201028229 六、發明說明： 【發明所屬之技術領域】 本發明係關於一種上水箱（header tank)及用於製造此 上水箱的方法。上水箱亦稱之為歧管水箱（manif〇ld tank), 可運用在硬焊式汽車熱交換器或靜止鋁熱交換器上，其具 有任意的水箱形狀。本發明亦關於一種含有上述方法所製 成的上水箱之熱交換器。 【先前技術】 為了能夠以合理的方式組裝所有的引擎蓋零件，現今 的/飞車工程師面臨越來越大的困難，因為除了引擎變得更 強而有力之外，為了支推引擎且提供乘客持續增加的駕驶 體驗、安全性及舒適度，所以必須安裝越來越多的不同零 件。如此一來，將會使引擎蓋底下所能獲得的空間變得不 足。大部分的熱交換器其出廠時的設定就是矩形，此形狀 會限制汽車工程師欲將熱交換器組裝到汽車内時所能考量 到的適當位置。在熱交換器幾何形狀上的大部分限制因素 是由欲製造上水箱板（header plate)及上水箱以產生出不規 則狀或客製化形狀的熱交換器之經濟可行性所決定；以目 前的製造方法來說’這樣的上水箱板及上水箱會使熱交換 器太過昂貴。 ，·、 、 而且，引擎蓋的安全性、舒適度與性能零件的增加量， 2致車輛的前端比後端更重，這一點是令人不喜歡的。在 普通的載客交通工具中’類似CAC的熱交換器、冷凝器、 201028229 散熱器、及EGR冷卻器等，均必須被定位在接近車輛的最 前端處，以便有助於充分的熱交換性能。本發明有助於減 少這些零件的重量且減少成本’同時増加封褒時的幾何彈 性’而不會損害性能。 ❹ 最常用來製造熱交換器上水箱的方法是備製一軋平的 硬焊片材，且成製此硬焊片材，使其產生具有用於捲曲塑 膠槽的翼片之上水箱板、用於***供冷卻流體循環且具有 上水箱板最終形狀的流體管件之開槽。這一方法通常是藉 由以下步驟而完成：將一軋平片材切割出正確尺寸；=壓 側邊以使此片材產生出矩形邊緣（用於翼片）；深抽拉此片材 以形成一上水箱板；以及最後沖壓出供流體管件/鰭片封裝 所***的開槽。之後，實施正常的硬谭程序。在銅銲之後， 上水箱板表面上的塗覆層已經溶化且流到上水箱板管件的 接點上，而產生出具有正確尺寸與形狀的内圓角⑽叫。之 後’上水箱被捲曲至適當位置。 在散熱器、加熱器及CAC的情形令，上水箱通常是由 聚合物材料所製成。用於形成上水箱的先前另一種技術是 液壓成形（hydro-forming) 〇 上述製造程序很昂貴，而且必須非常嚴謹地控制工且 戎何形狀及工具/片材之間的接觸 ^ a 各 、 伐蜩潤滑。而且，亦需要處置 與清潔潤滑劑殘餘物，而且必須虚 乂4處置生產地點上沖壓產生 的金屬碎片、人員配置、地面空 ^ ^ 吧囟二間、及控制機具的投資等， 廷二都會增加成本。此外，由於 ， 术抽拉法是在室溫下進行， 所以被限制成只能使用冷加工工 工具鋼，而這些冷加工工具 5 201028229 鋼通常报難切削成緊密的公差配合，且切削過程成本相當 而。 以射出模製成型法製造塑膠水箱是一種較慢且較昂貴 的程序’因為它需要大量投資機具、另外還要以工具修整 半成品、以及一連串的控制程序。水箱是熱交換器的一個 多功能部件’且亦被製作成具有固定件及容易進入的組裝 位置（例如：用於水箱内的油冷卻器及感測裝置）。而且，因 為相較於銘材來說’塑膠材料的堅硬度較差，所以水箱的 壁體很厚’且水箱被製作成具有一體成型的外部強化骨 架，以達到足夠的扭力堅硬度。因此，僅管水箱是由低密 度材料製成，但水箱仍會變得很沉重。然而，可以利用晶 鬚（whisker)或纖維強化件來增加堅硬度，但如此卻大幅增加 成本。 在CAC的情形中，操作溫度可能會超過使塑膠材料損 失過多強度的溫度，而使塑膠材料無法使用。因此，現今， 水箱通常都疋以銘材製成。大部分這些水箱是利用模禱成 型技術所製成，其通常會將水箱的厚度限制在大於15腿 的範圍内，如此會增加整個熱交換器的重量。而且，鑄造 過的銘材無法輕易捲曲至上水箱±，且通常所使用的結合 法疋以MIG或TIG的熔接方式。在正常情形下’此種水箱 及π «法a夠產生很強力的組裝效果。然@，熔接法既昂 貴又耗時’且會對整個熱交換器增加很大的重量，特別是 因為水箱必須被製作成具有非常大的厚度方可實施炼接， 而且上水箱板必須夠厚才能夠產生成功的熔接點。 201028229 【發明内容】 箱 因此，需要-種有效且具有彈性的方法來製造上水箱。 本發明係關於，AA3XXX叙合金所製成的上水 通常用於熱交換器上水箱的這—組合金系列 (AA3XXX)，很難藉由典型製造上水箱的方法而成型出相要 ❹ 鲁 的形狀。在鎢造及滾軋的情形下，這些合金並未具有可供 上水箱…下更進-t…成型性 (formability)。 習知的方法並無法滿足對於上水箱的長期需要—就是 必須能夠被硬焊且成型為複雜形狀。根據本發明，提出一 種用於製造上水箱的方法，其步驟係如申請專利範圍所 定。 為了達到足夠的高品質成型效果，必須要有超過2〇% 的延伸率。為了獲得相當好的可成㈣，在本項技術現有 、技術水平中’塗覆有鋼銲片材的核心碇必須施以高溫均 質化咖m〇genization)_，此肖句化處理能產生一種微結 構，假如執打正確的#，此種微結構在冷熱滚軋與退火處 =之後會增加合金片的可成型性。在均質化期間，存在於 :金^的大部分料沉搬而形成很大的分散顆粒，如此一 會損失掉在固態溶液中由鐘所潛在提供的-些強度。均 :理可月b會不利地影響ΑΑ3χχχ合金的抗腐蝕性；相 ;、有在熱滾軋之前預熱，均質化及退火也會增加材料 7 201028229 的成本。因此，對於打算用作為熱交換器中的上水箱之合 金來說，最好能避免均質化與退火。 為了在運送條件下獲得高伸長量，材料被施以完全回 火（O-temper)，或者有時候施以HU2回火（亦即：退火條 件）。此項操作也會增加熱交換器材料的成本。藉由本發明 的方法所製造的熱交換器上水箱，管件的合金並不需要被 均質化，如此能夠有效地形成未均質化的鋁合金管件。而 且，管件胚料也不需要在成型之前先經過退火如此能使 此方法變得更合乎成本效益。 本發明提供一種用於製造熱交換器上水箱的方法，其 步驟包括：備製具有由ΑΑ3χχχ·鋁合金所製成的核心之一 管件；選擇性地預熱該管件；將該管件***一成型工具内， 該成型工具具有最終上水箱的形狀之一成型凹穴；塞住該 管件的兩端；假如該管件並未被充分預熱的話則加熱= 管件至成型溫度，且利用一氣體對該管件的内部加壓，藉 此使該管件符合該工具凹穴的形狀，而獲得最终的上水 箱；從該工具中移除該上水箱；以及冷卻該上水箱。此方 法能夠有效地製造出ΑΑ3ΧΧΧ鋁合金製成的上水箱。 藉由使用尚未被均質化的管件材料，可以獲^進的 腐蝕與機械特性。尚未被退火的管件有助於降低成：，且 減少對環境的負荷。因Λ，相較於由對應但受過均質化處 理的ΑΑ3ΧΧΧ合金所製成之深抽拉上水箱，依據本發明方 :所製成之未受均質化的ΑΑ3ΧΧΧ合金上水箱，其具有更 尚的強度與抗腐姓性。 201028229 管件核心可以具有至少一個由鋁合金所製成的塗覆 層’藉此增加可硬焊性（brazeability)。可以在成型之後，在 塑形過的上水箱中產生用於管件或連接部位的開槽，藉此 有助於熱交換器的製造。 在成型斯間所使用的氣壓較佳為85bar以上，以便使管 件能夠緊貼著工具的成型凹穴而達到有效成型。 假如想要的話，可以在管件的成型期間，在管件尾端 施加一軸向壓力，以便在成型期間將材料供應到成型凹穴 而且，在管件的成型期間，可以在管件的尾端上形成 連接部位、螺紋或錨件，以便使熱交換器更容易組裝。 根據水箱的形狀及銘胚料的厚度’可能會需要2〇〇bar 以上的壓力。 形成上水箱所用的管件可以由滾軋過的鋁合金胚料所 製成，將此鋁合金胚料熔接起來而形成管件。藉此，可以 ❹冑效製造管件。特別有利地，可以從滾乾過且具有銅焊塗 覆層的鋁胚料製造管件，因為這是一種獲得鋼銲塗覆層管 件的有效方法。銅銲塗覆層管件是非常昂責且極難以二出 、作為另-替代方式，管件可以由播出成型的銘合金製 成，這一點在一些情形中是很有利的，特別是當管件上並 無任何銅銲塗覆層的時候格外有利。 其係藉由上述 本發明另外提供一種熱交換器上水箱 熱金屬氣體成型法而形成。 9 201028229 本發明亦提供一種熱交換器，其包含本發明的上水 箱，且該熱交換器具有非矩形的形狀。 本發明另外提供一種用於製造熱交換器的方法，其中 該上水箱係連接到多條管件以及該等管件之間所***的多 個波紋鰭片，接著將這些鰭片硬焊至管件上。 熱金屬氣體成型法能夠使AA3XXX鋁合金製成的上水 箱結構具有任意的形狀且可用於熱交換器。 本發明用於熱交換器的上水箱，其重量低，且相較於 競爭技術來說可以運用低成本而達到最佳化。 消除塑膠製水箱能夠使材料回收更加容易；比起競爭 的鋁成型技術來說（例如：液壓成型法或深抽拉法），水箱的 剖面幾何形狀可以在較大的限度内變化。經實施張力測試 之後發現· g成型溫度增加時，上水箱材料的可成型性也 會顯著增加，如此意味著相較於室溫時的2〇3〇%伸長率， 當溫度增加至400。(：時，伸長量可以增加超過1〇〇%。 依據本發明所製成的上水箱之幾何形狀並未侷限於矩 形的熱交換器而已，也可以製造出不規則的形狀。特別是 考量到形狀的時候，也可以形成具有高彈性的非矩形熱交 換器。 … 本發明所製成的上水箱可以具有非常高的材料強度， 這是比目前所運用的深抽拉技術或液壓成型技術所能達到 的材料強度更高。 本發明的上水箱能夠促進以更經濟的方式製造熱交換 器，如此能夠使汽車工程師在引擎蓋隔間内更有效地裝入 201028229 零件’且同時使熱交換器的性能達到最佳化。 可以利用具有更高強度及抗腐蝕性的材料，而製造出 本發明的上水箱；而且’相較於競爭技術，能夠以較少的 熱機械操作且對環境更為有利的方式製造出材料。 從以下參考隨附圖式所做的詳細說明中，可以輕易地 了解本發明的實施例。然而，本發明的實施例僅作為範例 用途，而非用於偈限本發明。 ® 【實施方式】 本發明的上水箱是以下列的方法製成，此方法其步驟 包括.〇根據標準工業實務而製造出一硬焊片材；⑴熔接且 可犯黏接由该硬焊片材所製成的管件；iH)以熱金屬氣體成 型法在-工具中成型該管件，該工具的内部是依據上水箱 產物而設計；iv)製造用於流體管件的開槽及用於熱交換器 系統的剩餘部份上之連接部位。 