US20060108096A1 - Joint structure of header tank and connector in heat exchanger, and method of joining thereof - Google Patents
Joint structure of header tank and connector in heat exchanger, and method of joining thereof Download PDFInfo
- Publication number
- US20060108096A1 US20060108096A1 US11/252,237 US25223705A US2006108096A1 US 20060108096 A1 US20060108096 A1 US 20060108096A1 US 25223705 A US25223705 A US 25223705A US 2006108096 A1 US2006108096 A1 US 2006108096A1
- Authority
- US
- United States
- Prior art keywords
- header tank
- communication hole
- connector
- joint structure
- plate wall
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/04—Arrangements for sealing elements into header boxes or end plates
- F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
- F28F9/18—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
- F28F9/185—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding with additional preformed parts
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/0246—Arrangements for connecting header boxes with flow lines
Definitions
- the invention relates to a joint structure of a header tank and a connector in a heat exchanger, and a method of joining thereof.
- Ordinary heat exchangers have a plurality of tubes in which fluid flows, fins arranged between the tubes, and header tanks for distribution and confluence joined at both ends of the tubes.
- the header tank is joined with a block-shaped connector for external pipe connection. Joining of the header tank and the connector is generally performed by brazing simultaneously when the tubes, fins, and the header tanks are brazed together.
- the header tank and the connector When the header tank and the connector are brazed, they must be placed in a brazing furnace in such a state that they have been positioned and temporarily fixed in advance.
- a method is adopted that positioning and temporary fixing are performed utilizing a positioning unit provided, or positioning and temporary fixing is conducted by welding (for example, see Japanese Patent Applications Laid-open Nos. H6-229696 and H10-238987).
- the positioning and temporary fixing method according to the related art requires a complicated structure or takes man-hours, or it is difficult to conduct reliable positioning and temporary fixing, which may cause variations of the positioning and temporary fixing and further increases in cost.
- the invention is directed to provide a joint structure of a header tank and a connector in a heat exchanger and a joining method thereof, which allows reliable positioning and temporary fixing with a simple constitution and allows constant-quality brazing at a low cost.
- the first aspect of the invention provides a joint structure of a header tank and a connector in a heat exchanger.
- the joint structure includes a header tank ( 1 ) including a plate wall ( 1 c ) formed with a first communication hole ( 1 a ).
- the joint structure includes a block-shaped connector ( 2 ) having a second communication hole ( 2 b ) positioned to the first communication hole ( 1 a ) and joined to the header tank ( 1 ).
- the first communication hole ( 1 a ) is smaller than the second communication hole ( 2 b ).
- the first communication hole ( 1 a ) has therearound a periphery ( 1 b ) caulked and fixed on an inner peripheral surface of the second communication hole ( 2 a ) by burring formation.
- the header tank ( 1 ) and the connector ( 2 ) caulked and fixed on each other by burring formation may be brazed to each other.
- the connector ( 2 ) includes a first portion ( 2 d ) diverged in a concave form.
- the joint structure further includes a header-tank backup member ( 12 ) mating with the connector and having a second portion ( 12 a ) converged in a convex form. The diverged first portion and the converged second portion hold the plate wall ( 1 c ) therebetween.
- the second aspect of the invention provides a method of joining a header tank and a connector in a heat exchanger.
- the method includes the step of forming, on a plate wall ( 1 c ) of a header tank ( 1 ) of a heat exchanger, a first communication hole ( 1 a ) smaller than a second communication hole ( 2 b ) of a block-shaped connector ( 2 ).
- the method includes the step of positioning the first and second communication holes ( 1 a ; 2 b ) to each other.
- the method includes the step of inserting a punch ( 13 a ) into the header tank ( 1 ) to burring form a periphery ( 1 b ) around the first communication hole ( 1 a ), with the first and second communication holes positioned to each other.
- the method includes the step of caulking and fixing the periphery ( 1 b ) around the first communication hole ( 1 a ) on an inner peripheral surface of the second communication hole ( 2 b ) by the punch ( 13 a ).
- the method includes the step of brazing the header tank ( 1 ) and the connector ( 2 ) caulked and fixed.
