during the brazing process when manufacturing the distributor 1B, and even if the inner tube 10B comes into contact with the inner peripheral surface of the outer tube 20B, the orifice 11 will not be blocked by the molten material.
• the inner circumferential surface portions of the outer tubes 20A, 20B are formed of a material having a higher melting point than the brazing material and have a portion facing the orifice 11. Therefore, the cover portions 22A, 22B may be formed only of the core material 223 without having the coating layer 224.
• Figure 9 is a cross-sectional view of a modified example of distributor 1B.
• Figure 10 is a cross-sectional view of another modified example of distributor 1B.
• Figures 9 and 10 also show cross sections taken along the same line as the III-III line shown in Figure 2.
• the cover portion 22B may be formed only from a core material 223 and joined to the main body portion 21B by a brazing material portion 225.
• the brazing material portion 225 is a portion formed by the penetration of molten brazing material into the gap between the cover portion 22B and the main body portion 21B during the brazing process when manufacturing the distributor 1B, and is formed, for example, by a pre-placed brazing material or a paste brazing material.
• the cover portion 22B is lightly press-fitted into the main body portion 21B, so that the molten brazing material can penetrate between the cover portion 22B and the main body portion 21B.
• the brazing material portion 225 is formed by the penetration of molten brazing material between the cover portion 22B and the main body portion 21B.
• the inner surface portion of the outer tube 20B is also formed from a material with a higher melting point than the brazing material. Therefore, even if the inner tube 10B comes into contact with the inner surface portion of the outer tube 20B during the brazing process, the orifice 11 will not be blocked by the molten material.
• the main body portion 21B of the outer tube 20B and the heat transfer tube 3 can be joined by the penetration of molten brazing material between the main body portion 21B and the heat transfer tube 3 during the brazing process, for example, by using a pre-placed brazing material or a paste brazing material.
• the cover portion 22B may be formed only from a core material 223 and attached to the main body portion 21B by fitting it into a U-shaped opening in cross section of the main body portion 21B.
• the cover portion 22B is preferably joined to the main body portion 21B by fitting, rather than by brazing material.
• the fitting is preferably a light press fit, which facilitates assembly and ensures sufficient bonding strength.
• the fitting may be a press fit or a strong press fit.
• the inner circumferential surface of the outer tube 20B can be formed from a material with a higher melting point than the brazing material, thereby preventing the orifice 11 from becoming blocked.
• the ends of the U-shaped cross-section of the main body portions 21A and 21B of the outer tubes 20A and 20B are linear in cross-section.
• the ends of the inverted U-shaped cross-section of the cover portions 22A and 22B of the outer tubes 20A and 20B are also linear in cross-section.
• the shapes of the main body portions 21A and 21B and the cover portions 22A and 22B are not limited to this.
• the main body portions 21A and 21B only need to form a portion of a cylindrical portion whose inner diameter is larger than the outer diameter of the inner tube 10A.
• the cover portions 22A and 22B only need to form the remaining portion of the cylindrical portion and be joined to the main body portions 21A and 21B with brazing material.
• the shapes of the main body portions 21A and 21B and the cover portions 22A and 22B of the outer tube 20B are arbitrary as long as they satisfy this condition.
• the main body 21C of the outer tube 20C has a sloped surface at the open end of its U-shaped cross section to make it easier to fit the cover 22C.
• the configuration of distributor 1C will be described below with reference to Figure 11. The description of embodiment 3 will focus on the differences in configuration from embodiments 1 and 2.
• Figure 11 is a cross-sectional view of a distributor 1C according to embodiment 3. Note that Figure 11 shows a cross section taken along the same cutting line as the III-III cutting line shown in Figure 2.
• the outer tube 20C includes a main body 21C and a cover 22C.
• Chamfered portions 216 and 217 are formed at the corners formed by the end faces and inner peripheral surfaces of the two opposing side wall portions of the main body 21C that form a U-shaped cross section.
• the chamfered portions 216, 217 have an outward sloping surface toward the end face of the side wall portion of the U-shaped cross section of the main body portion 21C. That is, the chamfered portion 216 has an inclined surface that slopes toward the +Y side toward the +Z end of the side wall portion. The chamfered portion 217 has an inclined surface that slopes toward the -Y side toward the +Z end of the side wall portion.
• the chamfered portions 216, 217 can guide the end of the inverted U-shaped cross section of the cover portion 22C into the inside of the U-shaped cross-sectional opening of the main body portion 21C. This makes it easy to press-fit the cover portion 22C into the main body portion 21C.