硬焊片材含有201028229 VI. Description of the Invention: [Technical Field of the Invention] The present invention relates to a header tank and a method for manufacturing the same. The header tank, also known as the manif〇ld tank, can be used on hard-welded automotive heat exchangers or stationary aluminum heat exchangers with any tank shape. The invention also relates to a heat exchanger comprising a header tank formed by the above method. [Prior Art] In order to be able to assemble all the hood parts in a reasonable manner, today's/flying engineers face increasing difficulties because, in addition to the engine becoming stronger and more powerful, in order to support the engine and provide passengers With ever-increasing driving experience, safety and comfort, more and more different parts must be installed. As a result, the space available under the hood will be insufficient. Most heat exchangers are factory-set in a rectangular shape that limits the proper position that automotive engineers can consider when assembling a heat exchanger into a car. Most of the limiting factors in the geometry of the heat exchanger are determined by the economic viability of the heat exchanger to produce the header plate and the header tank to produce an irregular or customized shape; The manufacturing method says that such a water tank plate and a water tank would make the heat exchanger too expensive. , ·, and, the safety, comfort and performance of the hood increase, 2 the front end of the vehicle is heavier than the rear end, which is unpleasant. In ordinary passenger vehicles, 'CAC-like heat exchangers, condensers, 201028229 radiators, and EGR coolers must be positioned close to the foremost end of the vehicle to facilitate adequate heat exchange performance. . The present invention contributes to reducing the weight of these parts and reducing the cost 'while adding the geometrical elasticity at the time of sealing' without impairing performance. ❹ The most common method for manufacturing a water tank on a heat exchanger is to prepare a flattened brazing sheet and form the brazing sheet to produce a water tank plate with fins for crimping the plastic groove. A slot for inserting a fluid tube for circulation of a cooling fluid and having a final shape of the upper header plate. This method is usually accomplished by cutting a flat sheet into the correct size; = pressing the side to create a rectangular edge (for the flap); drawing the sheet deep to Forming an upper header plate; and finally punching the slot into which the fluid tube/fin package is inserted. After that, implement the normal hard tan program. After brazing, the coating on the surface of the upper tank plate has melted and flows onto the joints of the upper header plate fitting to produce a fillet (10) of the correct size and shape. After that, the water tank is curled into place. In the case of radiators, heaters and CAC, the header tank is usually made of a polymer material. Another prior art technique for forming a header tank is hydro-forming. The above manufacturing process is expensive and must be very rigorously controlled and the geometry and contact between the tool and the sheet.蜩 Lubricated. Moreover, it is necessary to dispose of and clean the lubricant residue, and it must be imaginary 4 to dispose of the metal fragments generated by the stamping at the production site, the staffing, the floor space, the investment in the control equipment, etc. cost. In addition, since the drawing method is performed at room temperature, it is limited to use only cold-worker tool steel, and these cold-working tools 5 201028229 steels are often difficult to cut into tight tolerance fits, and the cutting process costs are considerable. . The manufacture of plastic water tanks by injection molding is a slower and more expensive procedure 'because it requires a large investment in tools, a semi-finished product with tools, and a series of control procedures. The water tank is a multi-functional component of the heat exchanger' and is also fabricated with fixtures and easy-to-access assembly locations (e.g., for oil coolers and sensing devices in water tanks). Moreover, because the plastic material is less rigid than the name material, the wall of the water tank is very thick and the water tank is made of an integrally formed external reinforced frame to achieve sufficient torsion stiffness. Therefore, only if the water tank is made of a low-density material, the water tank will still become heavy. However, whiskers or fiber reinforcements can be used to increase stiffness, but this adds significant cost. In the case of CAC, the operating temperature may exceed the temperature at which the plastic material loses too much strength, making the plastic material unusable. Therefore, today, water tanks are usually made of Ming materials. Most of these tanks are made using a mold-making technique that typically limits the thickness of the tank to more than 15 legs, which increases the weight of the entire heat exchanger. Moreover, the cast inscription cannot be easily crimped to the upper tank ±, and the bonding method usually used is welded by MIG or TIG. Under normal circumstances, this type of water tank and π «method a can produce a very strong assembly effect. However, the fusion method is expensive and time consuming, and adds a lot of weight to the entire heat exchanger, especially since the water tank must be made to have a very large thickness to perform the refining, and the upper tank plate must be thick enough. Only a successful fusion point can be produced. 