US20070251682A1 - Heat exchanger - Google Patents

Heat exchanger Download PDF

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Publication number
US20070251682A1
US20070251682A1 US11/736,724 US73672407A US2007251682A1 US 20070251682 A1 US20070251682 A1 US 20070251682A1 US 73672407 A US73672407 A US 73672407A US 2007251682 A1 US2007251682 A1 US 2007251682A1
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United States
Prior art keywords
header
portions
plate
refrigerant flow
refrigerant
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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
Application number
US11/736,724
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English (en)
Inventor
Hironaka Sasaki
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Resonac Holdings Corp
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Showa Denko KK
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Assigned to SHOWA DENKO K. K. reassignment SHOWA DENKO K. K. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SASAKI, HIRONAKA
Publication of US20070251682A1 publication Critical patent/US20070251682A1/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
    • F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
    • F28D1/053—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
    • F28D1/0535—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight the conduits having a non-circular cross-section
    • F28D1/05366—Assemblies of conduits connected to common headers, e.g. core type radiators
    • F28D1/05391—Assemblies of conduits connected to common headers, e.g. core type radiators with multiple rows of conduits or with multi-channel conduits combined with a particular flow pattern, e.g. multi-row multi-stage radiators
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
    • F28D1/03—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits
    • F28D1/0391—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits a single plate being bent to form one or more conduits
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00—Tubular elements; Assemblies of tubular elements
    • F28F1/02—Tubular elements of cross-section which is non-circular
    • F28F1/022—Tubular elements of cross-section which is non-circular with multiple channels
    • 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
    • F28F9/0219—Arrangements for sealing end plates into casing or header box; Header box sub-elements
    • F28F9/0221—Header boxes or end plates formed by stacked elements
    • 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
    • F28F9/026—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits
    • F28F9/0278—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits in the form of stacked distribution plates or perforated plates arranged over end plates
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B39/00—Evaporators; Condensers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
    • F28D2021/0068—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for refrigerant cycles
    • F28D2021/0073—Gas coolers
    • 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
    • F28F9/0219—Arrangements for sealing end plates into casing or header box; Header box sub-elements
    • F28F9/0224—Header boxes formed by sealing end plates into covers
    • 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 present invention relates to a heat exchanger, and more particularly to a heat exchanger that can be favorably used as a gas cooler or an evaporator of a supercritical refrigeration cycle in which a CO 2 (carbon dioxide) refrigerant or a like supercritical refrigerant is used.
  • a CO 2 (carbon dioxide) refrigerant or a like supercritical refrigerant is used.
  • the term “supercritical refrigeration cycle” means a refrigeration cycle in which a refrigerant on the high-pressure side is in a supercritical state; i.e., assumes a pressure in excess of a critical pressure.
  • the term “supercritical refrigerant” means a refrigerant used in a supercritical refrigeration cycle.
  • the applicant of the present application has proposed a heat exchanger for use in a supercritical refrigeration cycle (refer to Japanese Patent Application Laid-Open (kokai) No. 2005-300135).
  • the proposed heat exchanger includes a pair of header tanks disposed apart from each other and each having at least one header section; and a plurality of flat tubes disposed in parallel between the two header tanks and having opposite end portions connected to the respective header tanks.
  • Each of the two header tanks is configured such that an outside plate, an inside plate, and an intermediate plate intervening between the outer and inside plates are brazed together in layers.
  • the outside plate has at least one outwardly bulging portion extending in the longitudinal direction of the header tank and having an opening closed by the intermediate plate.
  • the interior of the outwardly bulging portion serves as a first refrigerant flow section.
  • the inside plate has a plurality of tube insertion holes in the form of through-holes formed in a region corresponding to the outwardly bulging portion and spaced apart from one another along the longitudinal direction thereof. Opposite end portions of the flat tubes are inserted through the respective tube insertion holes of the inside plates of the two header tanks, and are brazed to the inside plates.
  • the intermediate plate has communication holes in the form of through-holes formed for allowing the tube insertion holes of the inside plate to communicate with the first refrigerant flow section of the outside plate. The communication holes communicate with one another via communication portions, each of which is formed between adjacent communication holes of the intermediate plate.
  • the communication portions and portions of the communication holes which correspond to the communication portions form a second refrigerant flow section in the intermediate plate.
  • the second refrigerant flow section communicates with the first refrigerant flow section of the outside plate and allows refrigerant to flow therethrough in the longitudinal direction of the header tank.
  • the header section is formed by portions of the three plates which constitute the corresponding header thank and which correspond to the outwardly bulging portion.
  • the width of the second refrigerant flow section of the intermediate plate is smaller than that of the first refrigerant flow section of the outside plate.
  • the longitudinal opposite ends of the flat tubes are positioned within the second refrigerant flow sections of the intermediate plates; i.e., at thicknesswise intermediate portions of the intermediate plates.