• the inner circumferential surface of main body 21C of outer tube 20C is formed from a material with a higher melting point than the brazing filler metal. Therefore, even if outer tube 20C comes into contact with the outer circumferential surface of inner tube 10C, the molten brazing filler metal is less likely to adhere to the outer circumferential surface of inner tube 10C. As a result, even in distributor 1C, the orifice of inner tube 10C is less likely to become clogged.
• dowels 211 are formed on the main body 21C of the outer tube 20C, but the presence or absence of the dowels 211 is optional. Therefore, in distributor 1C, the dowels 211 may be omitted.
• chamfered portions 216, 217 are provided at the corners formed by the opening periphery and inner peripheral surface of the main body portion 21C of the outer tube 20C. This makes it easier to lightly press-fit the cover portion 22C into the main body portion 21C during manufacturing.
• chamfered portions 216, 217 are provided on the inner surface side of the opening end portion of the main body portion 21C of the outer tube 20C, but the configuration that makes it easier to lightly press-fit the cover portion 22C is not limited to this.
• Figure 12 is a cross-sectional view of a modified example of distributor 1C according to embodiment 3.
• Figure 13 is a cross-sectional view of another modified example of distributor 1C.
• Figure 14 is a cross-sectional view of yet another modified example of distributor 1C. Note that Figures 12 to 14 show cross sections taken along the same cutting line as the III-III cutting line shown in Figure 2.
• cover portion 22C of outer tube 20C may have chamfered portions 226, 227.
• chamfered portions 226, 227 may be provided on the outer peripheral surface of each end of two opposing side wall portions of the inverted U-shape of cover portion 22C in cross section. This configuration makes it easier to lightly press-fit cover portion 22C into main body portion 21C during manufacturing.
• the two opposing sidewall portions of the U-shaped cross section of main body 21C of outer tube 20C may be bent outward at the opening end portions.
• the width of the opening may increase toward the opening end. This configuration also makes it easier to lightly press-fit cover 22C into main body 21C during manufacturing.
• main body 21C of outer tube 20C is elastically or plastically deformable, and the width W1 of the U-shaped cross-sectional opening of main body 21C of outer tube 20C may be smaller than the width W3 of the internal space at the back of the opening.
• cover portion 22C is lightly press-fitted into the U-shaped cross-sectional opening of main body 21C during manufacturing of distributor 1C, the force applied by the light press-fitting may elastically or plastically deform main body 21C, expanding the width W1 of the opening to a size that allows cover portion 22C to be inserted.
• the width W1 when the cover portion 22C is lightly press-fitted into the main body portion 21C, the width W1 is smaller than the width W3. However, when the cover portion 22C is not lightly press-fitted into the main body portion 21C, the width W1 may be smaller than the width W3, and when the cover portion 22C is lightly press-fitted into the main body portion 21C, the width W1 may be greater than or equal to the width W3.
• the distributor 1A-1C, heat exchanger 100, and manufacturing method of distributor 1A-1C and heat exchanger 100 according to the embodiments of the present disclosure have been described above, but the manufacturing methods of distributor 1A-1C, heat exchanger 100, and distributor 1A-1C and heat exchanger 100 are not limited to these.
• the inner tubes 10A-10C are cylindrical.
• the inner tubes 10A-10C are not limited to this.
• the inner tubes 10A-10C only need to have an orifice 11 on their outer circumferential surface, and the refrigerant will flow out from the orifice 11. Therefore, the specific shape of the inner tubes 10A-10C is arbitrary as long as it satisfies condition (a).
• the inner tubes 10A-10C may be a square tube with rounded corners or a square tube with right-angled corners.
• the orifice 11 hole is oriented toward the sidewall portion of the U-shaped cross section of the main body portions 21A-21C of the outer tubes 20A-20C. In other words, it is oriented in the Y direction.
• the orientation of the orifice 11 hole is not limited to this.
• the orifice 11 only needs to be provided on the outer peripheral surface portion of the inner tubes 10A-10C. Therefore, the orientation of the orifice 11 hole is arbitrary as long as it satisfies condition (b).
• the orifice 11 may be oriented toward the cover portions 22A-22C of the outer tubes 20A-20C.
• the outer tubes 20A-20C have a rectangular cylindrical shape with rounded corners, in other words, an oval shape in cross section.
• the outer tubes 20A-20C are not limited to this.
• the outer tubes 20A-20C have an inner diameter larger than the outer diameter of the inner tubes 10A-10C, and the inner circumferential surface portion may accommodate the inner tubes 10A-10C in an internal space formed by the inner circumferential surface portion, with the inner circumferential surface portion surrounding the outer circumferential surface portion of the inner tubes 10A-10C.