201028229 SUMMARY OF THE INVENTION Therefore, there is a need for an efficient and flexible method for manufacturing a water tank. The present invention relates to the fact that the water produced by the AA3XXX alloy is generally used in the water tank of the heat exchanger, the combination gold series (AA3XXX), which is difficult to form by the typical method of manufacturing the water tank. shape. In the case of tungsten and rolling, these alloys do not have a formability for the upper tank. The conventional method does not meet the long-term need for the water tank - that is, it must be able to be brazed and shaped into a complex shape. According to the present invention, a method for manufacturing a water tank is proposed, the steps of which are as set forth in the scope of the patent application. In order to achieve sufficient high-quality molding, it is necessary to have an elongation of more than 2%. In order to obtain a fairly good (4), in the current state of the art, the core of the steel-coated sheet must be subjected to high-temperature homogenization, which can produce a kind of Microstructure, if the correct #, the microstructure will increase the formability of the alloy sheet after hot and cold rolling and annealing. During homogenization, most of the material present in the gold is sunk to form large dispersed particles, which will lose some of the strength that is potentially provided by the clock in the solid solution.均:理可月 b will adversely affect the corrosion resistance of ΑΑ3χχχ alloy; phase; preheating before hot rolling, homogenization and annealing will also increase the cost of material 7 201028229. Therefore, it is preferable to avoid homogenization and annealing for an alloy intended to be used as a header tank in a heat exchanger. In order to achieve high elongation under shipping conditions, the material is subjected to full tempering (O-temper) or sometimes HU2 tempering (i.e., annealing conditions). This operation also increases the cost of the heat exchanger material. According to the water tank upper tank manufactured by the method of the present invention, the alloy of the pipe member does not need to be homogenized, so that the unhomogenized aluminum alloy pipe member can be effectively formed. Moreover, the tube blank does not need to be annealed prior to forming, making the process more cost effective. The present invention provides a method for manufacturing a water tank on a heat exchanger, the method comprising: preparing a pipe member having a core made of ΑΑ3χχχ·aluminum alloy; selectively preheating the pipe member; inserting the pipe member into a molding In the tool, the forming tool has a shape forming pocket of the final water tank; plugging both ends of the pipe; if the pipe is not sufficiently preheated, heating = pipe to molding temperature, and using a gas The interior of the tubular member is pressurized whereby the tubular member conforms to the shape of the tool pocket to obtain a final header tank; the header tank is removed from the tool; and the header tank is cooled. This method can effectively manufacture a water tank made of ΑΑ3ΧΧΧ aluminum alloy. Corrosion and mechanical properties can be obtained by using tube materials that have not been homogenized. Fittings that have not been annealed can help reduce: and reduce the load on the environment. Because of the enthalpy, the deep drawn water tank made of the corresponding but homogenized ΑΑ3ΧΧΧ alloy, according to the invention: the un-homogenized ΑΑ3ΧΧΧ alloy water tank, which has a more Strength and anti-corruption. 