- the method may include the step of applying a brazing material on an outer surface of the plate wall ( 1 c ) of a header tank ( 1 ) before the step of caulking and fixing by burring formation.
- the method may include the step of brazing the header tank ( 1 ) and the connector ( 2 ) to each other with the brazing material.
- FIGS. 1A to 1 C are step diagrams illustrating a caulking process based upon a burring formation for obtaining a joint structure according to an embodiment of the invention.
- FIGS. 1A to 1 C are step diagrams illustrating a caulking process based upon a burring formation.
- a header tank 1 a connector 2 , a connector backup member 11 , a header tank backup member 12 , a punch rod 13 , and a punch 13 a are illustrated.
- the header tank 1 is of a two-separate type. Only a tank main unit in which a heat exchange fluid passage is formed is illustrated. The tank main unit is assembled with a header plate (not illustrated) joined to another tube, constituting an actual header tank.
- the header tank 1 has a tubular base 1 d extending straight.
- the header tank 1 has a semi-cylindrical plate wall 1 c , and a central portion thereof in a transverse direction has a communication hole 1 a communicating with a flow holes 2 a and 2 b .
- the semi-cylindrical plate wall 1 c has, at the end, an oblique peripheral surface relative to the base 1 d .
- the plate wall 1 c extends from the base 1 d to be converged.
- the flow holes 2 a and 2 b of the connector 2 constitute a stepped hole.
- the flow holes 2 a and 2 b have an enlarged diameter portion 2 a connected to an external pipe and a reduced diameter portion 2 b connected to the communication hole 1 a of the header tank 1 .
- the diameter of the communication hole 1 a of the header tank 1 is formed smaller than a diameter of the flow hole 2 b of the connector 2 in advance.
- the connector 2 and the header tank 1 are supported by the backup members 11 and 12 , respectively.
- the connector 2 and the plate wall 1 c of the header tank 1 are caused to abut against each other, so that the communication hole 1 a and the flow hole 2 b are positioned to each other.
- the plate wall 1 c of the header tank 1 is supported from inside thereof by the semicircular column portion 12 a of the backup member 12 on the side of the header tank 1 .
- the semicircular column portion 12 a as a second portion has, at the end, a periphery converged to conform to the inner surface's shape of the semi-cylindrical plate wall 1 c .
- the end face of the connector 2 is supported by the flat portion of the backup member 11 on the side of the connector 2 .
- the abutting portion 2 d of the connector 2 is caused to abut against the outer face of the plate wall 1 c of the header tank 1 .
- the abutting portion 2 d as a first portion is shaped to conform to the oblique outer surface of the distal end of the plate wall 1 c .
- the abutting portion 2 d is diverged to conform to the converged outer surface of the plate wall 1 c.
- the punch rod 13 is elevated from inside of the header tank 1 , while being guided by a slide hole 12 b of the backup member 12 .
- the punch 13 a at the distal end of the punch rod 13 burring-forms the periphery 1 b around the communication hole 1 a formed in the plate wall 1 c of the header tank 1 .
- the punch 13 a caulks and fixes the periphery 1 b (burring portion) of the communication hole 1 a on the inner peripheral portion of the flow hole 2 b .
- the friction between the burring formation portion and the flow hole 2 b of the connector 2 establishes fixing force.
- the “burring formation” means that the punch 13 a stretches and flanges the periphery 1 b around the communication hole 1 a .
- the punch 13 a presses the periphery 1 b burred against the inner peripheral surface of the flow hole 1 b.
- brazing material may be applied on the outer face of the plate wall 1 c of the header tank 1 in advance. After caulking and fixing are performed in this state by the burring formation, the header tank 1 and the connector 2 are brazed to each other by the brazing material. This method establishes brazing with stable quality without supplying brazing material later.
- brazing is performed in a state that the header tank 1 and the connector 2 have been positioned and temporarily fixed to each other reliably and firmly, so that products with stable quality are provided. Furthermore, the burring formation is conducted simply without taking man-hours, and the automation may be performed.
- the first communication hole is smaller than the second communication hole, and the periphery around the first communication hole is burring formed.