• the outer tubes 20A-20C may completely accommodate the entire inner tubes 10A-10C, or may accommodate only a portion of the inner tubes 10A-10C.
• the outer tubes 20A-20C may have a first member forming a portion of the tubular section whose inner diameter is larger than the outer diameter of the inner tubes 10A-10C, and a second member forming the remaining portion of the tubular section and joined to the first member with brazing material, and may house the inner tubes 10A-10C in an internal space formed by the inner circumferential surface of the tubular section, with the inner circumferential surface surrounding the outer circumferential surface of the inner tubes 10A-10C.
• the first member refers, for example, to the main body portions 21A-21C described in embodiments 1-3.
• the second member refers, for example, to the cover portions 22A-22C described in embodiments 1-3.
• the specific shape of the outer tubes 20A-20C is arbitrary as long as it satisfies the above condition (d).
• the outer tubes 20A-20C may be cylindrical, i.e., circular tubes, or may be angular, i.e., rectangular tubes, for example.
• multiple dowels 211 are formed at a constant pitch in the direction of the tube axis A1 across the entire main body 21A of the outer tubes 20A-20C.
• the outer tubes 20A-20C are not limited to this.
• the outer tubes 20A-20C may be any tube that satisfies the above-mentioned conditions (c) and (d). Therefore, the presence or absence of dowels 211 is optional.
• the shape of the dowels is also optional.
• Figure 15 is an enlarged front view of a first modified example of the dowel 211 provided in the distributor 1A according to embodiment 1.
• the dowel 211 may extend in the direction of the tube axis A1, and as a result, extend over the entire body portion 21A of the outer tube 20A.
• the dowel 211 prevents the molten brazing material from flowing into the internal space of the outer tube 20A through the gap between the cover portion 22A and the body portion 21A. As a result, the orifice 11 is prevented from being blocked.
• the outer tubes 20A-20C do not necessarily have to have the dowel 211.
• Figure 16 is a cross-sectional view of a modified outer tube 20A provided in the distributor 1A according to embodiment 1. Note that Figure 16 shows a cross-section taken along a cutting line that cuts the same location as the III-III cutting line shown in Figure 2.
• the Y-direction width of the cover portion 22A is larger than the width W4 to an extent that it can be lightly press-fitted, and larger than the inner diameter R3 to an extent that it cannot be press-fitted. If the main body portion 21A has this shape, when the cover portion 22A is lightly press-fitted into the main body portion 21A, the cover portion 22A cannot be lightly press-fitted beyond a certain depth from the opening of the main body portion 21A, and as a result, the press-fit length of the cover portion 22A can be kept constant.
• the end of the inverted U-shaped cross section of the cover portion 22A can be abutted against a step 218 on the inner surface of the main body portion 21A, and the step 218 can be used to position the cover portion 22A.
• the brazing process in the manufacturing method of the heat exchanger 100 and distributors 1A-1C is performed by simply heating the main body portion 21A into which the cover portion 22A is lightly press-fitted.
• the brazing process is not limited to this.
• the brazing process may use at least one brazing jig that maintains the positional relationship between the main body portion 21A and the cover portion 22A.
• the cover portion 22A may be fixed to the main body portion 21A with at least one brazing jig, and heated to melt the brazing material.
• Figure 17 is a cross-sectional view of a brazing jig 30 used in the brazing process of a modified example of the manufacturing method of distributor 1A according to embodiment 1, and the main body portion 21A and cover portion 22A fixed by the brazing jig 30.
• Figure 18 is an enlarged front view showing an example of the mounting position of the brazing jig 30 used in the brazing process.
• Figure 19 is an enlarged front view showing another example of the mounting position of the brazing jig 30 used in the brazing process.
• the brazing process may use a brazing jig 30 having an inverted U-shaped cross section, as shown in Figure 17.
• the main body portion 21A and cover portion 22A to be brazed are in a state in which the cover portion 22A, which is inverted U-shaped in cross section, is lightly press-fit into the U-shaped opening of the main body portion 21A, which is U-shaped in cross section.
• the brazing jig 30 is placed over the main body portion 21A and cover portion 22A in this state and tightens the side walls of the U-shape of the main body portion 21A.
• tightening the brazing jig 30 compresses the main body portion 21A and cover portion 22A by a compression amount P on each of the +Y side and the -Y side, and the sum of these compression amounts, 2P, is preferably the amount equivalent to the amount of light press-fit. This is because, if the brazing jig 30 is tightened in this manner, even if the cover portion 22A is not lightly press-fitted into the main body portion 21A, the brazing jig 30 tightens the side wall of the main body portion 21A, thereby allowing the cover portion 22A to be lightly press-fitted into the main body portion 21A. It is preferable that the brazing jig 30 be tightened at a brazing temperature, for example, 600°C.