201028229 The tubular core may have at least one coating layer made of an aluminum alloy' thereby increasing brazeability. Slotting for the pipe or joint can be created in the shaped header tank after forming, thereby facilitating the manufacture of the heat exchanger. The gas pressure used in the forming process is preferably 85 bar or more in order to enable the tube to be effectively formed by being in close contact with the forming pocket of the tool. If desired, an axial pressure can be applied to the end of the tubular during the shaping of the tubular member to supply material to the forming pocket during forming and, during the forming of the tubular member, a connection can be made at the trailing end of the tubular member. Parts, threads or anchors to make the heat exchanger easier to assemble. Depending on the shape of the tank and the thickness of the blank, it may take more than 2 〇〇bar. The tubular member used to form the upper water tank may be made of rolled aluminum alloy blank, which is welded to form a tubular member. In this way, pipe fittings can be manufactured efficiently. Particularly advantageously, the tubular member can be fabricated from an aluminum billet that has been dried and has a braze coating as this is an effective method of obtaining a steel welded coating. Bronze-coated pipe fittings are very cumbersome and extremely difficult to produce. As an alternative, the pipe fittings can be made of a cast-formed alloy, which is advantageous in some cases, especially when the pipe fittings are used. It is especially advantageous when there is no brazing coating. It is furthermore provided by the above-described invention, which further provides a hot metal gas forming method for a water tank on a heat exchanger. 9 201028229 The present invention also provides a heat exchanger comprising the header tank of the present invention, and the heat exchanger has a non-rectangular shape. The present invention further provides a method for manufacturing a heat exchanger, wherein the header tank is coupled to a plurality of tubes and a plurality of corrugated fins interposed between the tubes, and then the fins are brazed to the tubes. The hot metal gas forming method enables the upper tank structure made of AA3XXX aluminum alloy to have any shape and can be used for a heat exchanger. The present invention is applicable to a water tank of a heat exchanger which is low in weight and which can be optimized at a low cost compared to competitive technology. Eliminating plastic water tanks makes material recovery easier; the cross-sectional geometry of the tank can vary to a greater extent than competing aluminum forming techniques (eg hydroforming or deep drawing). After the tensile test was carried out, it was found that the formability of the material of the header tank was also significantly increased when the molding temperature of g was increased, which means that the temperature was increased to 400 as compared with the elongation of 2〇3〇% at room temperature. (: When the amount of elongation can be increased by more than 1%. The geometry of the header tank made according to the present invention is not limited to a rectangular heat exchanger, and an irregular shape can also be produced. When the shape is formed, a non-rectangular heat exchanger having high elasticity can also be formed. The water tank produced by the present invention can have a very high material strength, which is a deep drawing technique or a hydroforming technology than currently used. The achievable material strength is higher. The water tank of the present invention can promote the manufacture of the heat exchanger in a more economical manner, which enables the vehicle engineer to more efficiently load the 201028229 part in the hood compartment while simultaneously making the heat exchanger The performance is optimized. The water tank of the present invention can be manufactured by using materials with higher strength and corrosion resistance; and 'can be operated with less thermomechanical and more environmentally friendly than competitive technology. The material is manufactured in an advantageous manner. The embodiments of the present invention can be easily understood from the following detailed description with reference to the accompanying drawings. The examples are for illustrative purposes only and are not intended to limit the invention. ® [Embodiment] The header tank of the present invention is produced in the following manner, the steps of which include: manufacturing according to standard industrial practice a brazing sheet; (1) welded and affixed to the tube member made of the brazing sheet; iH) formed in the tool by hot metal gas forming, the inside of the tool is based on the product of the upper tank And design; iv) making a slot for the fluid pipe and a joint for the remainder of the heat exchanger system. Brazed sheet contains