- This method allows the periphery around the first communication hole to be caulking fixed on the inner peripheral surface, thus securely and firmly positioning and temporarily fixing the header tank and the connector to each other. Further, the burring formation allows for secure positioning and temporary fixing with a simple structure without taking man-hours, thus achieving brazing with a constant quality at a lower production cost.
- the header tank and the connector are brazed to each other, thus securely joining the header tank and the connector to each other.
- a brazing material is applied on the outer surface of the plate wall before the step of caulking and fixing by burring formation, and the header tank and the connector are brazed to each other. This method achieves brazing with a stable quality without feeding a brazing material later.
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Details Of Heat-Exchange And Heat-Transfer (AREA)
Abstract
A joint structure of a header tank and a connector in a heat exchanger includes a header tank (1) including a plate wall (1 c) formed with a first communication hole (1 a). The joint structure includes a block-shaped connector (2) having a second communication hole (2 b) positioned to the first communication hole (1 a) and joined to the header tank (1). The first communication hole (1 a) is smaller than the second communication hole (2 b). The first communication hole (1 a) has therearound a periphery (1 b) caulked and fixed on an inner peripheral surface of the second communication hole (2 a) by burring formation.
Description
- This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2004-303250 filed on Oct. 18, 2004; the entire contents of which are incorporated herein by reference.
- The invention relates to a joint structure of a header tank and a connector in a heat exchanger, and a method of joining thereof.
- Ordinary heat exchangers have a plurality of tubes in which fluid flows, fins arranged between the tubes, and header tanks for distribution and confluence joined at both ends of the tubes. The header tank is joined with a block-shaped connector for external pipe connection. Joining of the header tank and the connector is generally performed by brazing simultaneously when the tubes, fins, and the header tanks are brazed together.
- When the header tank and the connector are brazed, they must be placed in a brazing furnace in such a state that they have been positioned and temporarily fixed in advance. In the related art, such a method is adopted that positioning and temporary fixing are performed utilizing a positioning unit provided, or positioning and temporary fixing is conducted by welding (for example, see Japanese Patent Applications Laid-open Nos. H6-229696 and H10-238987).
- The positioning and temporary fixing method according to the related art, however, requires a complicated structure or takes man-hours, or it is difficult to conduct reliable positioning and temporary fixing, which may cause variations of the positioning and temporary fixing and further increases in cost.
- The invention is directed to provide a joint structure of a header tank and a connector in a heat exchanger and a joining method thereof, which allows reliable positioning and temporary fixing with a simple constitution and allows constant-quality brazing at a low cost.
- The first aspect of the invention provides a joint structure of a header tank and a connector in a heat exchanger. The joint structure includes a header tank (1) including a plate wall (1 c) formed with a first communication hole (1 a). The joint structure includes a block-shaped connector (2) having a second communication hole (2 b) positioned to the first communication hole (1 a) and joined to the header tank (1). The first communication hole (1 a) is smaller than the second communication hole (2 b). The first communication hole (1 a) has therearound a periphery (1 b) caulked and fixed on an inner peripheral surface of the second communication hole (2 a) by burring formation.
- The header tank (1) and the connector (2) caulked and fixed on each other by burring formation may be brazed to each other.
- The connector (2) includes a first portion (2 d) diverged in a concave form. The joint structure further includes a header-tank backup member (12) mating with the connector and having a second portion (12 a) converged in a convex form. The diverged first portion and the converged second portion hold the plate wall (1 c) therebetween.
- The second aspect of the invention provides a method of joining a header tank and a connector in a heat exchanger. The method includes the step of forming, on a plate wall (1 c) of a header tank (1) of a heat exchanger, a first communication hole (1 a) smaller than a second communication hole (2 b) of a block-shaped connector (2). The method includes the step of positioning the first and second communication holes (1 a; 2 b) to each other. The method includes the step of inserting a punch (13 a) into the header tank (1) to burring form a periphery (1 b) around the first communication hole (1 a), with the first and second communication holes positioned to each other. The method includes the step of caulking and fixing the periphery (1 b) around the first communication hole (1 a) on an inner peripheral surface of the second communication hole (2 b) by the punch (13 a). The method includes the step of brazing the header tank (1) and the connector (2) caulked and fixed.
