JPWO2020217940A1 - Heat exchanger manufacturing method and heat exchanger - Google Patents

Heat exchanger manufacturing method and heat exchanger Download PDF

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JPWO2020217940A1
JPWO2020217940A1 JP2021515943A JP2021515943A JPWO2020217940A1 JP WO2020217940 A1 JPWO2020217940 A1 JP WO2020217940A1 JP 2021515943 A JP2021515943 A JP 2021515943A JP 2021515943 A JP2021515943 A JP 2021515943A JP WO2020217940 A1 JPWO2020217940 A1 JP WO2020217940A1
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heat transfer
transfer tube
outer shell
heat exchanger
shell wall
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里美 浅井
政博 横井
卓 関谷
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Mitsubishi Electric Corp
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Mitsubishi Electric Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D28/00—Shaping by press-cutting; Perforating
    • B21D28/24—Perforating, i.e. punching holes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
    • B21D53/08—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of both metal tubes and sheet metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • 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
    • F28F9/007—Auxiliary supports for elements
    • F28F9/013—Auxiliary supports for elements for tubes or tube-assemblies
    • 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

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
  • Punching Or Piercing (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

熱交換器（１Ａ）の製造方法は、伝熱管（２０）と、伝熱管（２０）が溶接された外殻壁（１１）を有する分配器（１０）と、を備える熱交換器（１Ａ）の製造方法である。熱交換器（１Ａ）の製造方法は、外殻壁（１１）の一部の領域に、伝熱管（２０）の外径よりも厚みが小さい肉薄部（１４Ａ）を形成する肉薄部形成工程と、肉薄部（１４Ａ）に伝熱管（２０）が挿入可能な貫通孔（１３Ａ）を形成する貫通孔形成工程と、貫通孔（１３Ａ）に伝熱管（２０）を挿入し、挿入した伝熱管（２０）と貫通孔（１３Ａ）の内壁の間隙と肉薄部（１４Ａ）が形成された一部の領域の内部にろう材料（４０）を充填して、伝熱管（２０）を外殻壁（１１）に溶接する溶接工程と、を備える。A method of manufacturing the heat exchanger (1A) is a heat exchanger (1A) including a heat transfer tube (20) and a distributor (10) having an outer shell wall (11) to which the heat transfer tube (20) is welded. It is a manufacturing method of. The method for manufacturing the heat exchanger (1A) includes a thin portion forming step of forming a thin portion (14A) having a thickness smaller than the outer diameter of the heat transfer tube (20) in a part of the outer shell wall (11). , A through hole forming step of forming a through hole (13A) into which a heat transfer tube (20) can be inserted into a thin portion (14A), and a heat transfer tube (20) inserted by inserting the heat transfer tube (20) into the through hole (13A). A brazing material (40) is filled inside a part of the region where the gap between the inner wall of the through hole (13A) and the thin portion (14A) and the thin portion (14A) are formed, and the heat transfer tube (20) is attached to the outer shell wall (11). ) Is provided with a welding process for welding.

Description

本開示は熱交換器の製造方法及び熱交換器に関する。 The present disclosure relates to a method of manufacturing a heat exchanger and a heat exchanger.

熱交換器の製造方法には、冷媒を分配する分配器に複数の伝熱管を接続するため、分配器が有する外殻壁に、伝熱管を挿入するための貫通孔を複数個、形成する工程を備えるものがある。 In the method of manufacturing a heat exchanger, in order to connect a plurality of heat transfer tubes to a distributor that distributes a refrigerant, a step of forming a plurality of through holes for inserting the heat transfer tubes in the outer shell wall of the distributor is formed. There is something that has.

この貫通孔を形成する工程には、様々な手法が用いられる。例えば、この工程にプレス加工が使用されることがある。 Various methods are used in the step of forming the through hole. For example, stamping may be used in this process.

例えば、熱交換器の製造方法ではないが、特許文献１には、母材をプレス加工して、肉薄部を形成し、その肉薄部をさらにプレス加工して、貫通孔を形成する貫通孔形成工程が開示されている。特許文献１では、この工程によって電子銃のグリッド電極を形成する。そして、肉薄部を形成し、その肉薄部に電子レンズを配置する。 For example, although it is not a method for manufacturing a heat exchanger, Patent Document 1 states that a base material is press-processed to form a thin portion, and the thin portion is further press-processed to form a through-hole. The process is disclosed. In Patent Document 1, a grid electrode of an electron gun is formed by this step. Then, a thin portion is formed, and an electronic lens is arranged in the thin portion.

特開平１１−３１４５５号公報Japanese Unexamined Patent Publication No. 11-31455

近年、熱交換器には、伝熱管の表面積をフィンの表面積よりも相対的に小さくして、熱交換効率を上げるために、比較的細い伝熱管が用いられる傾向にある。例えば、熱交換器に、分配器の板厚よりも小さい外径の伝熱管が用いられる傾向にある。 In recent years, in heat exchangers, a relatively thin heat transfer tube has tended to be used in order to make the surface area of the heat transfer tube relatively smaller than the surface area of the fins and improve the heat exchange efficiency. For example, heat exchangers tend to use heat transfer tubes having an outer diameter smaller than the plate thickness of the distributor.

伝熱管の外径が分配器の板厚よりも小さくなると、プレス加工によって、伝熱管を挿入する貫通孔を分配器に形成することが難しくなることがある。詳細には、貫通孔形成時に、分配器とプレス金型の接触面に発生する応力がプレス金型の座屈応力よりも大きくなってしまうことがある。その結果、分配器に均一な加工品質の貫通孔を多数形成することが難しくなることがある。その場合、均一な貫通孔を形成するため、放電加工又は、ドリルを用いた切削加工等によって貫通孔を個別に形成することが望ましいが、そのような貫通孔の形成では、生産性が低くなってしまう。 If the outer diameter of the heat transfer tube is smaller than the plate thickness of the distributor, it may be difficult to form a through hole for inserting the heat transfer tube in the distributor by press working. Specifically, when forming a through hole, the stress generated on the contact surface between the distributor and the press die may be larger than the buckling stress of the press die. As a result, it may be difficult to form a large number of through holes of uniform processing quality in the distributor. In that case, in order to form a uniform through hole, it is desirable to individually form the through hole by electric discharge machining or cutting with a drill, but the formation of such a through hole lowers the productivity. Will end up.

この貫通孔の形成に、特許文献１に記載の貫通孔形成工程を適用することが考えられる。しかし、特許文献１に記載の貫通孔形成方法の場合、形成した肉薄部の厚みが伝熱管の外径よりも大きいと、貫通孔を形成するときの、プレス加工で発生する応力が金型の座屈応力よりも大きくなってしまう。この場合、貫通孔の形成が難しくなってしまう。 It is conceivable to apply the through hole forming step described in Patent Document 1 to the formation of the through hole. However, in the case of the through-hole forming method described in Patent Document 1, if the thickness of the formed thin portion is larger than the outer diameter of the heat transfer tube, the stress generated in the press working when forming the through-hole is generated in the mold. It becomes larger than the buckling stress. In this case, it becomes difficult to form a through hole.

また、特許文献１に記載の貫通孔形成工程を熱交換器の製造方法に適用する場合、肉薄部に形成された貫通孔に伝熱管を挿入して、貫通孔の内壁と伝熱管を接合することになってしまう。その結果、十分な接合強度が得られないおそれがある。 Further, when the through hole forming step described in Patent Document 1 is applied to the method for manufacturing a heat exchanger, a heat transfer tube is inserted into the through hole formed in the thin portion to join the inner wall of the through hole and the heat transfer tube. It will end up being. As a result, sufficient bonding strength may not be obtained.

本開示は上記の課題を解決するためになされたもので、分配器の板厚よりも細い伝熱管を分配器に容易かつ十分な強度で接合することができる熱交換器の製造方法及び熱交換器を提供することを目的とする。 The present disclosure has been made to solve the above problems, and is a method for manufacturing a heat exchanger and heat exchange capable of easily joining a heat transfer tube thinner than the plate thickness of the distributor to the distributor with sufficient strength. The purpose is to provide a vessel.

上記の目的を達成するため、本開示に係る熱交換器の製造方法は、伝熱管と、伝熱管が溶接された外殻壁を有する分配器と、を備える熱交換器の製造方法である。熱交換器の製造方法は、外殻壁の一部の領域に、伝熱管の外径よりも厚みが小さい肉薄部を形成する肉薄部形成工程と、肉薄部に伝熱管が挿入可能な貫通孔を形成する貫通孔形成工程と、貫通孔に伝熱管を挿入し、挿入した伝熱管と貫通孔の内壁の間隙と肉薄部が形成された一部の領域の内部に溶接材料を充填して、伝熱管を外殻壁に溶接する溶接工程と、を備える。 In order to achieve the above object, the method for manufacturing a heat exchanger according to the present disclosure is a method for manufacturing a heat exchanger including a heat transfer tube and a distributor having an outer shell wall to which the heat transfer tube is welded. The heat exchanger is manufactured by a thin portion forming step of forming a thin portion having a thickness smaller than the outer diameter of the heat transfer tube in a part of the outer shell wall and a through hole into which the heat transfer tube can be inserted. A heat transfer tube is inserted into the through hole, and a welding material is filled in the gap between the inserted heat transfer tube and the inner wall of the through hole and a part of the area where the thin portion is formed. It includes a welding process for welding the heat transfer tube to the outer shell wall.

本開示の構成によれば、分配器が有する外殻壁の一部の領域に、伝熱管の外径よりも厚みが小さい肉薄部を形成し、その肉薄部に貫通孔を形成する。このため、分配器の板厚よりも細い伝熱管であっても、その伝熱管が挿入可能な貫通孔を容易に形成することができる。また、肉薄部に溶接材料を充填するので、十分な接合強度を保つことができる。 According to the configuration of the present disclosure, a thin portion having a thickness smaller than the outer diameter of the heat transfer tube is formed in a part of the outer shell wall of the distributor, and a through hole is formed in the thin portion. Therefore, even if the heat transfer tube is thinner than the plate thickness of the distributor, a through hole into which the heat transfer tube can be inserted can be easily formed. Further, since the thin portion is filled with the welding material, sufficient bonding strength can be maintained.