〜你〜何科可以被塗覆於 片材表面的一側或兩側上，此核心材料係選自ΑΑ3χχχ系 列且熔點超過610°C，例如為ΑΑ3〇03或ΑΑ3〇〇5。正常情 形下’硬焊塗層是選自低熔點的亞共晶（hyp〇eute(J) AA4XXX 合金（例如：AA4343 與 AA4〇45)。 而且，任-側或兩側上均可以塗覆_種以上的材料， 亦即所謂的多層塗覆（multi_clad)。此外， ™ Λ 1将別是在用於散 '、、、U熱器及其他熱交換器的管件上，此塗覆層 一種在電化學上取得平衡且在腐純環境下可以作為核心 201028229 的犧牲屏蔽層之材料所製成。因此，核心材料可以被塗覆 於一側或兩側上，或者兩側完全不需要塗覆也行❶此塗覆 層在一側或兩側上可以是單層式或雙層式，此塗覆層包含 一低熔點的硬焊或犧牲性塗覆層，或者存在於硬焊與核心 之間以減少硬焊與核心之間例如擴散的交互作用之塗覆 層。 這些塗覆層係藉由熱滾軋、接著是冷滾軋、及必要的 熱處理而塗在核心外’藉此在切割成正確寬度之前達到正 確的中間及最終韌度。然後，由硬焊片材所製成的產物可❿ 以藉由控制氣體硬焊（controlled atmosphere brazing，CAB) 或真空硬焊而施以硬焊》 6XXX或5XXX合金是經常用於不打算利用CAB法實 施硬焊的產物上，這些合金是用於需要高強度的產物上（例 如：建築結構零件）。雖然由於鎂及助熔劑之間的反應，很 難以對這些具有高含量鎂的合金實施CAB硬焊，但是6χχχ 或5ΧΧΧ合金仍可獲得其強度。 對於使用控制氣體硬焊（CAB)而製造的散熱器製造商 ❹ 來說’利用以前所能獲得的上水箱核心材料會產生兩個主 要問題.機械強度太低以及抗腐钱性太低^ AA6063是一種 可熱處理的合金，其中鎂的含量大約為0.7%重量百分比， 但是此種合金被認為無法在CAB過程中被硬焊。AA6060 中含有大約0.4至0.5 %重量百分比的鎮，儘管它需要更多 助熔劑、特殊助熔劑、及特殊的助熔劑塗抹技術，而且其 強度在一些應用情形之後較為不足，但是此種合金仍可用 12 201028229 於硬焊。 在AlMgSi合金中，+札 疋化期間會沉澱出报小的Mg2Si， 致使其強度增加。因此，兔 马了增加強度的普通解決方案似 乎只是增加鎂與矽的含量而p ^ 而已，如此一來卻形成了更多的~ You ~ He Ke can be applied to one or both sides of the surface of the sheet. This core material is selected from the ΑΑ3χχχ series and has a melting point of over 610 ° C, such as ΑΑ3〇03 or ΑΑ3〇〇5. Under normal circumstances, the brazing coating is selected from hypoeutectic (hyp〇eute(J) AA4XXX alloys (for example: AA4343 and AA4〇45). Moreover, it can be coated on either side or both sides. More than one type of material, the so-called multi-clad. In addition, TM Λ 1 will be used on the tubes used in the bulk, heat exchangers and other heat exchangers. Electrochemically balanced and made in a pure environment as a sacrificial barrier for core 201028229. Therefore, the core material can be applied to one or both sides, or both sides do not need to be coated at all. The coating may be a single layer or a double layer on one or both sides, the coating layer comprising a low melting point brazing or sacrificial coating layer, or between the brazing and the core a coating to reduce the interaction between the brazing and the core, such as diffusion. These coatings are applied to the core by hot rolling, followed by cold rolling, and the necessary heat treatment. Achieve the correct intermediate and final toughness before the correct width. Then, by The product made of the soldering sheet can be brazed by controlled atmosphere brazing (CAB) or vacuum brazing. 6XXX or 5XXX alloys are often used for brazing without the CAB method. On the product, these alloys are used on products that require high strength (for example, building structural parts). Although it is difficult to perform CAB brazing on these alloys with high content of magnesium due to the reaction between magnesium and flux, The strength of 6χχχ or 5ΧΧΧ alloys is still available. For radiator manufacturers that use controlled gas brazing (CAB), 'using the previously used core material of the header creates two major problems. The mechanical strength is too Low and anti-corrosion is too low ^ AA6063 is a heat treatable alloy with a magnesium content of about 0.7% by weight, but this alloy is considered to be incapable of being brazed during CAB. AA6060 contains about 0.4 to 0.5 % by weight of the town, although it requires more flux, special flux, and special flux application techniques, and its strength in some applications After that, it is not enough, but this alloy can still be used for brazing on 12 201028229. In AlMgSi alloy, the small Mg2Si precipitates during the Sapporo, which increases the strength. Therefore, the rabbit has a common solution to increase the strength. It seems to increase the content of magnesium and strontium only, but it has formed more
Mg2Si。然而，由於在硬焊教 砰期間鎂會與助熔劑產生反應，且 如此一來會限制鎂的量，所 所U鎖含量超過0.4%的合金很難 在CAB法中有效被硬焊。 ,^ a t 而且，由於晶粒之間的腐蝕，所 以上述 AA6060 及 AA6063 — a" * ❹ 一般來說展現出很低的抗穿孔腐 触性。 具有大約0.4%的最大鎂含量之3χχχ合金係可以在 CAB法中被硬焊。藉由本發明的方法，可以克服欲將找灯 合金成型出想要形狀所面臨到的難題。因此，本發明的方 法能夠選擇3ΧΧΧ合金作為上水箱，如此能使上水箱在稍 後的階段中以CAB法進行硬輝。 根據本發明，在製造上水箱時的其中一項中間產物是 為了此夠由具有塗覆層或沒有塗覆層的硬焊片材製 造出一管件，必須從此硬焊片材中製造出一熔接管件。實 際的熔接法可以是感應熔接、MIG、TIG、摩擦攪拌熔接、 或任何其他適當的熔接法。 管件可以具有圓形、橢圓形、正方形、矩形、三角形 或任何其他適當對稱或非對稱的剖面形狀。可以根據消費 者的需求而定’將管件製作成沿著其全長具有固定或變化 的剖面形狀與尺寸。雖然不一定總是如此，但最好所選用 的剖面形狀能防止在後續的處理中產生過度變形。而且， 13 201028229 假如管件被熔接成使其沿著全長具有固定的剖面形狀的 法，則理論上材料的產量在熔接操作中為i〇〇%，緊接著就 是長度上的切割。 在汽車工業中所使用的熱交換器一般具有矩形的形 狀，如此會限制將熱交換器組裝於汽車内可考慮的適當位 置。在一些情形中，圓形、彎曲或階梯狀、或甚至不規則 形的熱父換器都是適合組裝到引擎蓋空間内的理想形狀， 或者是以最好的方式運用有限的引擎蓋空間而使熱交換器 的性能達到最佳化。 在這樣的情形下，最好能提出一種熱交換器，其形狀 被製作成適合車子内所能獲得的空間，或者適合一個想要 的流體形式。這樣的熱交換器需要一個量身裁製的上水 箱。本發明#方法能夠使上水箱纟三維方向上具有任何想 要的形狀’可構思出的形狀例如有環形、S形、匕形、或^ 形。