- The method may include the step of applying a brazing material on an outer surface of the plate wall (1 c) of a header tank (1) before the step of caulking and fixing by burring formation. The method may include the step of brazing the header tank (1) and the connector (2) to each other with the brazing material.
-
FIGS. 1A to 1C are step diagrams illustrating a caulking process based upon a burring formation for obtaining a joint structure according to an embodiment of the invention. - Embodiments of the invention will be described below with reference to the drawings.
-
FIGS. 1A to 1C are step diagrams illustrating a caulking process based upon a burring formation. InFIGS. 1A to 1C, aheader tank 1, aconnector 2, aconnector backup member 11, a headertank backup member 12, apunch rod 13, and apunch 13 a are illustrated. - The
header tank 1 is of a two-separate type. Only a tank main unit in which a heat exchange fluid passage is formed is illustrated. The tank main unit is assembled with a header plate (not illustrated) joined to another tube, constituting an actual header tank. - The
header tank 1 has atubular base 1 d extending straight. Theheader tank 1 has asemi-cylindrical plate wall 1 c, and a central portion thereof in a transverse direction has acommunication hole 1 a communicating with aflow holes semi-cylindrical plate wall 1 c has, at the end, an oblique peripheral surface relative to thebase 1 d. Theplate wall 1 c extends from thebase 1 d to be converged. Theflow holes connector 2 constitute a stepped hole. Theflow holes diameter portion 2 a connected to an external pipe and a reduceddiameter portion 2 b connected to thecommunication hole 1 a of theheader tank 1. - Prior to brazing, as illustrated in
FIG. 1A , the diameter of thecommunication hole 1 a of theheader tank 1 is formed smaller than a diameter of theflow hole 2 b of theconnector 2 in advance. Theconnector 2 and theheader tank 1 are supported by thebackup members connector 2 and theplate wall 1 c of theheader tank 1 are caused to abut against each other, so that thecommunication hole 1 a and theflow hole 2 b are positioned to each other. - At this time, the
plate wall 1 c of theheader tank 1 is supported from inside thereof by thesemicircular column portion 12 a of thebackup member 12 on the side of theheader tank 1. Thesemicircular column portion 12 a as a second portion has, at the end, a periphery converged to conform to the inner surface's shape of thesemi-cylindrical plate wall 1 c. The end face of theconnector 2 is supported by the flat portion of thebackup member 11 on the side of theconnector 2. The abuttingportion 2 d of theconnector 2 is caused to abut against the outer face of theplate wall 1 c of theheader tank 1. The abuttingportion 2 d as a first portion is shaped to conform to the oblique outer surface of the distal end of theplate wall 1 c. The abuttingportion 2 d is diverged to conform to the converged outer surface of theplate wall 1 c. - In this state, as illustrated in
FIG. 1B , thepunch rod 13 is elevated from inside of theheader tank 1, while being guided by aslide hole 12 b of thebackup member 12. Thepunch 13 a at the distal end of thepunch rod 13 burring-forms theperiphery 1 b around thecommunication hole 1 a formed in theplate wall 1 c of theheader tank 1. Thepunch 13 a caulks and fixes theperiphery 1 b (burring portion) of thecommunication hole 1 a on the inner peripheral portion of theflow hole 2 b. When caulking is conducted in this manner, the friction between the burring formation portion and theflow hole 2 b of theconnector 2 establishes fixing force. - The “burring formation” means that the
punch 13 a stretches and flanges theperiphery 1 b around thecommunication hole 1 a. Thepunch 13 a presses theperiphery 1 b burred against the inner peripheral surface of theflow hole 1 b. - After caulking and fixing, as illustrated in
FIG. 1C , thepunch 13 a moves down, thebackup members header tank 1 with theconnector 2 temporarily fixed is transferred to a brazing step. Theheader tank 1 and theconnector 2 are brazed to each other and the both are finally joined to each other, so that the joint structure is completed. During the formation, brazing material may be applied on the outer face of theplate wall 1 c of theheader tank 1 in advance. After caulking and fixing are performed in this state by the burring formation, theheader tank 1 and theconnector 2 are brazed to each other by the brazing material. This method establishes brazing with stable quality without supplying brazing material later. - According to the joint structure produced by the above method, brazing is performed in a state that the
header tank 1 and theconnector 2 have been positioned and temporarily fixed to each other reliably and firmly, so that products with stable quality are provided. Furthermore, the burring formation is conducted simply without taking man-hours, and the automation may be performed. - Although the invention has been described above by reference to certain embodiments of the invention, the invention is not limited to the embodiments described above. Modifications and variations of the embodiments described above will occur to those skilled in the art, in light of the above teachings. The scope of the invention is defined with reference to the following claims.