本開示の実施の形態１に係る熱交換器の斜視図Perspective view of the heat exchanger according to the first embodiment of the present disclosure. 本開示の実施の形態１に係る熱交換器が備える分配器の外殻壁と伝熱管の接合箇所の拡大斜視図An enlarged perspective view of a joint portion between the outer shell wall of the distributor and the heat transfer tube included in the heat exchanger according to the first embodiment of the present disclosure. 図２に示すＩＩＩ−ＩＩＩ切断線に沿って切断したときの断面図Cross-sectional view when cutting along the III-III cutting line shown in FIG. 本開示の実施の形態１に係る熱交換器の製造方法で分配器の外殻壁となる金属板に窪みを形成したときの金属板の断面図Cross-sectional view of the metal plate when a recess is formed in the metal plate to be the outer shell wall of the distributor in the method for manufacturing the heat exchanger according to the first embodiment of the present disclosure. 本開示の実施の形態１に係る熱交換器の製造方法で分配器の外殻壁となる金属板の窪みに貫通孔を形成したときの金属板の断面図Cross-sectional view of the metal plate when a through hole is formed in the recess of the metal plate serving as the outer shell wall of the distributor in the method for manufacturing the heat exchanger according to the first embodiment of the present disclosure. 本開示の実施の形態１に係る熱交換器の製造方法で貫通孔に伝熱管を挿入し、伝熱管にろう材料を置いたときの外殻壁の断面図Cross-sectional view of the outer shell wall when a heat transfer tube is inserted into the through hole and a brazing material is placed in the heat transfer tube in the method for manufacturing a heat exchanger according to the first embodiment of the present disclosure. 本開示の実施の形態２に係る熱交換器が備える分配器の外殻壁と伝熱管の接合箇所の断面図Cross-sectional view of a joint portion between the outer shell wall of the distributor and the heat transfer tube included in the heat exchanger according to the second embodiment of the present disclosure. 本開示の実施の形態２に係る熱交換器の製造方法で分配器の外殻壁となる金属板に第一窪み部を形成したときの金属板の断面図Cross-sectional view of the metal plate when the first recess is formed in the metal plate to be the outer shell wall of the distributor by the method for manufacturing the heat exchanger according to the second embodiment of the present disclosure. 本開示の実施の形態２に係る熱交換器の製造方法で分配器の外殻壁となる金属板の第一窪み部に第二窪み部を形成したときの金属板の断面図Cross-sectional view of the metal plate when the second recess is formed in the first recess of the metal plate to be the outer shell wall of the distributor by the method for manufacturing the heat exchanger according to the second embodiment of the present disclosure. 本開示の実施の形態２に係る熱交換器の製造方法で分配器の外殻壁となる金属板の第二窪み部に貫通孔を形成したときの金属板の断面図Cross-sectional view of the metal plate when a through hole is formed in the second recess of the metal plate serving as the outer shell wall of the distributor in the method for manufacturing the heat exchanger according to the second embodiment of the present disclosure. 本開示の実施の形態３に係る熱交換器が備える分配器の外殻壁と伝熱管の接合箇所の斜視図Perspective view of a joint portion between the outer shell wall of the distributor and the heat transfer tube included in the heat exchanger according to the third embodiment of the present disclosure. 図１１に示すＸＩＩ−ＸＩＩ切断線に沿って切断したときの断面図Cross-sectional view when cutting along the XII-XII cutting line shown in FIG. 本開示の実施の形態４に係る熱交換器が備える分配器の外殻壁と伝熱管の接合箇所の断面図Cross-sectional view of a joint portion between the outer shell wall of the distributor and the heat transfer tube included in the heat exchanger according to the fourth embodiment of the present disclosure.

以下、本開示の実施の形態に係る熱交換器の製造方法及び熱交換器について図面を参照して詳細に説明する。なお、図中、同一又は同等の部分には同一の符号を付す。図に示す直交座標系ＸＹＺにおいて、伝熱管が延在する方向を左右方向としたときの、その左右方向がＸ軸、上下方向がＺ軸、Ｘ軸とＺ軸とに直交する方向がＹ軸である。以下、適宜、この座標系を引用して説明する。 Hereinafter, the method for manufacturing the heat exchanger and the heat exchanger according to the embodiment of the present disclosure will be described in detail with reference to the drawings. In the figure, the same or equivalent parts are designated by the same reference numerals. In the Cartesian coordinate system XYZ shown in the figure, when the direction in which the heat transfer tube extends is the left-right direction, the left-right direction is the X-axis, the up-down direction is the Z-axis, and the direction orthogonal to the X-axis and the Z-axis is the Y-axis. Is. Hereinafter, this coordinate system will be referred to and described as appropriate.

（実施の形態１）
実施の形態１に係る熱交換器の製造方法は、外径が小さい伝熱管を分配器に接合するため、分配器が有する外殻壁に肉薄部を形成する工程と、肉薄部を形成した後、肉薄部に伝熱管を挿入するための貫通孔を形成する工程と、を備える。さらに、この製造方法は、形成された貫通孔に伝熱管を挿入して伝熱管を貫通孔の内壁に接合する工程を備える。まず、図１−図３を参照して、製造対象物の熱交換器について説明する。次に、図４−図６を参照して、熱交換器の製造方法について説明する。(Embodiment 1)
In the method for manufacturing a heat exchanger according to the first embodiment, in order to join a heat transfer tube having a small outer diameter to the distributor, a step of forming a thin portion on the outer shell wall of the distributor and after forming the thin portion. A step of forming a through hole for inserting a heat transfer tube into a thin portion is provided. Further, this manufacturing method includes a step of inserting a heat transfer tube into the formed through hole and joining the heat transfer tube to the inner wall of the through hole. First, the heat exchanger of the product to be manufactured will be described with reference to FIGS. 1 to 3. Next, a method of manufacturing the heat exchanger will be described with reference to FIGS. 4 to 6.

図１は、実施の形態１に係る熱交換器１Ａの斜視図である。図２は、熱交換器１Ａが備える分配器の外殻壁１１と伝熱管２０の接合箇所の拡大斜視図である。図３は、図２に示すＩＩＩ−ＩＩＩ切断線に沿って切断したときの断面図である。なお、図１では、理解を容易にするため、フィン３０それぞれの形状を示さず、フィン３０全体の形状を示している。また、分配器１０Ｒ、１０Ｌに冷媒を供給、排出するための冷媒管、継手等の部品を省略している。図２では、ろう材料４０を省略している。図３では、伝熱管２０の内部構造を省略している。 FIG. 1 is a perspective view of the heat exchanger 1A according to the first embodiment. FIG. 2 is an enlarged perspective view of a joint portion between the outer shell wall 11 of the distributor and the heat transfer tube 20 included in the heat exchanger 1A. FIG. 3 is a cross-sectional view taken along the line III-III cut line shown in FIG. In addition, in FIG. 1, in order to facilitate understanding, the shape of each of the fins 30 is not shown, but the shape of the entire fin 30 is shown. Further, parts such as a refrigerant pipe and a joint for supplying and discharging the refrigerant to the distributors 10R and 10L are omitted. In FIG. 2, the brazing material 40 is omitted. In FIG. 3, the internal structure of the heat transfer tube 20 is omitted.

図１に示すように、熱交換器１Ａは、外部機器から冷媒が供給され、又は、外部機器へ冷媒を排出する分配器１０Ｒ、１０Ｌと、分配器１０Ｒ、１０Ｌによって分配された冷媒を流通させる複数の伝熱管２０と、冷媒から伝熱管２０に伝わる熱を放熱する複数のフィン３０と、を備えている。 As shown in FIG. 1, the heat exchanger 1A circulates the refrigerants 10R and 10L to which the refrigerant is supplied from the external device or discharges the refrigerant to the external device and the refrigerant distributed by the distributors 10R and 10L. It includes a plurality of heat transfer tubes 20 and a plurality of fins 30 that dissipate heat transferred from the refrigerant to the heat transfer tubes 20.

分配器１０Ｒ、１０Ｌは、直方体状の外殻壁１１を有する。その外殻壁１１の内部には、図示しないが、冷媒を流すための流路が形成されている。分配器１０Ｒと１０Ｌは、長手方向を上下方向に向け、互いに離されて配置されている。分配器１０Ｒと１０Ｌは、それらの間で冷媒を流通させるため、複数の伝熱管２０によって接続されている。 The distributors 10R and 10L have a rectangular parallelepiped outer shell wall 11. Although not shown, a flow path for flowing a refrigerant is formed inside the outer shell wall 11. The distributors 10R and 10L are arranged so as to be separated from each other with the longitudinal direction facing the vertical direction. The distributors 10R and 10L are connected by a plurality of heat transfer tubes 20 in order to allow a refrigerant to flow between them.

なお、分配器１０Ｒ、１０Ｌは、外部機器から供給された冷媒を複数の伝熱管２０に分配するか、あるいは、複数の伝熱管２０の冷媒を集約して外部機器に排出する部品である。本明細書では、このような部品のことを、複数の伝熱管２０に分配する機能に着目して、単に分配器と称する。また、分配器１０Ｒと１０Ｌは、左右対称であることを除いて、共に同じ構成を備える。このため、以下、分配器１０Ｒ、１０Ｌの位置関係を説明する場合は、符号１０Ｒ、１０Ｌを用い、その他の場合は、符号１０を用いる。 The distributors 10R and 10L are components that distribute the refrigerant supplied from the external device to the plurality of heat transfer tubes 20, or aggregate the refrigerants of the plurality of heat transfer tubes 20 and discharge the refrigerant to the external device. In the present specification, such a component is simply referred to as a distributor, paying attention to a function of distributing to a plurality of heat transfer tubes 20. Further, the distributors 10R and 10L both have the same configuration except that they are symmetrical. Therefore, when the positional relationship of the distributors 10R and 10L will be described below, reference numerals 10R and 10L will be used, and in other cases, reference numeral 10 will be used.

伝熱管２０は、伝熱性を高めるため、図２に示すように、管断面扁平状の、いわゆる扁平管によって構成されている。ここで、扁平状とは、平たい長円の形状のことであり、詳細には、扁平状とは、長手方向に細長く、その長手方向の両端の角が丸められた形状のことである。伝熱管２０は、図３に示すように、外殻壁１１が有する窪み１２Ａに形成された貫通孔１３Ａに挿入されている。そして、伝熱管２０の端部は、外殻壁１１の内側にある、図示しない流路に達している。伝熱管２０は、窪み１２Ａに充填されたろう材料４０によって、外殻壁１１に接合されている。これにより、伝熱管２０は、外殻壁１１に固定されている。なお、伝熱管２０は、例えば分配器１０Ｒと１０Ｌを隣接させる場合に途中で変形されても良い。また、伝熱管２０は、管同士を連絡する部品を用いて折り返されても良い。 As shown in FIG. 2, the heat transfer tube 20 is formed of a so-called flat tube having a flat tube cross section in order to enhance heat transfer. Here, the flat shape is a flat oval shape, and more specifically, the flat shape is a shape that is elongated in the longitudinal direction and has rounded corners at both ends in the longitudinal direction. As shown in FIG. 3, the heat transfer tube 20 is inserted into the through hole 13A formed in the recess 12A of the outer shell wall 11. The end of the heat transfer tube 20 reaches a flow path (not shown) inside the outer shell wall 11. The heat transfer tube 20 is joined to the outer shell wall 11 by the brazing material 40 filled in the recess 12A. As a result, the heat transfer tube 20 is fixed to the outer shell wall 11. The heat transfer tube 20 may be deformed in the middle when, for example, the distributors 10R and 10L are adjacent to each other. Further, the heat transfer tube 20 may be folded back by using a component that connects the tubes.