• the brazing jig 30 is preferably made of a material with a smaller linear expansion coefficient than the material of the main body 21A and the cover 22A.
• the brazing jig 30 is preferably made of stainless steel or carbon. If the brazing jig 30 is made of stainless steel, a lubricant may be applied to the brazing jig 30. For example, carbon may be sprayed onto the brazing jig 30 using a carbon spray.
• a specific surface shape may be formed on the surface of the brazing jig 30, resulting in the surface of the brazing jig 30 having a specific surface roughness.
• the brazing jig 30 may be able to transfer the specific surface shape by plastically deforming the side wall of the clamped main body portion 21A. This is because such a brazing jig 30 can process the side wall of the main body portion 21A to have the above-mentioned surface roughness.
• the above-mentioned surface roughness can improve the drainage properties of the main body portion 21A.
• brazing jig 30 is formed with a thickness in the X direction that is shorter than the main body portion 21A and the cover portion 22A, it is desirable to prepare multiple brazing jigs 30. These multiple brazing jigs 30 can then be placed in positions that overlap the dowels 211 to fasten the main body portion 21A. Alternatively, as shown in Figure 19, these multiple brazing jigs 30 can be placed between the dowels 211 to fasten the main body portion 21A without the brazing jigs 30 overlapping the dowels 211.
• multiple claw portions 212 are provided on the main body portions 21A-21C of the outer pipes 20A-20C.
• the outer pipes 20A-20C only need to satisfy the above-mentioned conditions (c) and (d). Therefore, the presence or absence of the claw portions 212 is optional.
• the main body portion 21A of the outer pipes 20A-20C may not be provided with the claw portions 212, in which case the above-mentioned brazing jig 30 may be used in the brazing process. This is because the brazing jig 30 performs the same function as the claw portions 212, which firmly join the main body portion 21A and the cover portion 22A. As a result, when the brazing jig 30 is used in the brazing process, the main body portion 21A and the cover portion 22A can be firmly joined.
• Figure 20 is an enlarged front view showing an example of a brazing jig 30 used in the brazing process included in the manufacturing method of a modified example of the distributor 1A according to embodiment 1.
• Figure 21 is a front view showing another example of the brazing jig 30.
• Figure 22 is a front view showing yet another example of the brazing jig 30.
• the outer tube 20A does not have a claw portion 212, but may have a dowel 211.
• At least one of the above-mentioned brazing jigs 30 may be used in the brazing process of a modified manufacturing method for a distributor 1A including such an outer tube 20A.
• each brazing jig 30 may be positioned so as to overlap one dowel 211 in a front view as shown in FIG. 20.
• each brazing jig 30 may have a width that overlaps multiple dowels 211 in a front view, and may be positioned so as to overlap multiple dowels 211.
• the brazing jig 30 may cover the entire main body portion 21A and cover portion 22A, specifically the entire X-direction, as shown in FIG. 22, and tighten the entire U-shaped side wall of the main body portion 21A in the X-direction.
• the brazing jig 30 may clamp the entire U-shaped side wall of the main body 21A in the X direction, or may clamp only a portion of the U-shaped side wall in the X direction.
• the claws 212 are bent along the outer circumferential surfaces of the cover portions 22A-22C, resulting in an arc-shaped bend.
• the presence or absence of the claws 212 is optional, and as a result, when the main body portions 21A-21C are provided with the claws 212, the shape of the claws 212 is also optional.
• the core materials 213, 223 of the main body portions 21A-21C and cover portions 22A-22C of the outer tubes 20A-20C are described as being made of an Al-Mn-based aluminum alloy, and the coating layers 214, 224 are made of an Al-Si-based aluminum alloy.
• the core materials 213, 223 are formed of a material with a higher melting point than the brazing material, and the coating layers 214, 224 are formed of the brazing material.
• the material with a higher melting point than the brazing material that forms the core materials 213, 223 refers to a material with a higher melting point than the brazing material that forms the coating layers 214, 224, or a material with a higher melting point than the brazing material that forms the coating layer that covers the outer surface of the heat transfer tube 3. Therefore, the material of the core materials 213, 223 may be any material as long as it satisfies the above condition (e).
• distributors 1A-1C are provided on the top of heat exchanger 100, but distributors 1A-1C are not limited to this and may be applicable to heat exchangers 100 in general.
• the heat exchanger 100 includes the heat transfer tubes 3 and fins 4 in addition to the distributors 1A-1C, but the heat exchanger 100 is not limited to this.