- According to the invention, the first communication hole is smaller than the second communication hole, and the periphery around the first communication hole is burring formed. This method allows the periphery around the first communication hole to be caulking fixed on the inner peripheral surface, thus securely and firmly positioning and temporarily fixing the header tank and the connector to each other. Further, the burring formation allows for secure positioning and temporary fixing with a simple structure without taking man-hours, thus achieving brazing with a constant quality at a lower production cost.
- With the header tank and the connector caulked and fixed by burring formation, the header tank and the connector are brazed to each other, thus securely joining the header tank and the connector to each other.
- A brazing material is applied on the outer surface of the plate wall before the step of caulking and fixing by burring formation, and the header tank and the connector are brazed to each other. This method achieves brazing with a stable quality without feeding a brazing material later.
Claims (5)
1. A joint structure of a header tank and a connector in a heat exchanger comprising:
a header tank including a plate wall formed with a first communication hole; and
a block-shaped connector having a second communication hole positioned to the first communication hole and joined to the header tank,
wherein the first communication hole is smaller than the second communication hole,
wherein the first communication hole has therearound a periphery caulked and fixed on an inner peripheral surface of the second communication hole by burring formation.
2. The joint structure according to claim 1 ,
wherein the header tank and the connector caulked and fixed on each other by burring formation are brazed to each other.
3. The joint structure according to claim 1 ,
wherein the connector comprises a first portion diverged in a concave form,
wherein the joint structure further comprises a header-tank backup member mating with the connector and having a second portion converged in a convex form,
wherein the diverged first portion and the converged second portion hold the plate wall therebetween.
4. A method of joining a header tank and a connector in a heat exchanger, comprising:
forming, on a plate wall of a header tank of a heat exchanger, a first communication hole smaller than a second communication hole of a block-shaped connector;
positioning the first and second communication holes to each other;
inserting a punch into the header tank to burring form a periphery around the first communication hole, with the first and second communication holes positioned to each other;
caulking and fixing the periphery around the first communication hole on an inner peripheral surface of the second communication hole by the punch; and
brazing the header tank and the connector caulked and fixed.
5. The method according to claim 4 , further comprising:
applying a brazing material on an outer surface of the plate wall of a header tank before the step of caulking and fixing by burring formation; and
brazing the header tank and the connector to each other with the brazing material.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2004303250A JP2006112759A (en) | 2004-10-18 | 2004-10-18 | Structure and method for connecting header tank of heat exchanger to connector |
JPP2004-303250 | 2004-10-18 |
Publications (1)
Publication Number | Publication Date |
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US20060108096A1 true US20060108096A1 (en) | 2006-05-25 |
Family
ID=35811627
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/252,237 Abandoned US20060108096A1 (en) | 2004-10-18 | 2005-10-18 | Joint structure of header tank and connector in heat exchanger, and method of joining thereof |
Country Status (3)
Country | Link |
---|---|
US (1) | US20060108096A1 (en) |
EP (1) | EP1650523A1 (en) |
JP (1) | JP2006112759A (en) |
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- 2005-10-18 US US11/252,237 patent/US20060108096A1/en not_active Abandoned
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Also Published As
Publication number | Publication date |
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JP2006112759A (en) | 2006-04-27 |
EP1650523A1 (en) | 2006-04-26 |
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