  • supercritical refrigerant flows from each flat tube into the first refrigerant flow section of the outside plate of each header tank as follows. That is, at a portion of each flat tube which faces the second refrigerant flow section of the intermediate plate, the supercritical refrigerant flows directly into the second refrigerant flow section, and then flows into the first refrigerant flow section via the second refrigerant flow section.
  • the supercritical refrigerant first flows into the corresponding communication hole of the intermediate plate, flows within the communication hole in the longitudinal direction thereof to enter the second refrigerant flow section, and then flows into the first refrigerant flow section via the second refrigerant flow section.
  • the supercritical refrigerant flows from the first refrigerant flow section of the outside plate of each header tank to each flat tube as follows. That is, at a portion of each flat tube which faces the second refrigerant flow section of the intermediate plate, the supercritical refrigerant flows from the first refrigerant flow section directly into the flat tube via the second refrigerant flow section. Meanwhile, at portions of each flat tube which face the inner surface of the outside plate, the supercritical refrigerant first flows from the first refrigerant flow section into the second refrigerant flow section, and then flows within the communication hole in the longitudinal direction thereof to enter the flat tube.
  • An object of the present invention is to solve the above problem and to provide a heat exchanger which can minimize an increase in pressure loss at the time when supercritical refrigerant flows from each flat tube into a first refrigerant flow section of an outside plate and when the supercritical refrigerant flows from the first refrigerant flow section of the outside plate into the flat tube.
  • the present invention comprises the following modes.
  • a heat exchanger comprising a pair of header tanks disposed apart from each other and each having at least one header section; and a plurality of flat tubes disposed in parallel between the two header tanks and having opposite end portions connected to the respective header tanks, wherein each of the two header tanks is configured such that an outside plate, an inside plate, and an intermediate plate intervening between the outside and inside plates are brazed together in layers;
  • the outside plate has at least one outwardly bulging portion extending in the longitudinal direction of the header tank and having an opening closed by the intermediate plate, the interior of the outwardly bulging portion serving as a first refrigerant flow section;
  • the inside plate has a plurality of tube insertion holes in the form of through-holes formed in a region corresponding to the outwardly bulging portion and spaced apart from one another along the longitudinal direction of the inside plate; opposite end portions of the flat tubes are inserted through the respective tube insertion holes of the inside plates of the two header tanks, and are brazed to the inside plates;
  • the intermediate plate has communication holes in the
  • the first header tank includes a plurality of header sections arranged in the longitudinal direction of the header tank;
  • the second header tank includes a header section(s), the number of which is one fewer than the number of header sections of the first header tank and which face adjacent two header sections of the first header tank;
  • a header section at one end portion of the first header thank is an inlet header section having a refrigerant inlet, and
  • a header section at the other end portion of the first header thank is an outlet header section having a refrigerant outlet.
  • a heat exchanger according to par. 3), wherein the first header tank includes two header sections, and the second header tank includes a single header section.
  • FIG. 1 is a perspective view showing the overall construction of a gas cooler to which the heat exchanger according to the present invention is applied;
  • FIG. 2 is a fragmentary view in vertical section showing the gas cooler of FIG. 1 as it is seen frontward from rear;
  • FIG. 3 is a perspective view showing a first header tank of the gas cooler of FIG. 1 ;
  • FIG. 4 is an enlarged view in section taken along line A-A of FIG. 2 ;
  • FIG. 5 is an enlarged view in section taken along line B-B of FIG. 2 ;
  • FIG. 6 is an enlarged view in section taken along line C-C of FIG. 5 ;
  • FIG. 7 is an exploded perspective view showing the first header tank of the gas cooler of FIG. 1 ;
  • FIG. 8 is an exploded perspective view showing a second header tank of the gas cooler of FIG. 1 ;
  • FIG. 9 is a cross-sectional view showing a flat tube of the gas cooler of FIG. 1 ;
  • FIG. 10 is a fragmentary enlarged view of FIG. 9 ;
  • FIG. 11 is a view showing a method of manufacturing the flat tube shown in FIG. 9 ;
  • FIG. 12 is a diagram showing the flow of a refrigerant through the gas cooler of FIG. 1 ;
  • FIG. 13 is a graph sowing results of Test Example 1.
  • FIG. 14 is a graph sowing results of Test Example 2.
  • FIGS. 1 and 2 will be referred to as “upper,” “lower,” “left,” and “right,” respectively.
  • the downstream side of flow (represented by arrow X in FIG. 1 ) of air through air-passing clearances between adjacent flat tubes will be referred to as the “front,” and the opposite side as the “rear.”
  • aluminum encompasses aluminum alloys in addition to pure aluminum.
  • FIGS. 1 and 2 show the overall construction of a gas cooler to which the heat exchanger according to the present invention is applied.
  • FIGS. 3 to 8 show the configuration of essential portions of the gas cooler.