伝熱管２０は、図１に示すように、左右方向に延在している。そして、伝熱管２０は、上下方向に一定のピッチで配列している。伝熱管２０の端部は、上述したように、外殻壁１１内の図示しない流路に位置している。このため、伝熱管２０は、分配器１０Ｒと１０Ｌが備える図示しない流路どうしをつないでいる。その結果、伝熱管２０には、分配器１０Ｒと１０Ｌの冷媒が流通して、その冷媒の熱が伝えられる。伝熱管２０には、その熱を空気中に放熱するため、複数のフィン３０が接続されている。 As shown in FIG. 1, the heat transfer tube 20 extends in the left-right direction. The heat transfer tubes 20 are arranged at a constant pitch in the vertical direction. As described above, the end portion of the heat transfer tube 20 is located in a flow path (not shown) in the outer shell wall 11. Therefore, the heat transfer tube 20 connects the flow paths (not shown) provided in the distributors 10R and 10L. As a result, the refrigerants of the distributors 10R and 10L flow through the heat transfer tube 20, and the heat of the refrigerants is transferred. A plurality of fins 30 are connected to the heat transfer tube 20 in order to dissipate the heat into the air.

フィン３０は、図示しないが、矩形状の板の形状に形成されている。そして、フィン３０は、長手方向を上下方向に向けて、左右方向に一定のピッチで配列している。これにより、フィン３０同士の間に空隙が設けられている。フィン３０は、その空隙の空気と熱交換する。 Although not shown, the fins 30 are formed in the shape of a rectangular plate. The fins 30 are arranged at a constant pitch in the left-right direction with the longitudinal direction facing up and down. As a result, a gap is provided between the fins 30. The fin 30 exchanges heat with the air in the void.

図２に戻って、伝熱管２０の短径ＳＤは、外殻壁１１の厚みＴよりも小さい。すなわち、伝熱管２０の外径は、外殻壁１１の厚みＴよりも小さい。このような外径が小さい伝熱管２０を外殻壁１１の貫通孔１３Ａに挿入して接合する場合、その貫通孔１３Ａをプレス加工で形成しようとすると、外殻壁１１の厚みＴが伝熱管２０の外径よりも大きいため、プレス加工で外殻壁１１に発生する応力が金型の座屈応力よりも大きくなってしまう。その結果、外殻壁１１に当たった金型が座屈したりたわみが大きくなったりして、外殻壁１１に貫通孔１３Ａが一律に形成できないことがある。そして、プレス加工の生産性が低下してしまうことがある。 Returning to FIG. 2, the short-diameter SD of the heat transfer tube 20 is smaller than the thickness T of the outer shell wall 11. That is, the outer diameter of the heat transfer tube 20 is smaller than the thickness T of the outer shell wall 11. When such a heat transfer tube 20 having a small outer diameter is inserted into the through hole 13A of the outer shell wall 11 and joined, when the through hole 13A is to be formed by press working, the thickness T of the outer shell wall 11 becomes the heat transfer tube. Since it is larger than the outer diameter of 20, the stress generated in the outer shell wall 11 by press working becomes larger than the buckling stress of the die. As a result, the mold that hits the outer shell wall 11 may buckle or bend significantly, and the through hole 13A may not be uniformly formed in the outer shell wall 11. Then, the productivity of press working may decrease.

そこで、熱交換器１Ａの製造方法では、プレス加工で発生する応力を座屈応力よりも小さくするため、まず、外殻壁１１に窪み１２Ａを形成することにより、外殻壁１１に肉薄部１４Ａを形成する。次に、その肉薄部１４Ａに貫通孔１３Ａを形成する。次に、図４−図６を参照して、熱交換器１Ａの製造方法について説明する。 Therefore, in the method of manufacturing the heat exchanger 1A, in order to make the stress generated by the press working smaller than the buckling stress, first, by forming a recess 12A in the outer shell wall 11, the thin portion 14A is formed in the outer shell wall 11. To form. Next, a through hole 13A is formed in the thin portion 14A. Next, a method of manufacturing the heat exchanger 1A will be described with reference to FIGS. 4 to 6.

図４は、実施の形態１に係る熱交換器１Ａの製造方法で分配器１０の外殻壁１１となる金属板１５に窪み１２Ａを形成したときの金属板１５の断面図である。図５は、金属板１５の窪み１２Ａに貫通孔１３Ａを形成したときの金属板１５の断面図である。図６は、貫通孔１３Ａに伝熱管２０を挿入し、伝熱管２０にろう材料４０を置いたときの外殻壁１１の断面図である。なお、図６では、理解を容易にするため、伝熱管２０の内部構造を省略している。 FIG. 4 is a cross-sectional view of the metal plate 15 when the recess 12A is formed in the metal plate 15 serving as the outer shell wall 11 of the distributor 10 by the method of manufacturing the heat exchanger 1A according to the first embodiment. FIG. 5 is a cross-sectional view of the metal plate 15 when the through hole 13A is formed in the recess 12A of the metal plate 15. FIG. 6 is a cross-sectional view of the outer shell wall 11 when the heat transfer tube 20 is inserted into the through hole 13A and the brazing material 40 is placed in the heat transfer tube 20. In FIG. 6, the internal structure of the heat transfer tube 20 is omitted for ease of understanding.

熱交換器１Ａの製造方法では、まず、伝熱性が高い、アルミニウム合金で形成された金属板１５を用意する。金属板１５の厚みは、上述した外殻壁１１と同じであり、例えば、３ｍｍである。 In the method for manufacturing the heat exchanger 1A, first, a metal plate 15 made of an aluminum alloy and having high heat transfer properties is prepared. The thickness of the metal plate 15 is the same as that of the outer shell wall 11 described above, and is, for example, 3 mm.

続いて、図４に示すように、金属板１５に窪み１２Ａを形成する。これにより、金属板１５に肉薄部１４Ａが形成される。 Subsequently, as shown in FIG. 4, a recess 12A is formed in the metal plate 15. As a result, the thin portion 14A is formed on the metal plate 15.

詳細には、製造する熱交換器１Ａの伝熱管２０と同数の第一パンチ部を備える、図示しない金型を２つ用意する。それら金型では、第一パンチ部が、伝熱管２０と同ピッチで一方向に並んでいる。それら金型を互いに第一パンチ部が対向した状態に配置し、それら金型の間に金属板１５を差し込む。そして、差し込んだ金属板１５を金型によってプレス加工する。 Specifically, two dies (not shown) having the same number of first punch portions as the heat transfer tubes 20 of the heat exchanger 1A to be manufactured are prepared. In these dies, the first punch portions are arranged in one direction at the same pitch as the heat transfer tube 20. The dies are arranged so that the first punch portions face each other, and the metal plate 15 is inserted between the dies. Then, the inserted metal plate 15 is press-processed by a mold.

このとき、金型の第一パンチ部は、図４に示す矢印Ａ方向に、以下に示す式を満たす距離だけ押し込まれる。
ＰＤ＞（Ｔ−ＳＤ）／２・・・（式１）
ここで、ＰＤは、押し込み量、Ｔは、金属板１５の厚み、ＳＤは、伝熱管２０の短径である。At this time, the first punch portion of the die is pushed in the direction of arrow A shown in FIG. 4 by a distance satisfying the following formula.
PD> (T-SD) / 2 ... (Equation 1)
Here, PD is the pushing amount, T is the thickness of the metal plate 15, and SD is the minor diameter of the heat transfer tube 20.

これにより、伝熱管２０と同数かつ上述したピッチに配列する複数の窪み１２Ａが、金属板１５の両面に形成される。その結果、図４に示す上下方向に重なる窪み１２Ａの間に、肉薄部１４Ａが形成される。金型の第一パンチ部が式１の距離だけ押し込まれるので、形成する肉薄部１４Ａの厚みＴ１は、伝熱管２０の短径ＳＤよりも小さくなる。例えば、伝熱管２０の短径ＳＤが２ｍｍである場合に、厚みが１．５−１．９ｍｍの肉薄部１４Ａが形成される。 As a result, a plurality of recesses 12A having the same number as the heat transfer tubes 20 and arranged at the pitch described above are formed on both surfaces of the metal plate 15. As a result, a thin portion 14A is formed between the recesses 12A overlapping in the vertical direction shown in FIG. Since the first punch portion of the die is pushed by the distance of the formula 1, the thickness T1 of the thin portion 14A to be formed is smaller than the short diameter SD of the heat transfer tube 20. For example, when the minor axis SD of the heat transfer tube 20 is 2 mm, a thin portion 14A having a thickness of 1.5-1.9 mm is formed.

また、上述した第一パンチ部は、図示しないが、形状が伝熱管２０の管断面形状に概ね相似した矩形であり、面積が伝熱管２０の断面積よりも大きい先端面を有する。これにより、金型によって形成される窪み１２Ａは、図２に示す矩形状の底を有する。その窪み１２Ａの長さＬ、幅Ｗは、伝熱管２０の管断面形状の短径ＳＤ、長径ＬＤよりも大きく、窪み１２Ａに伝熱管２０が差し込まれた場合に、後述する熔解したろう材料４０が表面張力でろうフィレット４１を形成可能な程度に、短径ＳＤ、長径ＬＤよりも大きい。例えば、長さＬは、伝熱管２０の短径ＳＤが２ｍｍである場合に、７−１０ｍｍである。このように、窪み１２Ａｍの底は、伝熱管２０の管断面よりも大きい。 Further, although not shown, the above-mentioned first punch portion has a rectangular shape whose shape is substantially similar to the cross-sectional shape of the heat transfer tube 20, and has a tip surface whose area is larger than the cross-sectional area of the heat transfer tube 20. As a result, the recess 12A formed by the mold has a rectangular bottom as shown in FIG. The length L and width W of the recess 12A are larger than the short-diameter SD and the major-diameter LD of the tube cross-sectional shape of the heat transfer tube 20, and when the heat transfer tube 20 is inserted into the recess 12A, the melted brazing material 40 described later Is larger than the short-diameter SD and the long-diameter LD to the extent that the wax fillet 41 can be formed by surface tension. For example, the length L is 7-10 mm when the minor axis SD of the heat transfer tube 20 is 2 mm. As described above, the bottom of the recess 12 Am is larger than the cross section of the heat transfer tube 20.