上水箱沿著其長度軸線及/或橫跨其長度軸線可以是曲 線狀或f曲的’流體管件可以沿著上水箱的全長而裝配成Mg2Si. However, since magnesium reacts with the flux during the brazing process and thus limits the amount of magnesium, alloys having a U-lock content of more than 0.4% are difficult to be brazed effectively in the CAB method. , ^ a t Moreover, due to the corrosion between the crystal grains, the above AA6060 and AA6063 - a " * ❹ generally exhibit a very low resistance to perforation and rot. A 3 χχχ alloy system having a maximum magnesium content of about 0.4% can be brazed in the CAB method. By the method of the present invention, it is possible to overcome the problem of forming a desired alloy into a desired shape. Therefore, the method of the present invention enables the selection of a 3 ΧΧΧ alloy as a header tank, so that the header tank can be hardened by the CAB method in a later stage. According to the present invention, one of the intermediate products in the manufacture of the upper water tank is such that a tube member can be manufactured from a brazing sheet having a coating layer or no coating layer, and a welding must be produced from the brazing sheet material. Pipe fittings. The actual welding method can be induction welding, MIG, TIG, friction stir welding, or any other suitable welding method. The tubular member can have a circular, elliptical, square, rectangular, triangular or any other suitable symmetrical or asymmetrical cross-sectional shape. The tube can be made to have a fixed or varying cross-sectional shape and size along its entire length, depending on the needs of the consumer. Although this is not always the case, it is preferred that the cross-sectional shape selected will prevent excessive deformation in subsequent processing. Moreover, 13 201028229 If the pipe is welded such that it has a fixed cross-sectional shape along its entire length, then theoretically the yield of the material is i〇〇% in the welding operation, followed by the length cutting. Heat exchangers used in the automotive industry generally have a rectangular shape which limits the proper location of the heat exchanger for assembly in a vehicle. In some cases, a circular, curved or stepped, or even irregularly shaped, hot-female changer is ideal for assembly into the hood space, or in a best manner with limited hood space. Optimize the performance of the heat exchanger. In such a case, it is preferable to propose a heat exchanger which is shaped to fit the space available in the vehicle or to fit a desired fluid form. Such a heat exchanger requires a tailored water tank. The method of the present invention enables the upper tank to have any desired shape in three dimensions. The conceivable shape is, for example, a ring shape, an S shape, a 匕 shape, or a shape. The upper header may be curved or curved along its length axis and/or across its length axis. The fluid tube may be assembled along the entire length of the header tank.
Q 一直線，如此意味著整個熱交換器的剖面形狀將對應於上 水箱的形狀β 因此，基於引擎蓋封裝、熱交換器性能、或僅僅訂作 -產物等原因，必須要有一個非矩形(例如：圓形)的熱交換 器。然後，藉由㈣覆層硬焊片材所製成的熔接管件彎曲 成具有適當曲料徑的雜，就^滿足上述需求。作為 另一替代方式，可能需| S形 '梯形、或不規則形上 水箱。 上 14 201028229 當欲製造一個彎曲或曲線狀的水箱時，在實施熱氣髏 成型之前’管件可以被彎曲成一個適當的預先形狀。可以 使用任何適用於製造出特殊形狀的彎曲法，而實施管件的 彎曲。可以在周圍溫度或升高的溫度下實施彎曲，以配合 最終上水箱的特殊形狀要求。 根據顧客需要而實施熔接與彎曲的管件，可選擇性地 藉由任何適當的手段予以加熱（例如：爐子、火焰 '感應加 熱、或利用加熱過的工具）。感應加熱與火焰加熱的優點在 β 於：熱量輸入可以被侷限在管件的選定區域内，如此可以 被運用作為改變選擇區域上的機械特性，這是因為已知材 料的溫度對於其特性（諸如：降伏應力、極限拉伸應力、伸 長量、及可成型性）來說具有決定性的影響力。根據合金的 種類、勒性、片材厚度、及上水箱所需要產生的變形程度 而疋，理想的成型溫度可以介於25〇〇c與55〇〇c之間。 s件被放置於一成型工具内，此成型工具的内表面被 製作成對應於最終上水箱料部幾何％狀。&工具可以是 攀冷的（例如：室溫），在此情形下，管件必須事先予以加熱， 但管件較佳地被加熱至一適當的升高溫度即可，此加熱步 驟可以在成型之前或成型期間進行。才艮據管件材料的機械 特！·生與可成型性，以及上水箱的最終幾何形狀，可以選擇 工具與管件溫度。 接著，塞住管件的兩端，且管件被連接至一高壓氣體 系統在成型期間，管件係介於250°C與550°C之間。可 以在管件***成型凹穴之前，或者藉由感應加熱而在成型 15 201028229 期間加熱此工具，藉由將管件事先加熱，而可以達成此成 型溫度。氣體的壓力在管件内側會增加，此壓力增加對應 於變形所導致的壓力增加。壓力增加會直到管件已經符合 工具的表面為止，真正最終的壓力及氣體壓力增加速度是 由管件在此溫度的機械特性、管壁厚度、最終上水箱形狀、 及用以獲得想要形狀所需的變形量。 在成型之後，咼壓氣體可以被排放出去，且將成型好 的產物從工具中移開。此氣體可以為空氣、氮氣、惰性氣 體、或任何其他適當的氣態物質。在成型期間的壓力相當鲁 低，比起在液壓成型過程期間所使用的壓力小更多。大約 250bar的上限就應該足以使作為熱交換器的鋁合金材料成 型出想要的形狀。由於在上水箱的成型期間之壓力限制， 所以在依據本發明製造上水箱時所使用的成型工具，可以 由習知成型法所使用的卫具以外之材料製成。纟已經結束 成型之後，所形成的產物可在空氣中加以冷卻、或者經水 施以淬火。Q is a straight line, which means that the cross-sectional shape of the entire heat exchanger will correspond to the shape of the upper tank. Therefore, depending on the hood package, heat exchanger performance, or just the order-product, etc., there must be a non-rectangular (for example) : Round) heat exchanger. Then, the welded pipe member made of the (4) coated brazing sheet is bent into a powder having an appropriate meandering diameter to satisfy the above demand. As an alternative, an S-shaped trapezoidal or irregularly shaped water tank may be required. Upper 14 201028229 When a curved or curved water tank is to be made, the pipe can be bent into a suitable pre-shape before the hot air enthalpy is formed. The bending of the pipe can be carried out using any bending method suitable for producing a special shape. Bending can be performed at ambient or elevated temperatures to