• the heat exchanger 100 may not include the fins 4, but may include only the distributors 1A-1C and the heat transfer tubes 3, i.e., the refrigerant tubes.
• distributors 1A-1C, heat exchanger 100, the manufacturing method of distributors 1A-1C, and the manufacturing method of heat exchanger 100 are not limited to the above embodiments, and various modifications and substitutions can be made.
• Various embodiments of the present disclosure are described below as appendices.
• Appendix 1 an inner pipe having an orifice on its outer circumferential surface from which the refrigerant flows; an outer tube having an inner diameter larger than an outer diameter of the inner tube, and accommodating the inner tube in an internal space defined by an inner circumferential surface portion such that the inner circumferential surface portion surrounds the outer circumferential surface portion of the inner tube; Equipped with a plurality of refrigerant pipes, which are joined to the outer pipe by brazing material and through which the refrigerant is distributed, are connected; a portion of the inner circumferential surface of the outer tube facing the orifice is formed of a material having a melting point higher than that of the brazing material; distributor.
• the entire inner circumferential surface portion including the facing portion is formed of the material having a melting point higher than that of the brazing material; 3.
• the distributor of claim 1 or 2. the first member has an opening in the part of the cylindrical portion that exposes an internal space of the cylindrical portion, the second member is fitted into the opening, and a portion of the second member that comes into contact with an inner wall of the opening is covered with a coating layer formed from the brazing material; 3.
• the first member has a U-shape when viewed in a cross section perpendicular to a cylindrical axis of the cylindrical portion,
• the second member has a U-shape that is smaller than the U-shape of the first member when viewed in cross section, and is fitted inside the U-shaped opening of the first member.
• the distributor of claim 2. (Appendix 6)
• the first member has a chamfered portion at a corner portion formed by an end portion of the U-shape and an inner surface portion when viewed in the cross section. 6.
• the U-shape of the first member when viewed in cross section has a shape in which the opening becomes larger toward the opening end. 7.
• the second member has a chamfered portion at a corner portion formed by an outer surface and an end portion of the other U-shape when viewed in the cross section.
• the distributor of any one of claims 5 to 7. the first member has, on the inner surfaces of two opposing side wall portions of the U-shape when viewed in the cross section, a protrusion that abuts against an end of another U-shape of the second member when viewed in the cross section and determines the position of the end when the second member is fitted; 9.
• the distributor of any one of claims 5 to 8. (Appendix 10) The protrusion extends in the direction in which the cylindrical axis of the cylindrical portion extends. 10.
• the first member has a step on each of inner surfaces of two side wall portions facing each other in the U-shape when viewed in the cross section, and a distance between the two side wall portions on the opening side is larger than the distance between the step portions;
• Each end of the second member having a U-shape when viewed in cross section abuts against each of the steps.
• (Appendix 12) A distributor according to any one of Supplementary Notes 1 to 11; and a plurality of refrigerant pipes connected to the distributor, through which the refrigerant is distributed from the distributor and through which the heat of the refrigerant is transferred by the flow of the refrigerant; a plurality of fins attached to the plurality of refrigerant pipes; Equipped with heat exchanger.
• (Appendix 13) a step of assembling an outer tube including the cylindrical portion by combining a first member forming a part of the cylindrical portion with a second member forming the remaining part of the cylindrical portion and having a brazing material provided in a part that will become a joining part when combined and joined with the first member, and further, placing an inner tube having an orifice on its outer peripheral surface and an outer diameter smaller than the inner diameter of the cylindrical portion in the internal space of the cylindrical portion, and arranging the orifice opposite a part of an inner peripheral surface of either the first member or the second member that is made of a material having a higher melting point than the brazing material; a step of brazing the second member to the first member by heating the assembled cylindrical portion and the inner tube disposed in the internal space of the cylindrical portion at a temperature higher than the melting point of the brazing material to melt the brazing material; Equipped with A method for manufacturing a distributor.
• the first member has a U-shape when viewed in a cross section perpendicular to a cylindrical axis of the cylindrical portion, the second member has a U-shape that is smaller than the U-shape of the first member when viewed in cross section and that can be fitted into the U-shaped opening of the first member;
• the second member is lightly press-fitted into the U-shaped opening of the first member, thereby assembling them.
• Appendix 19 A method for manufacturing a distributor according to any one of appendices 13 to 18, before the step of brazing the second member to the first member, a step of assembling a plurality of refrigerant pipes, each having a plurality of fins attached thereto, to the combined first member and the second member; A method for manufacturing a heat exchanger.

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