なお、上述した肉薄部１４Ａを形成する工程は、本明細書でいうところの肉薄部形成工程の一例である。以下、本明細書では、この工程を肉薄部形成工程という。また、この工程で窪み１２Ａが形成される外殻壁１１の領域は、本明細書でいうところの外殻壁１１の一部の領域の一例である。この工程で使用される第一パンチ部を有する金型は、本明細書でいうところの凸状の金型の一例である。 The above-mentioned step of forming the thin portion 14A is an example of the thin portion forming step as referred to in the present specification. Hereinafter, in the present specification, this step is referred to as a thin portion forming step. Further, the region of the outer shell wall 11 in which the recess 12A is formed in this step is an example of a part of the region of the outer shell wall 11 as referred to in the present specification. The die having the first punch portion used in this step is an example of the convex die as referred to in the present specification.

次に、図５に示すように、窪み１２Ａに貫通孔１３Ａを形成する。 Next, as shown in FIG. 5, a through hole 13A is formed in the recess 12A.

詳細に説明すると、図示しないが、上述した第一パンチ部と同数の第二パンチ部を備える金型を用意する。その金型では、第二パンチ部が伝熱管２０の管断面形状と相似すると共に、管断面形状よりも一定の程度だけ大きい矩形状の先端面を有する。また、第二パンチ部が上述した第一パンチ部と同ピッチに配列されている。 Although not shown in detail, a die having the same number of second punch portions as the above-mentioned first punch portions is prepared. In the mold, the second punch portion has a rectangular tip surface similar to the pipe cross-sectional shape of the heat transfer tube 20 and larger than the pipe cross-sectional shape by a certain degree. Further, the second punch portion is arranged at the same pitch as the first punch portion described above.

また、この金型に加えて、平坦面を有するダイを備える金型と用意する。 Further, in addition to this mold, a mold having a die having a flat surface is prepared.

図示しないが、用意したそれら金型を、第二パンチ部とダイが対向する向きに配置して、それら金型の間に金属板１５を差し込み、窪み１２Ａを第二パンチ部に向け、さらに窪み１２Ａの中心を第二パンチ部の先端面の中心に合わせる。また、窪み１２Ａの長手方向を第二パンチ部の先端面の長手方向に向ける。そして、差し込んだ金属板１５をプレス加工する。これにより、窪み１２Ａそれぞれの中央に、貫通孔１３Ａが形成される。また、複数の貫通孔１３Ａが一括して形成される。形成された貫通孔１３Ａそれぞれは、窪み１２Ａそれぞれの長手方向に長手方向が揃えられる。また、第二パンチ部の先端面が伝熱管２０の管断面形状よりも一定の程度だけ大きいので、貫通孔１３Ａそれぞれの径は、後述する熔解したろう材料４０が浸透可能な大きさ程度に伝熱管２０の外径よりも大きい。 Although not shown, the prepared dies are arranged so that the second punch portion and the die face each other, the metal plate 15 is inserted between the dies, the recess 12A is directed toward the second punch portion, and the recess is further recessed. Align the center of 12A with the center of the tip surface of the second punch portion. Further, the longitudinal direction of the recess 12A is directed to the longitudinal direction of the tip surface of the second punch portion. Then, the inserted metal plate 15 is press-processed. As a result, a through hole 13A is formed in the center of each of the recesses 12A. Further, a plurality of through holes 13A are collectively formed. Each of the formed through holes 13A is aligned in the longitudinal direction in the longitudinal direction of each of the recesses 12A. Further, since the tip surface of the second punch portion is larger than the cross-sectional shape of the heat transfer tube 20 by a certain degree, the diameter of each of the through holes 13A is transmitted to a size that allows the molten wax material 40 described later to permeate. It is larger than the outer diameter of the heat tube 20.

なお、この貫通孔を形成する工程は、本明細書でいうところの貫通孔形成工程の一例である。以下、本明細書では、この工程を貫通孔形成工程という。 The step of forming the through hole is an example of the through hole forming step as referred to in the present specification. Hereinafter, in the present specification, this step is referred to as a through hole forming step.

続いて、図示しないが、貫通孔１３Ａが形成された金属板１５をプレス加工して、上述した形状の外殻壁１１を有する分配器１０Ｒ、１０Ｌを作製する。 Subsequently, although not shown, the metal plate 15 in which the through hole 13A is formed is press-processed to produce distributors 10R and 10L having the outer shell wall 11 having the above-mentioned shape.

一方で、上述した形状の複数の伝熱管２０と複数のフィン３０を用意する。続いて、用意した伝熱管２０とフィン３０を上述した形状に配置して、伝熱管２０にフィン３０をろう付けする。これにより、伝熱管２０にフィン３０が組み付けられる。 On the other hand, a plurality of heat transfer tubes 20 and a plurality of fins 30 having the above-mentioned shapes are prepared. Subsequently, the prepared heat transfer tubes 20 and fins 30 are arranged in the shape described above, and the fins 30 are brazed to the heat transfer tubes 20. As a result, the fins 30 are assembled to the heat transfer tube 20.

なお、この工程は、本明細書でいうところの組み付け工程の一例である。以下、本明細書では、この工程を組み付け工程という。 This step is an example of the assembling step as referred to in the present specification. Hereinafter, in the present specification, this process is referred to as an assembly process.

次に、図６に示すように、分配器１０の外殻壁１１に形成された貫通孔１３Ａに、フィン３０が組み付けられた伝熱管２０を挿入する。 Next, as shown in FIG. 6, the heat transfer tube 20 to which the fins 30 are assembled is inserted into the through hole 13A formed in the outer shell wall 11 of the distributor 10.

続いて、伝熱管２０にろう材料４０を置き、その状態で、ろう材料４０を融解させる。 Subsequently, the brazing material 40 is placed in the heat transfer tube 20, and the brazing material 40 is melted in that state.

ろう材料４０が融解すると、そのろう材料４０は、伝熱管２０を伝って伝熱管２０と貫通孔１３Ａの内壁の隙間に浸透する。また、ろう材料４０は、窪み１２Ａを充填する。その後、ろう材料４０は、図３に示すように、窪み１２Ａの側壁と外殻壁１１の壁面とが形成する開口の角から伝熱管２０までの間を表面張力によって覆い、ろうフィレット４１を形成する。 When the brazing material 40 is melted, the brazing material 40 penetrates into the gap between the heat transfer tube 20 and the inner wall of the through hole 13A through the heat transfer tube 20. Further, the brazing material 40 fills the recess 12A. After that, as shown in FIG. 3, the brazing material 40 covers the area from the corner of the opening formed by the side wall of the recess 12A and the wall surface of the outer shell wall 11 to the heat transfer tube 20 by surface tension to form the wax fillet 41. do.

ろう材料４０が窪み１２Ａに充填され、かつろうフィレット４１が形成された後、ろう材料４０を冷却する。これにより、伝熱管２０が外殻壁１１に接合される。以上の工程により、熱交換器１Ａが完成する。 After the wax material 40 is filled in the recess 12A and the wax fillet 41 is formed, the wax material 40 is cooled. As a result, the heat transfer tube 20 is joined to the outer shell wall 11. The heat exchanger 1A is completed by the above steps.

なお、ろう付けは、溶接の一種である。このことから明らかなように、上述した、ろう材料４０で伝熱管２０を外殻壁１１に接合する工程は、本明細書でいうところの溶接工程の一例である。以下、本明細書では、この工程を溶接工程という。また、ろう材料４０は、本明細書でいうところの溶接材料の一例である。 Brazing is a type of welding. As is clear from this, the above-mentioned step of joining the heat transfer tube 20 to the outer shell wall 11 with the brazing material 40 is an example of the welding step as referred to in the present specification. Hereinafter, in the present specification, this process is referred to as a welding process. Further, the brazing material 40 is an example of a welding material as referred to in the present specification.

以上のように、実施の形態１に係る熱交換器１Ａの製造方法では、外殻壁１１に窪み１２Ａを形成することにより、外殻壁１１に伝熱管２０の短径ＳＤよりも厚みが小さい肉薄部１４Ａを形成する。肉薄部１４Ａが座屈しやすいため、貫通孔１３Ａの形成が容易である。 As described above, in the method for manufacturing the heat exchanger 1A according to the first embodiment, the thickness of the outer shell wall 11 is smaller than that of the short diameter SD of the heat transfer tube 20 by forming the recess 12A in the outer shell wall 11. A thin portion 14A is formed. Since the thin portion 14A is likely to buckle, the through hole 13A can be easily formed.

熱交換器１Ａの製造方法では、肉薄部１４Ａが座屈しやすいので、プレス加工により、複数の貫通孔１３Ａを一括して形成することができる。その結果、熱交換器１Ａの製造方法の生産性が高い。熱交換器１Ａの製造方法によれば、放電加工したりドリルで切削加工したりすることにより、貫通孔１３Ａを個別に形成する必要がない。 In the method for manufacturing the heat exchanger 1A, since the thin portion 14A is likely to buckle, a plurality of through holes 13A can be collectively formed by press working. As a result, the productivity of the manufacturing method of the heat exchanger 1A is high. According to the method of manufacturing the heat exchanger 1A, it is not necessary to individually form the through holes 13A by electric discharge machining or cutting with a drill.

熱交換器１Ａの製造方法では、窪み１２Ａをろう材料４０で充填する。このため、窪み１２Ａが形成されているにもかかわらず、外殻壁１１の強度を保つことができる。また、熱交換器１Ａの製造方法によれば、外殻壁１１の強度を、外殻壁１１に窪み１２Ａが形成されていない場合と同程度まで高めることができる。また、窪み１２Ａに充填されたろう材料４０が伝熱管２０を支持するので、伝熱管２０と分配器１０の接合強度が高い。 In the method of manufacturing the heat exchanger 1A, the recess 12A is filled with the brazing material 40. Therefore, the strength of the outer shell wall 11 can be maintained even though the recess 12A is formed. Further, according to the method of manufacturing the heat exchanger 1A, the strength of the outer shell wall 11 can be increased to the same degree as when the recess 12A is not formed in the outer shell wall 11. Further, since the brazing material 40 filled in the recess 12A supports the heat transfer tube 20, the joint strength between the heat transfer tube 20 and the distributor 10 is high.