match the special shape requirements of the final header. The welded and bent tubular members may be optionally heated by any suitable means (e.g., furnace, flame 'inductive heating, or using heated tools). The advantage of induction heating and flame heating is that the heat input can be confined to selected areas of the tube so that it can be used as a function of changing the mechanical properties of the selected area because the temperature of the material is known for its characteristics (such as: Degradation stress, ultimate tensile stress, elongation, and formability) have a decisive influence. Depending on the type of alloy, the nature of the sheet, the thickness of the sheet, and the degree of deformation that the tank needs to produce, the ideal molding temperature can be between 25 ° C and 55 ° c. The s piece is placed in a forming tool, and the inner surface of the forming tool is made to correspond to the geometry of the final upper tank. The & tool can be cold (eg room temperature), in which case the tube must be heated beforehand, but the tube is preferably heated to a suitable elevated temperature, which can be done prior to forming Or during molding. Only according to the mechanical properties of the pipe fittings! • Health and formability, as well as the final geometry of the tank, the tool and tube temperature can be selected. Next, the ends of the tubular member are plugged and the tubular member is connected to a high pressure gas system during which the tubular member is between 250 ° C and 550 ° C. This molding temperature can be achieved by inserting the tubular member into the forming pocket or by induction heating during molding 15 201028229, by heating the tubular member in advance. The pressure of the gas increases inside the tube and this pressure increase corresponds to the pressure increase caused by the deformation. The pressure increase will continue until the tube has conformed to the surface of the tool. The true final pressure and gas pressure increase rate is determined by the mechanical properties of the tube at this temperature, the wall thickness, the final tank shape, and the desired shape to achieve the desired shape. The amount of deformation. After molding, the helium gas can be vented and the shaped product removed from the tool. This gas can be air, nitrogen, an inert gas, or any other suitable gaseous species. The pressure during molding is quite low and is much less than the pressure used during the hydroforming process. An upper limit of about 250 bar should be sufficient to shape the aluminum alloy material as a heat exchanger into a desired shape. Due to the pressure limitation during the forming of the header tank, the molding tool used in the manufacture of the header tank according to the present invention can be made of materials other than the fixture used in the conventional molding method. After the molding has been completed, the formed product can be cooled in the air or quenched by water.
也可以藉由在成型期間施加軸向壓力於管件兩端上 而將材料供應至工具内，這一點有助於在成型之後獲得』 小管壁厚度’或者避免因需要报大的局部變形的高要求彳 管件形狀（例如：急遽的半徑範圍或角落附近）而導致管 裂。 為了避免管件黏著於工具表面上，可能需要塗抹脫模 劑（release agent)或高溫潤滑劑，此塗抹步驟可以在管件或 工具表面上進行，且可以在每個新管子欲成型之前進行塗 16 201028229 抹，或者以塗層的形式進行’因此不需要重新補充。 有好幾種用於製造供管件、連接部位、及扣件***的 開槽之方式。其中一個方式就是藉由個別地沖壓開槽或一 -人冲壓出好各個開槽，而對熱氣體成型過的產物實施加 工。可以藉由銑磨、鑽孔、或者藉由使用任何其他適當的 技術於熱氣體成型過的產物上成型出孔洞與開槽。作為另 一種方式’當已經獲得管件的最終形狀時，且熱氣體壓力 ❹ 可以從管件内側提供支撑以防纟因沖塵而導致凹陷時，可 以在稍後的熱氣體成型的階段期間沖壓出孔洞。可以藉由 任何適當的手段⑼如：鉚釘連接、硬焊、料、或膠黏）， 而將扣件裝附於熱乳體成型過的產物上。彳以根據顧客需 求、所容許的成本、性能、及是否要在硬焊之前或之後實 施固定，而選擇固定方法。上水箱可成型有凹痕，以促進 在上水箱中形成開槽，其中-範例係顯示於圖2。It is also possible to supply material into the tool by applying axial pressure on both ends of the pipe during forming, which helps to obtain a "small pipe wall thickness" after forming or to avoid high local deformation due to the need to report large It is required to have a pipe shape (for example, a sharp radius or a corner) to cause cracking. In order to avoid sticking of the pipe to the surface of the tool, it may be necessary to apply a release agent or a high temperature lubricant. This application step can be carried out on the surface of the pipe or tool and can be applied before each new pipe is to be formed. 16 201028229 Wipe, or in the form of a coating' so there is no need to replenish it. There are several ways to make a slot for the fitting, the joint, and the fastener. One of the methods is to process the hot gas formed product by individually punching or unscrewing the individual slots. Holes and slots can be formed in the hot gas formed product by milling, drilling, or by using any other suitable technique. As another way, 'when the final shape of the pipe has been obtained, and the hot gas pressure ❹ can provide support from the inside of the pipe to prevent sag due to dusting, the hole can be punched out during the later stage of hot gas forming. . The fastener can be attached to the hot, milk-formed product by any suitable means (9) such as rivet attachment, brazing, material, or gluing.选择 Choose a fixed method based on customer needs, allowed cost, performance, and whether or not to be fixed before or after brazing. The header tank may be formed with indentations to facilitate the formation of slots in the header tank, wherein - the example is shown in Figure 2.