熱交換器１Ａの製造方法では、窪み１２Ａの内壁を、表面張力でろうフィレット４１を形成可能な程度の距離だけ伝熱管２０から離す。このため、熔解したろう材料４０が供給されたときに、窪み１２Ａの内壁と伝熱管２０との間にろうフィレット４１が形成され、伝熱管２０と分配器１０の接合強度を高めることができる。また、熱交換器１Ａの製造方法によれば、分配器１０の水密性を高めて冷媒に対する耐圧性を高めることができる。 In the method of manufacturing the heat exchanger 1A, the inner wall of the recess 12A is separated from the heat transfer tube 20 by a distance that allows the wax fillet 41 to be formed by surface tension. Therefore, when the molten brazing material 40 is supplied, a brazing fillet 41 is formed between the inner wall of the recess 12A and the heat transfer tube 20, and the joint strength between the heat transfer tube 20 and the distributor 10 can be increased. Further, according to the method of manufacturing the heat exchanger 1A, the watertightness of the distributor 10 can be increased and the pressure resistance to the refrigerant can be increased.

（実施の形態２）
実施の形態１に係る熱交換器１Ａの製造方法では、外殻壁１１の一方の面とその反対側の面の両方に、窪み１２Ａを形成することにより、肉薄部１４Ａを形成する。しかし、熱交換器１Ａの製造方法はこれに限定されない。実施の形態２に係る熱交換器１Ｂの製造方法では、窪み１２Ｂを、外殻壁１１の一方の面だけに形成することにより、肉薄部１４Ｂを形成する。以下、図７−図１０を参照して、実施の形態２に係る熱交換器１Ｂの製造方法について説明する。実施の形態２では、実施の形態１と異なる構成について説明する。(Embodiment 2)
In the method for manufacturing the heat exchanger 1A according to the first embodiment, the thin portion 14A is formed by forming the recess 12A on both one surface and the opposite surface of the outer shell wall 11. However, the manufacturing method of the heat exchanger 1A is not limited to this. In the method for manufacturing the heat exchanger 1B according to the second embodiment, the thin portion 14B is formed by forming the recess 12B only on one surface of the outer shell wall 11. Hereinafter, the method for manufacturing the heat exchanger 1B according to the second embodiment will be described with reference to FIGS. 7 to 10. In the second embodiment, a configuration different from that of the first embodiment will be described.

まず、図７を参照して、実施の形態２に係る熱交換器１Ｂの製造方法で製造される熱交換器１Ｂについて説明する。 First, the heat exchanger 1B manufactured by the method for manufacturing the heat exchanger 1B according to the second embodiment will be described with reference to FIG. 7.

図７は、実施の形態２に係る熱交換器１Ｂが備える分配器１０の外殻壁１１と伝熱管２０の接合箇所の断面図である。なお、図７では、図２に示すＩＩＩ−ＩＩＩ切断線の同じ切断線での接合箇所の断面を示している。また、図７では、理解を容易にするため、伝熱管２０の内部構造を省略している。 FIG. 7 is a cross-sectional view of a joint portion between the outer shell wall 11 of the distributor 10 and the heat transfer tube 20 included in the heat exchanger 1B according to the second embodiment. Note that FIG. 7 shows a cross section of the joint portion of the III-III cutting line shown in FIG. 2 at the same cutting line. Further, in FIG. 7, the internal structure of the heat transfer tube 20 is omitted for ease of understanding.

図７に示すように、熱交換器１Ｂが備える分配器１０の外殻壁１１には、第一窪み部１２１と、第一窪み部１２１内に配置された第二窪み部１２２と、を有する窪み１２Ｂが形成されている。そして、外殻壁１１には、窪み１２Ｂが形成されることにより、伝熱管２０の短径ＳＤよりも厚みＴ１が小さい肉薄部１４Ｂが形成されている。 As shown in FIG. 7, the outer shell wall 11 of the distributor 10 included in the heat exchanger 1B has a first recessed portion 121 and a second recessed portion 122 arranged in the first recessed portion 121. A recess 12B is formed. The outer shell wall 11 is formed with a recess 12B, so that a thin portion 14B having a thickness T1 smaller than that of the short diameter SD of the heat transfer tube 20 is formed.

肉薄部１４Ｂには、実施の形態１で説明した貫通孔１３Ａと同じ構成の貫通孔１３Ｂが形成されている。その貫通孔１３Ｂには、伝熱管２０が挿入されている。 The thin portion 14B is formed with a through hole 13B having the same configuration as the through hole 13A described in the first embodiment. A heat transfer tube 20 is inserted into the through hole 13B.

上述した窪み１２Ｂには、ろう材料４０が充填されている。また、貫通孔１３Ｂの内壁と伝熱管２０の隙間には、ろう材料４０が浸透している。これにより、窪み１２Ｂ及び貫通孔１３Ｂの内壁と伝熱管２０が接合されている。 The recess 12B described above is filled with a brazing material 40. Further, the brazing material 40 permeates into the gap between the inner wall of the through hole 13B and the heat transfer tube 20. As a result, the inner wall of the recess 12B and the through hole 13B is joined to the heat transfer tube 20.

次に、図８−図１０を参照して、実施の形態２に係る熱交換器１Ｂの製造方法について説明する。 Next, a method of manufacturing the heat exchanger 1B according to the second embodiment will be described with reference to FIGS. 8 to 10.

図８は、分配器１０の外殻壁１１となる金属板１５に第一窪み部１２１を形成したときの、その金属板１５の断面図である。図９は、第一窪み部１２１に第二窪み部１２２を形成したときの金属板１５の断面図である。図１０は、第二窪み部１２２に貫通孔１３Ｂを形成したときの金属板１５の断面図である。 FIG. 8 is a cross-sectional view of the metal plate 15 when the first recessed portion 121 is formed in the metal plate 15 serving as the outer shell wall 11 of the distributor 10. FIG. 9 is a cross-sectional view of the metal plate 15 when the second recessed portion 122 is formed in the first recessed portion 121. FIG. 10 is a cross-sectional view of the metal plate 15 when the through hole 13B is formed in the second recessed portion 122.

まず、実施の形態１と同様の構成の金属板１５を用意する。そして、図８に示すように、用意した金属板１５に第一窪み部１２１を形成する。 First, a metal plate 15 having the same configuration as that of the first embodiment is prepared. Then, as shown in FIG. 8, the first recessed portion 121 is formed in the prepared metal plate 15.

この第一窪み部１２１の形成では、図示しないが、実施の形態１の肉薄部形成工程で説明した第一パンチ部の先端面と相似形の先端面を有し、かつ、その先端面の面積が実施の形態１で説明した第一パンチ部よりも大きい第三パンチ部を複数個、備える金型が用いられる。複数の第三パンチ部の配置は、実施の形態１の第一パンチ部と同じである。そして、この金型を、平坦面を有するダイを備えるもう一つの金型と対向させ、これらの金型の間に金属板１５を差し込んで金属板１５をプレス加工する。このとき、金型の押し込み量を調整することにより、金属板１５の厚みＴの半分程度の深さを有する第一窪み部１２１を形成する。例えば、厚みＴの４０％の深さを有する第一窪み部１２１を形成する。このようなプレス加工により、金属板１５に複数の第一窪み部１２１が一括して形成される。 Although not shown, the formation of the first recessed portion 121 has a tip surface similar to the tip surface of the first punch portion described in the thin portion forming step of the first embodiment, and has an area of the tip surface. A mold having a plurality of third punch portions larger than the first punch portion described in the first embodiment is used. The arrangement of the plurality of third punch portions is the same as that of the first punch portion of the first embodiment. Then, this die is opposed to another die provided with a die having a flat surface, and a metal plate 15 is inserted between these dies to press the metal plate 15. At this time, by adjusting the pushing amount of the mold, the first recessed portion 121 having a depth of about half the thickness T of the metal plate 15 is formed. For example, the first recess 121 having a depth of 40% of the thickness T is formed. By such press working, a plurality of first recessed portions 121 are collectively formed on the metal plate 15.

なお、第二窪み部１２２の形成前に、金属板１５の、窪み１２Ｂが形成される領域を肉薄化する工程のことを肉薄化工程というが、この工程は、その肉薄化工程の一例である。 The step of thinning the region where the recess 12B is formed in the metal plate 15 before the formation of the second recess 122 is called a thinning step, and this step is an example of the thinning step. ..

次に、図９に示すように、第一窪み部１２１内に、第二窪み部１２２を形成する。 Next, as shown in FIG. 9, a second recess 122 is formed in the first recess 121.

この第二窪み部１２２の形成では、図示しないが、実施の形態１の肉薄部形成工程で説明した金型が用いられる。そして、その金型と、上述したダイとなる金型を対向させ、これらの金型の間に、第一窪み部１２１が形成された面の側を、金型のパンチ部に向けた状態で金属板１５が差し込まれる。続いて、差し込んだ金属板１５をプレス加工する。これにより、複数の第二窪み部１２２が一括して形成される。また、第一窪み部１２１それぞれ中央に、第二窪み部１２２が形成される。これにより、肉薄部１４Ｂが形成される。 In the formation of the second recessed portion 122, although not shown, the mold described in the thin portion forming step of the first embodiment is used. Then, the mold and the mold to be the die described above are opposed to each other, and the side of the surface on which the first recessed portion 121 is formed between the molds is directed toward the punch portion of the mold. The metal plate 15 is inserted. Subsequently, the inserted metal plate 15 is press-processed. As a result, a plurality of second recessed portions 122 are collectively formed. Further, a second recess 122 is formed in the center of each of the first recess 121. As a result, the thin portion 14B is formed.

このプレス加工では、金型の押し込み量を調整することにより、肉薄部１４Ｂの厚みＴ１が伝熱管２０の短径ＳＤよりも小さくなる第二窪み部１２２を形成する。なお、この工程は、実施の形態１で説明した肉薄部形成工程に相当する工程である。 In this press working, by adjusting the pushing amount of the die, the second recessed portion 122 in which the thickness T1 of the thin portion 14B is smaller than the short diameter SD of the heat transfer tube 20 is formed. It should be noted that this step corresponds to the thin portion forming step described in the first embodiment.

次に、図１０に示すように、第二窪み部１２２に貫通孔１３Ｂを形成する。 Next, as shown in FIG. 10, a through hole 13B is formed in the second recessed portion 122.

この貫通孔１３Ｂの形成では、図示しないが、実施の形態１の貫通孔形成工程で説明した第二パンチ部を備える金型を用いて、第二窪み部１２２が形成された金属板１５をプレス加工する。これにより、第二窪み部１２２それぞれに、貫通孔１３Ｂを形成する。 In the formation of the through hole 13B, although not shown, the metal plate 15 on which the second recessed portion 122 is formed is pressed by using a die provided with the second punch portion described in the through hole forming step of the first embodiment. Process. As a result, through holes 13B are formed in each of the second recessed portions 122.

続いて、図示しないが、貫通孔１３Ａが形成された金属板１５をプレス加工して、上述した形状の外殻壁１１を有する分配器１０Ｒ、１０Ｌを作製する。このとき、金属板１５に形成されている第一窪み部１２１及び第二窪み部１２２を分配器１０Ｒ、１０Ｌの内側、換言すると流路側に配置する。 Subsequently, although not shown, the metal plate 15 in which the through hole 13A is formed is press-processed to produce distributors 10R and 10L having the outer shell wall 11 having the above-mentioned shape. At this time, the first recessed portion 121 and the second recessed portion 122 formed in the metal plate 15 are arranged inside the distributors 10R and 10L, in other words, on the flow path side.

次に、伝熱管２０へのフィン３０の組み付け工程と溶接工程を行う。これにより、熱交換器１Ｂが完成する。なお、伝熱管２０へのフィン３０の組み付け、溶接工程は、実施の形態1と同様である。このため、実施の形態２では、その説明を省略する。 Next, the fin 30 is assembled to the heat transfer tube 20 and the welding process is performed. As a result, the heat exchanger 1B is completed. The process of assembling and welding the fins 30 to the heat transfer tube 20 is the same as that of the first embodiment. Therefore, in the second embodiment, the description thereof will be omitted.

以上のように、実施の形態２に係る熱交換器１Ｂの製造方法では、外殻壁１１となる金属板１５に、第一窪み部１２１に重ねて第二窪み部１２２を形成することにより、窪み１２Ｂを形成する。一般に、プレス加工によって金属板１５に窪みを形成すると、窪みの周縁に金属が盛り上がった***部が形成される。しかし、熱交換器１Ｂの製造方法では、窪み１２Ｂを、第一窪み部１２１の形成と第二窪み部１２２の形成に分けて形成する。このため、プレス加工による場合でも、窪み１２Ｂの周縁に***部が形成されにくい。 As described above, in the method for manufacturing the heat exchanger 1B according to the second embodiment, the metal plate 15 to be the outer shell wall 11 is overlapped with the first recessed portion 121 to form the second recessed portion 122. A depression 12B is formed. Generally, when a depression is formed in the metal plate 15 by press working, a raised portion in which metal is raised is formed on the peripheral edge of the depression. However, in the method of manufacturing the heat exchanger 1B, the recess 12B is formed by dividing the formation of the first recess 121 and the formation of the second recess 122. Therefore, even in the case of press working, it is difficult for a raised portion to be formed on the peripheral edge of the recess 12B.

また、熱交換器１Ｂの製造方法では、複数回のプレス加工によって窪み１２Ｂを形成する。このため、熱交換器１Ｂの製造方法によれば、金属板１５の厚みが大きい場合でも、伝熱管２０の外径よりも小さい肉薄部１４Ｂを容易に形成することができる。 Further, in the method of manufacturing the heat exchanger 1B, the recess 12B is formed by press working a plurality of times. Therefore, according to the method for manufacturing the heat exchanger 1B, even when the thickness of the metal plate 15 is large, the thin portion 14B smaller than the outer diameter of the heat transfer tube 20 can be easily formed.

熱交換器１Ｂの製造方法では、窪み１２Ｂを分配器１０の内側に配置しているので、窪み１２Ｂが目立たず、分配器１０の意匠性が高い。 In the method of manufacturing the heat exchanger 1B, since the recess 12B is arranged inside the distributor 10, the recess 12B is inconspicuous and the design of the distributor 10 is high.

なお、窪み１２Ｂは、分配器１０の外側に配置しても良い。この場合、窪み１２Ｂに充填されたろう材料４０が、分配器１０の内部を流通する冷媒の圧力を受けにくい。 The recess 12B may be arranged outside the distributor 10. In this case, the brazing material 40 filled in the recess 12B is less likely to receive the pressure of the refrigerant flowing inside the distributor 10.

（実施の形態３）
実施の形態１に係る熱交換器１Ａの製造方法で用いる伝熱管２０の管断面は、扁平形状である。すなわち、伝熱管２０は扁平管である。しかし、伝熱管２０はこれに限定されない。実施の形態３に係る熱交換器１Ｃの製造方法で用いられる伝熱管２５は、円管である。以下、図１１及び図１２を参照して、実施の形態３に係る熱交換器１Ｃの製造方法について説明する。実施の形態３では、実施の形態１及び２と異なる構成について説明する。(Embodiment 3)
The cross section of the heat transfer tube 20 used in the method for manufacturing the heat exchanger 1A according to the first embodiment has a flat shape. That is, the heat transfer tube 20 is a flat tube. However, the heat transfer tube 20 is not limited to this. The heat transfer tube 25 used in the method for manufacturing the heat exchanger 1C according to the third embodiment is a circular tube. Hereinafter, the method for manufacturing the heat exchanger 1C according to the third embodiment will be described with reference to FIGS. 11 and 12. In the third embodiment, a configuration different from the first and second embodiments will be described.

図１１は、実施の形態３に係る熱交換器１Ｃが備える分配器１０の外殻壁１１と伝熱管２５の接合箇所の斜視図である。図１２は、図１１に示すＸＩＩ−ＸＩＩ切断線に沿って切断したときの断面図である。なお、理解を容易にするため、図１１では、ろう材料４０を省略している。また、図１２では、伝熱管２５の内部構造を省略している。 FIG. 11 is a perspective view of a joint portion between the outer shell wall 11 of the distributor 10 and the heat transfer tube 25 included in the heat exchanger 1C according to the third embodiment. FIG. 12 is a cross-sectional view taken along the XII-XII cutting line shown in FIG. In addition, in FIG. 11, the brazing material 40 is omitted for ease of understanding. Further, in FIG. 12, the internal structure of the heat transfer tube 25 is omitted.

図１１に示すように、熱交換器１Ｃは、円管で形成された伝熱管２５を備えている。 As shown in FIG. 11, the heat exchanger 1C includes a heat transfer tube 25 formed of a circular tube.

一方、外殻壁１１の、分配器１０の外側の面には、円錐台状の窪み１２Ｃが形成されている。これにより、その窪み１２Ｃの底には、肉薄部１４Ｃが形成されている。 On the other hand, a truncated cone-shaped depression 12C is formed on the outer surface of the distributor 10 of the outer shell wall 11. As a result, a thin portion 14C is formed at the bottom of the recess 12C.

肉薄部１４Ｃの厚みＴ１は、図１２に示すように、伝熱管２５の外径ＯＤよりも小さい。そして、肉薄部１４Ｃには、円筒状の貫通孔１３Ｃが形成され、その貫通孔１３Ｃには、伝熱管２５が挿入されている。伝熱管２５は、窪み１２Ｃに充填されたろう材料４０によって外殻壁１１に接合されている。 As shown in FIG. 12, the thickness T1 of the thin portion 14C is smaller than the outer diameter OD of the heat transfer tube 25. A cylindrical through hole 13C is formed in the thin portion 14C, and a heat transfer tube 25 is inserted into the through hole 13C. The heat transfer tube 25 is joined to the outer shell wall 11 by a brazing material 40 filled in the recess 12C.

熱交換器１Ｃの製造方法は、外殻壁１１の一方の面の側にだけ、円錐台状の窪み１２Ｃを形成し、その窪み１２Ｃに円筒状の貫通孔１３Ｃを形成すること、及び、窪み１２Ｃを流路側に配置して、分配器１０Ｒ、１０Ｌを作製すること、を除き、実施の形態１と同様である。このため、熱交換器１Ｃの製造方法の説明を省略する。 The method for manufacturing the heat exchanger 1C is to form a truncated cone-shaped recess 12C only on one side of the outer shell wall 11, and to form a cylindrical through hole 13C in the recess 12C, and to form a recess. It is the same as that of the first embodiment except that the distributors 10R and 10L are manufactured by arranging the 12C on the flow path side. Therefore, the description of the manufacturing method of the heat exchanger 1C will be omitted.

以上のように、実施の形態３に係る熱交換器１Ｃの製造方法では、円管で形成された伝熱管２５が用いられる。そして、実施の形態３でも、実施の形態１と同様に、外殻壁１１に肉薄部１４Ｃが形成されているので、貫通孔１３Ｃを形成しやすい。 As described above, in the method for manufacturing the heat exchanger 1C according to the third embodiment, the heat transfer tube 25 formed of a circular tube is used. Further, also in the third embodiment, as in the first embodiment, since the thin portion 14C is formed on the outer shell wall 11, it is easy to form the through hole 13C.

（実施の形態４）
実施の形態１−３に係る熱交換器１Ａ−１Ｃの製造方法では、外殻壁１１の内側に肉薄部１４Ａ−１４Ｃを形成する。しかし、熱交換器１Ａ−１Ｃの製造方法はこれに限定されない。実施の形態４に係る熱交換器１Ｄの製造方法では、外殻壁１１の外側に肉薄部１４Ｄを形成する。以下、図１３を参照して、実施の形態４に係る熱交換器１Ｄの製造方法について説明する。実施の形態４では、実施の形態１−３と異なる構成について説明する。(Embodiment 4)
In the method for manufacturing the heat exchanger 1A-1C according to the first to third embodiment, the thin portion 14A-14C is formed inside the outer shell wall 11. However, the method for manufacturing the heat exchanger 1A-1C is not limited to this. In the method for manufacturing the heat exchanger 1D according to the fourth embodiment, the thin portion 14D is formed on the outside of the outer shell wall 11. Hereinafter, a method of manufacturing the heat exchanger 1D according to the fourth embodiment will be described with reference to FIG. In the fourth embodiment, a configuration different from that of the first to third embodiments will be described.

図１３は、実施の形態４に係る熱交換器１Ｄが備える分配器１０の外殻壁１１と伝熱管２０の接合箇所の断面図である。なお、図１３では、図２に示すＩＩＩ−ＩＩＩ切断線の同じ切断線での接合箇所の断面を示している。また、図１３では、理解を容易にするため、伝熱管２０の内部構造を省略している。 FIG. 13 is a cross-sectional view of a joint portion between the outer shell wall 11 of the distributor 10 and the heat transfer tube 20 included in the heat exchanger 1D according to the fourth embodiment. Note that FIG. 13 shows a cross section of a joint portion of the III-III cutting line shown in FIG. 2 at the same cutting line. Further, in FIG. 13, the internal structure of the heat transfer tube 20 is omitted for ease of understanding.