為了使氣體能夠在敎备# + Λι| u Q 月匕幻任熟乳體成型期間進入管件，在管件 尾端上的其中至少一塞子必須 于义肩具有裝附於壓力氣體系統的 :開口。在上水箱被用於熱交換器之前，必須關閉此開口， 關閉的方式有好幾種。第一，藉 ^ β 精田貼附作為熱交換器媒介（不 否為液態或氣態）入口與出口的連接部位而塞住管件 广開放端。第一 ’可以藉由—密封件而關閉此開口，此 ::件可以被硬銲、熔接或膠黏至此位置，或以任何其他 適當手段貼附於此位置。作為 、 作為另一替代方式，管件尾端可 以被擠壓而關閉，而剩餘的办 二隙與裂縫則以適當的金屬或 聚《體填充劑填補，以確保 T外漏。可利用任何適當的 17 201028229 方法塗抹密封劑。 為了有助於管件或軟管的容易連接，可以構甩 件的尾端上成型出可供另一管件相互螺接的螺紋。作為另 一替代方式’可以藉由鉗？’而形成用於裝附軟管的錫件。 較佳實施例說明 為使本發明更容易理解，以下將提供一個實施本發明 的範例。 將3mm厚的鋁片材（AA3〇〇3鋁合金且其上具有 AA4343鋁合金的塗覆層）熔接而形成一 4〇mm直徑的管 件，此管件依照圖形γ被事先彎曲成指定形狀，且放入一 個預先被加熱至500。(：且具有類似形狀的工具内。此工具 已經塗有固態满滑劑，此潤滑劑能夠承受成型溫度而不會 分解。塞住管件的尾端’且藉由液壓汽缸施加力量以避免 兩個工件分開。將一氣體透過其中一塞子而灌注到管件内 側，且壓力從〇増加到2〇〇bar。在到達最大壓力幾秒鐘之 後就釋放壓力，且使成型好的管件從工具中移開，然後灑 水在管件上使其冷卻。在需要連接部位之處，沖壓出開槽。· 現在，管件具有上水箱砑需要的最終形狀，且具有預 先成型好的開槽與凸塊。現在，熱交換器鰭片及流體管件 可以與水箱組合並硬銲在一起，而形成一熱交換器。 【圖式簡單說明】 圖1係依據本發明的一實施例的熱交換器上水箱之示 意圖。 18 201028229 圖2係第—圖的熱交換器上水箱旋轉90度後之示意 圖。 圖3係用於本發明上水箱的管件刮面形狀之選擇。 圖4顯示一個含有本發明所製成的上水箱之非矩形熱 交換器之示意圖。 … 圖5係本發明熱交換器的側視圖，其中上水箱在橫跨 其長度抽線上是彎曲的。 ί 【主要元件符號說明】 無 19In order for the gas to enter the tube during preparation of the cooked milk, at least one of the plugs on the end of the tube must have an opening attached to the pressurized gas system. This opening must be closed before the upper tank is used in the heat exchanger. There are several ways to close it. First, the β open field is used as a heat exchanger medium (not liquid or gaseous) to connect the inlet to the outlet and plug the wide open end of the pipe. The first 'can be closed by a seal, which can be brazed, welded or glued to this location, or attached to this location by any other suitable means. As an alternative, the end of the tube can be squeezed to close, while the remaining two gaps and cracks are filled with a suitable metal or poly-filler to ensure T leakage. The sealant can be applied using any suitable 17 201028229 method. In order to facilitate the easy connection of the tubular member or the hose, the end of the structural member can be formed with a thread for the other tubular member to be screwed to each other. As an alternative, 'can be clamped? And forming a tin piece for attaching a hose. DESCRIPTION OF THE PREFERRED EMBODIMENTS In order to make the present invention easier to understand, an example for carrying out the invention will be provided below. A 3 mm thick aluminum sheet (AA3〇〇3 aluminum alloy and a coating layer having the AA4343 aluminum alloy thereon) is welded to form a 4 mm diameter pipe member which is previously bent into a prescribed shape according to the pattern γ, and Put one into a preheated to 500. (: and in a tool with a similar shape. This tool has been coated with a solid lubricant, which can withstand the molding temperature without decomposition. Plug the end of the tube' and apply force to the hydraulic cylinder to avoid two The workpiece is separated. A gas is passed through one of the plugs and poured into the inside of the tube, and the pressure is applied from the crucible to the 2 bar. After a few seconds of reaching the maximum pressure, the pressure is released and the formed tube is removed from the tool. Then sprinkle water on the tube to cool it. Punch the slot where it is needed. · Now, the tube has the final shape required for the tank, with pre-formed slots and bumps. Now, The heat exchanger fins and the fluid pipe fittings may be combined with the water tank and brazed together to form a heat exchanger. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic view of a water tank on a heat exchanger according to an embodiment of the present invention. 18 201028229 Figure 2 is a schematic view of the heat exchanger of the first heat exchanger rotated 90 degrees. Figure 3 is a selection of the shape of the scraping surface of the pipe used in the water tank of the present invention. A schematic view of a non-rectangular heat exchanger of the header tank made by the present invention. Fig. 5 is a side view of the heat exchanger of the present invention, wherein the header tank is curved across the length of the draw line. ί [Main component symbol description 】 no 19