図１３に示すように、分配器１０は、外殻壁１１に形成され、分配器１０の内側に突出した肉薄部１４Ｄを備える。 As shown in FIG. 13, the distributor 10 includes a thin portion 14D formed on the outer shell wall 11 and protruding inward of the distributor 10.

肉薄部１４Ｄは、断面視で３つの段差を有する窪み１２Ｄが外殻壁１１の外側の面に形成されることにより、設けられている。 The thin portion 14D is provided by forming a recess 12D having three steps in a cross-sectional view on the outer surface of the outer shell wall 11.

詳細には、窪み１２Ｄは、第一窪み部１２３、第二窪み部１２４及び、第三窪み部１２５を備える。そして、第二窪み部１２４は、第一窪み部１２３の内部に形成され、第一窪み部１２３よりも面積が小さい。また、第三窪み部１２５は、第二窪み部１２４の内部に形成され、第二窪み部１２４よりも面積が小さい。それら第一窪み部１２３、第二窪み部１２４及び、第三窪み部１２５は、外殻壁１１の内側に向かって窪んでいる。 Specifically, the recess 12D includes a first recess 123, a second recess 124, and a third recess 125. The second recessed portion 124 is formed inside the first recessed portion 123, and has a smaller area than the first recessed portion 123. Further, the third recessed portion 125 is formed inside the second recessed portion 124 and has a smaller area than the second recessed portion 124. The first recessed portion 123, the second recessed portion 124, and the third recessed portion 125 are recessed toward the inside of the outer shell wall 11.

それら第一窪み部１２３、第二窪み部１２４及び、第三窪み部１２５の底のうち、第二窪み部１２４と第三窪み部１２５の底は、外殻壁１１の内壁面よりも内側に突出している。換言すると、第二窪み部１２４と第三窪み部１２５の底は、外殻壁１１の内壁面よりも内側に浮き出している。そして、第三窪み部１２５の底は、最も内側に浮き出している。その第三窪み部１２５の底は、肉薄部１４Ｄを形成している。 Of the bottoms of the first recess 123, the second recess 124, and the third recess 125, the bottoms of the second recess 124 and the third recess 125 are inside the inner wall surface of the outer shell wall 11. It is protruding. In other words, the bottoms of the second recessed portion 124 and the third recessed portion 125 protrude inward from the inner wall surface of the outer shell wall 11. The bottom of the third recess 125 is projected to the innermost side. The bottom of the third recess 125 forms a thin portion 14D.

肉薄部１４Ｄの厚みＴ１は、実施の形態１、２と同様に、伝熱管２０の外径ＯＤよりも小さい。また、肉薄部１４Ｄには、実施の形態１、２で説明した貫通孔１３Ａ、１３Ｂと同じ構成の貫通孔１３Ｄが形成されている。そして、貫通孔１３Ｄには、伝熱管２０が挿入されている。 The thickness T1 of the thin portion 14D is smaller than the outer diameter OD of the heat transfer tube 20 as in the first and second embodiments. Further, the thin portion 14D is formed with a through hole 13D having the same configuration as the through holes 13A and 13B described in the first and second embodiments. A heat transfer tube 20 is inserted into the through hole 13D.

上述した第三窪み部１２５には、ろう材料４０が充填されている。また、貫通孔１３Ｄの内壁と伝熱管２０の隙間には、ろう材料４０が浸透している。さらに、第三窪み部１２５の内壁と伝熱管２０との間にろうフィレット４１が形成されている。これにより、伝熱管２０が、第三窪み部１２５と貫通孔１３Ｄの内壁に接合されている。 The wax material 40 is filled in the third recess 125 described above. Further, the brazing material 40 permeates into the gap between the inner wall of the through hole 13D and the heat transfer tube 20. Further, a wax fillet 41 is formed between the inner wall of the third recess 125 and the heat transfer tube 20. As a result, the heat transfer tube 20 is joined to the third recess 125 and the inner wall of the through hole 13D.

次に、熱交換器１Ｄの製造方法について説明する。 Next, a method of manufacturing the heat exchanger 1D will be described.

まず、実施の形態２で説明した肉薄化工程により、金属板１５に第一窪み部１２３を形成する。 First, the first recessed portion 123 is formed in the metal plate 15 by the thinning step described in the second embodiment.

次に、図示しないが、第一窪み部１２３内に第二窪み部１２４を形成する。このとき、実施の形態２と異なり、ハーフピアス加工、半抜き加工、ダボ加工、エンボス加工等の名称で呼ばれる加工方法で、第一窪み部１２３内の底の一部を、第一窪み部１２３の窪み方向に押し出す。これにより、その底の一部を、窪み方向に浮き出させる。なお、以下、本明細書では、この工程のことをハーフピアス工程という。 Next, although not shown, a second recess 124 is formed in the first recess 123. At this time, unlike the second embodiment, a part of the bottom in the first recess 123 is formed by a processing method called half piercing, half punching, dowel processing, embossing, etc. Extrude in the direction of the dent. As a result, a part of the bottom is raised in the recessing direction. Hereinafter, in the present specification, this process is referred to as a half piercing process.

続いて、ハーフピアス工程を再度行い、第二窪み部１２４内に、第二窪み部１２４よりも面積が小さい第三窪み部１２５を形成する。この工程では、金型の押し込み量を調整することにより、第三窪み部１２５の底の厚み、すなわち、肉薄部１４Ｄの厚みＴ１を伝熱管２０の外径ＯＤよりも小さくする。 Subsequently, the half piercing step is performed again to form a third recess 125 having a smaller area than the second recess 124 in the second recess 124. In this step, the thickness of the bottom of the third recess 125, that is, the thickness T1 of the thin portion 14D is made smaller than the outer diameter OD of the heat transfer tube 20 by adjusting the pushing amount of the mold.

次に、実施の形態１で説明した貫通孔形成工程を行って、第三窪み部１２５に、貫通孔１３Ｄを形成する。続いて、金属板１５をプレス加工して、実施の形態１で説明した形状の外殻壁１１を有する分配器１０を作製する。さらに、実施の形態１で説明した組み付け工程、溶接工程を行って、熱交換器１Ｄを完成させる。 Next, the through hole forming step described in the first embodiment is performed to form the through hole 13D in the third recess 125. Subsequently, the metal plate 15 is press-processed to produce a distributor 10 having an outer shell wall 11 having the shape described in the first embodiment. Further, the assembling step and the welding step described in the first embodiment are performed to complete the heat exchanger 1D.

なお、貫通孔形成工程から溶接工程までは、実施の形態１と同様であるため、実施の形態４では、詳細な説明を省略する。 Since the process from the through hole forming step to the welding step is the same as that of the first embodiment, detailed description thereof will be omitted in the fourth embodiment.

また、実施の形態４では、窪み１２Ｄが分配器１０の外側へ窪み、肉薄部１４Ｄが分配器１０の内側に突出しているが、窪み１２Ｄは、分配器１０の内側へ窪んでも良い。また、肉薄部１４Ｄは、分配器１０の外側に突出しても良い。 Further, in the fourth embodiment, the recess 12D is recessed to the outside of the distributor 10 and the thin portion 14D is projected to the inside of the distributor 10, but the recess 12D may be recessed to the inside of the distributor 10. Further, the thin portion 14D may protrude to the outside of the distributor 10.

以上のように、実施の形態４に係る熱交換器１Ｄの製造方法では、ハーフピアス加工により、外殻壁１１の一部を窪ませると共に、窪み方向に浮き出させて、肉薄部１４Ｄを形成する。このため、外殻壁１１の一部を浮き出させない加工と比較して、肉薄部１４Ｄが破損しにくく、加工が容易である。 As described above, in the method for manufacturing the heat exchanger 1D according to the fourth embodiment, a part of the outer shell wall 11 is recessed and raised in the recessing direction by half piercing to form a thin portion 14D. .. Therefore, as compared with the processing in which a part of the outer shell wall 11 is not raised, the thin portion 14D is less likely to be damaged and the processing is easy.

また、肉薄部１４Ｄがある第三窪み部１２５がろう材料４０で充填されるので、外殻壁１１の強度を高めることができる。 Further, since the third recessed portion 125 having the thin portion 14D is filled with the brazing material 40, the strength of the outer shell wall 11 can be increased.

また、第一窪み部１２３、第二窪み部１２４及び、第三窪み部１２５のうち、少なくとも第三窪み部１２５をろう材料４０で充填すれば外殻壁１１の強度を高めることができる。このため、熱交換器１Ｄの製造方法によれば、ろう材料４０での使用量を少なくすることができる。また、第三窪み部１２５をろう材料４０で充填すれば良いので、ろう付けが容易である。 Further, if at least the third recess 125 of the first recess 123, the second recess 124, and the third recess 125 is filled with the brazing material 40, the strength of the outer shell wall 11 can be increased. Therefore, according to the method for manufacturing the heat exchanger 1D, the amount used in the brazing material 40 can be reduced. Further, since the third recess 125 may be filled with the brazing material 40, brazing is easy.

以上、本開示の実施の形態に係る熱交換器１Ａ−１Ｄの製造方法について説明したが、熱交換器１Ａ−１Ｄの製造方法はこれに限定されない。例えば、実施の形態１−３では、伝熱管２０、２５を外殻壁１１にろう材料４０によってろう付けしている。しかし、伝熱管２０、２５の接合方法はろう付けに限定されず、伝熱管２０、２５は、外殻壁１１に溶接されると良い。例えば、伝熱管２０、２５は、外殻壁１１に融接されても良い。この場合、溶接材料は、外殻壁１１、すなわち、分配器１０の材料と同じ材料であると良い。これにより、窪み１２Ａ−１２Ｄを分配器１０の材料と同じ材料で充填して、分配器１０の強度を保つことができる。 Although the method for manufacturing the heat exchanger 1A-1D according to the embodiment of the present disclosure has been described above, the method for manufacturing the heat exchanger 1A-1D is not limited to this. For example, in the first to third embodiments, the heat transfer tubes 20 and 25 are brazed to the outer shell wall 11 with a brazing material 40. However, the method of joining the heat transfer tubes 20 and 25 is not limited to brazing, and the heat transfer tubes 20 and 25 may be welded to the outer shell wall 11. For example, the heat transfer tubes 20 and 25 may be fused to the outer shell wall 11. In this case, the welding material is preferably the same material as the outer shell wall 11, that is, the material of the distributor 10. As a result, the recesses 12A-12D can be filled with the same material as the material of the distributor 10 to maintain the strength of the distributor 10.

なお、溶接がろう付けの場合、ろう材料４０は、例えば、分配器１０又は伝熱管２０、２５と同種の材料であっても良い。また、異種の材料であっても良い。 In the case of welding brazing, the brazing material 40 may be, for example, the same material as the distributor 10 or the heat transfer tubes 20 and 25. Further, different materials may be used.

実施の形態１−４では、貫通孔１３Ａ−１３Ｄがプレス加工により形成されている。しかし、本開示はこれに限定されない。熱交換器１Ａ−１Ｄの製造方法では、貫通孔１３Ａ−１３Ｄを、プレス加工以外の塑性加工により形成されても良い。このような形態でも、窪み１２Ａ−１２Ｄが形成され、その厚みが小さいため、貫通孔１３Ａ−１３Ｄの形成が容易である。 In the first to fourth embodiments, the through holes 13A-13D are formed by press working. However, this disclosure is not limited to this. In the method for manufacturing the heat exchanger 1A-1D, the through holes 13A-13D may be formed by plastic working other than press working. Even in such a form, the recesses 12A-12D are formed and the thickness thereof is small, so that the through holes 13A-13D can be easily formed.

また、実施の形態１、２及び４では、伝熱管２０が扁平管であり、実施の形態３では、伝熱管２５が円管である。しかし、伝熱管２０、２５はこれに限定されない。伝熱管２０、２５は、窪み１２Ａ−１２Ｄの厚みよりも外径が大きい限りにおいて、その形状は任意である。例えば、伝熱管２０、２５は、角筒状の管であっても良い。また、断面楕円の円柱状であっても良い。 Further, in the first, second and fourth embodiments, the heat transfer tube 20 is a flat tube, and in the third embodiment, the heat transfer tube 25 is a circular tube. However, the heat transfer tubes 20 and 25 are not limited to this. The shape of the heat transfer tubes 20 and 25 is arbitrary as long as the outer diameter is larger than the thickness of the recesses 12A-12D. For example, the heat transfer tubes 20 and 25 may be square tubular tubes. Further, it may be a columnar shape having an elliptical cross section.

実施の形態１−４では、分配器１０が直法体状である。しかし、分配器１０は、外殻壁１１の一部の領域に、伝熱管２０の、２５外径よりも厚みが小さい肉薄部１４Ａ−１４Ｄが形成される限りにおいて、その形状は任意である。例えば、分配器１０を円筒状に作製しても良い。 In the first to fourth embodiments, the distributor 10 has a straight body shape. However, the shape of the distributor 10 is arbitrary as long as the thin portion 14A-14D of the heat transfer tube 20 having a thickness smaller than the outer diameter of 25 is formed in a part of the outer shell wall 11. For example, the distributor 10 may be made in a cylindrical shape.

また、分配器１０の内部構造も任意である。例えば、分配器１０の内部に隔壁を設け、内部に複数の流路を形成しても良い。 Further, the internal structure of the distributor 10 is also arbitrary. For example, a partition wall may be provided inside the distributor 10 to form a plurality of flow paths inside.

本開示は、本開示の広義の精神と範囲を逸脱することなく、様々な実施形態及び変形が可能とされるものである。また、上述した実施形態は、本開示を説明するためのものであり、本開示の範囲を限定するものではない。つまり、本開示の範囲は、実施形態ではなく、請求の範囲によって示される。そして、請求の範囲内及びそれと同等の開示の意義の範囲内で施される様々な変形が、本開示の範囲内とみなされる。 The present disclosure allows for various embodiments and modifications without departing from the broad spirit and scope of the present disclosure. Moreover, the above-described embodiment is for explaining the present disclosure, and does not limit the scope of the present disclosure. That is, the scope of the present disclosure is indicated by the claims, not the embodiments. And various modifications made within the scope of the claims and within the equivalent meaning of disclosure are considered to be within the scope of the present disclosure.

本出願は、２０１９年４月２２日に出願された日本国特許出願特願２０１９−８０６２６号に基づく。本明細書中に日本国特許出願特願２０１９−８０６２６号の明細書、特許請求の範囲、図面全体を参照として取り込むものとする。 This application is based on Japanese Patent Application No. 2019-80626 filed on April 22, 2019. The specification of Japanese Patent Application No. 2019-80626, the scope of claims, and the entire drawing shall be incorporated into this specification as a reference.

１Ａ−１Ｄ 熱交換器、１０，１０Ｒ、１０Ｌ 分配器、１１ 外殻壁、１２Ａ−１２Ｄ 窪み、１３Ａ−１３Ｄ 貫通孔、１４Ａ−１４Ｄ 肉薄部、１５ 金属板、２０、２５ 伝熱管、３０ フィン、４０ ろう材料、４１ ろうフィレット、１２１，１２３ 第一窪み部、１２２，１２４ 第二窪み部、１２５ 第三窪み部、Ｌ 長さ、ＬＤ 長径、ＯＤ 外径、ＳＤ 短径、Ｔ，Ｔ１ 厚み、Ｗ 幅。 1A-1D heat exchanger, 10,10R, 10L distributor, 11 outer shell wall, 12A-12D recess, 13A-13D through hole, 14A-14D thin part, 15 metal plate, 20, 25 heat transfer tube, 30 fins, 40 wax material, 41 wax fillet, 121,123 1st recess, 122,124 2nd recess, 125 3rd recess, L length, LD major axis, OD outer diameter, SD minor axis, T, T1 thickness, W width.

Claims (7)

伝熱管と、該伝熱管が溶接された外殻壁を有する分配器と、を備える熱交換器の製造方法であって、
前記外殻壁の一部の領域に、前記伝熱管の外径よりも厚みが小さい肉薄部を形成する肉薄部形成工程と、
前記肉薄部に前記伝熱管が挿入可能な貫通孔を形成する貫通孔形成工程と、
前記貫通孔に前記伝熱管を挿入し、挿入した前記伝熱管と前記貫通孔の内壁の間隙と前記肉薄部が形成された前記一部の領域の内部に溶接材料を充填して、前記伝熱管を前記外殻壁に溶接する溶接工程と、
を備える、熱交換器の製造方法。A method of manufacturing a heat exchanger comprising a heat transfer tube and a distributor having an outer shell wall to which the heat transfer tube is welded.
A thin portion forming step of forming a thin portion having a thickness smaller than the outer diameter of the heat transfer tube in a part of the outer shell wall.
A through hole forming step of forming a through hole into which the heat transfer tube can be inserted in the thin portion,
The heat transfer tube is inserted into the through hole, and a welding material is filled in the gap between the inserted heat transfer tube and the inner wall of the through hole and the part of the region where the thin portion is formed to fill the heat transfer tube. In the welding process of welding to the outer shell wall,
A method of manufacturing a heat exchanger. 前記肉薄部形成工程では、前記外殻壁の前記一部の領域を、一方の面側とその反対の面側の、少なくとも１つの面の側から凸状の金型を押し込んで、プレス加工することにより、前記肉薄部を形成し、
前記貫通孔形成工程では、前記肉薄部をプレス加工することにより、前記貫通孔を形成する、
請求項１に記載の熱交換器の製造方法。In the thin portion forming step, the partial region of the outer shell wall is pressed by pushing a convex mold from at least one surface side on one surface side and the opposite surface side. By forming the thin portion,
In the through hole forming step, the through hole is formed by pressing the thin portion.
The method for manufacturing a heat exchanger according to claim 1. 前記肉薄部形成工程の前に、前記外殻壁の前記一部の領域を含み前記一部の領域よりも広い領域を、プレス加工して、前記外殻壁の厚みを小さくする肉薄化工程をさらに備える、
請求項１又は２に記載の熱交換器の製造方法。Prior to the thinning portion forming step, a thinning step of reducing the thickness of the outer shell wall by pressing a region including the partial region of the outer shell wall and wider than the partial region is performed. Further prepare
The method for manufacturing a heat exchanger according to claim 1 or 2. 前記肉薄部形成工程では、前記外殻壁の一部の領域にある一部分を、前記外殻壁の一方の壁面側に浮き出させる、
請求項１から３のいずれか１項に記載の熱交換器の製造方法。In the thin portion forming step, a part of the outer shell wall in a part of the region is raised on one wall surface side of the outer shell wall.
The method for manufacturing a heat exchanger according to any one of claims 1 to 3. 前記貫通孔形成工程では、前記貫通孔を、前記伝熱管の管断面と同じ形状に形成する、
請求項１から４のいずれか１項に記載の熱交換器の製造方法。In the through-hole forming step, the through-hole is formed in the same shape as the cross section of the heat transfer tube.
The method for manufacturing a heat exchanger according to any one of claims 1 to 4. 前記伝熱管は、前記外殻壁と同材料で形成され、
前記溶接工程では、溶接材料が前記外殻壁及び前記伝熱管と同材料である、
請求項１から５のいずれか１項に記載の熱交換器の製造方法。The heat transfer tube is made of the same material as the outer shell wall.
In the welding step, the welding material is the same material as the outer shell wall and the heat transfer tube.
The method for manufacturing a heat exchanger according to any one of claims 1 to 5. 伝熱管と、
前記伝熱管の外径よりも厚みが小さい肉薄部及び、該肉薄部に配置され、前記伝熱管が挿入された貫通孔が形成された外殻壁を有する分配器と、
を備え、
前記伝熱管と前記貫通孔の内壁の間隙と前記肉薄部が形成された領域内に溶接材料が充填されている、
熱交換器。Heat transfer tube and
A distributor having a thin portion having a thickness smaller than the outer diameter of the heat transfer tube and an outer shell wall arranged in the thin portion and having a through hole into which the heat transfer tube is inserted.
With
The welding material is filled in the gap between the heat transfer tube and the inner wall of the through hole and the region where the thin portion is formed.
Heat exchanger.
JP2021515943A 2019-04-22 2020-04-06 Heat exchanger manufacturing method and heat exchanger Ceased JPWO2020217940A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0615441A (en) * 1989-08-25 1994-01-25 Showa Alum Corp Production of metal pipe for brazing having guide piece in tube inserting hole
JP2003053523A (en) * 2001-08-14 2003-02-26 Mitsubishi Alum Co Ltd Heat exchanger and its manufacturing method
JP2013204070A (en) * 2012-03-27 2013-10-07 Mitsubishi Alum Co Ltd Extruded heat-conducting tube for heat-exchanger and manufacturing method therefor

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0615441A (en) * 1989-08-25 1994-01-25 Showa Alum Corp Production of metal pipe for brazing having guide piece in tube inserting hole
JP2003053523A (en) * 2001-08-14 2003-02-26 Mitsubishi Alum Co Ltd Heat exchanger and its manufacturing method
JP2013204070A (en) * 2012-03-27 2013-10-07 Mitsubishi Alum Co Ltd Extruded heat-conducting tube for heat-exchanger and manufacturing method therefor

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