  • FIGS. 9 and 10 show a flat tube.
  • FIG. 11 shows a method of manufacturing the flat tube.
  • FIG. 12 shows the flow of a refrigerant through the gas cooler of FIG. 1 .
  • a gas cooler 1 of a supercritical refrigeration cycle wherein a supercritical refrigerant, such as CO 2 , is used includes two header tanks 2 and 3 extending vertically and spaced apart from each other in the left-right direction; a plurality of flat tubes 4 arranged in parallel between the two header tanks 2 and 3 and spaced apart from one another in the vertical direction in such a manner that the width direction of the flat tubes 4 coincides with the front-rear direction; corrugated fins 5 arranged in respective air-passing clearances between adjacent flat tubes 4 and at the outside of the upper-end and lower-end flat tubes 4 and each brazed to the adjacent flat tubes 4 or to the upper-end or lower-end flat tube 4 ; and side plates 6 of aluminum arranged externally of and brazed to the respective upper-end and lower-end corrugated fins 5 .
  • the header tank 2 at the right will be referred to as the “first header tank,” and the header tank 3 at the left as the “second header tank
  • the first header tank 2 is configured such that an outside plate 7 , an inside plate 8 , and an intermediate plate 9 intervening between the outside plate 7 and the inside plate 8 are brazed together in layers.
  • the outside plate 7 and the inside plate 8 are each formed from a brazing sheet having a brazing material layer on each of opposite sides; herein, an aluminum brazing sheet.
  • the intermediate plate 9 is formed from a bare metal material; herein, a bare aluminum material.
  • the first header tank 2 is configured such that an inlet header section 10 A and an outlet header section 10 B are arranged in the vertical direction.
  • the outside plate 7 has a plurality of; herein, two, dome-like outwardly bulging portions 11 A and 11 B spaced apart from each other in the vertical direction.
  • the outwardly bulging portions 11 A and 11 B have the same bulging height, length, and width.
  • a peripheral portion around a leftward-facing opening of each of the outwardly bulging portions 11 A and 11 B is brazed to the intermediate plate 9 , whereby the intermediate plate 9 covers the leftward-facing openings of the outwardly bulging portions 11 A and 11 B.
  • the interiors of the outwardly bulging portions 11 A and 11 B serve as first refrigerant flow sections 11 a and 11 b whose upper and lower ends are closed and through which refrigerant flows in the vertical direction.
  • a refrigerant inlet 12 is formed in a crest portion of the upper outwardly bulging portion 11 A of the outside plate 7 .
  • An inlet member 13 of a metal; herein, a bare aluminum material, having a refrigerant inflow channel 14 in communication with the refrigerant inlet 12 is brazed to the outer surface of the outwardly bulging portion 11 A by use of the brazing material on the outer surface of the outside plate 7 .
  • a refrigerant outlet 15 is formed in a crest portion of the lower outwardly bulging portion 11 B.
  • An outlet member 16 of a metal herein, a bare aluminum material, having a refrigerant outflow channel 17 in communication with the refrigerant outlet 15 is brazed to the outer surface of the outwardly bulging portion 11 B by use of the brazing material on the outer surface of the outside plate 7 .
  • the outside plate 7 is formed, by press work, from an aluminum brazing sheet having a brazing material layer on each of opposite sides.
  • a plurality of tube insertion holes 18 elongated in the front-rear direction are formed through the inside plate 8 and are vertically spaced apart from one another.
  • An upper-half group of tube insertion holes 18 are formed within a vertical range corresponding to the upper outwardly bulging portion 11 A of the outside plate 7 .
  • a lower-half group of tube insertion holes 18 are formed within a vertical range corresponding to the lower outwardly bulging portion 11 B.
  • the tube insertion holes 18 have a front-to-rear length slightly longer than the front-to-rear width of the outwardly bulging portions 11 A and 11 B such that front and rear end portions thereof project outward beyond the front and rear ends, respectively, of the outwardly bulging portions 11 A and 11 B.
  • Front and rear edge portions of the inside plate 8 have integrally formed respective cover walls 19 .
  • the cover walls 19 project rightward such that their ends reach the outer surface of the outside plate 7 , and cover respective boundary portions between the outside plate 7 and the intermediate plate 9 along the overall length of the boundary portions.
  • the cover walls 19 are brazed to the front and rear side surfaces, respectively, of the outside plate 7 and the intermediate plate 9 .
  • the projecting end of each of the cover walls 19 has a plurality of integrally formed engaging portions 21 which are vertically spaced apart from one another and which are engaged with the outer surface of the outside plate 7 .
  • the engaging portions 21 of the cover walls 19 are engaged with and brazed to the outer surface of the outside plate 7 .
  • the engaging portions 21 are not bent and extend straight from the cover walls 19 .
  • the straight engaging portions before being bent are denoted by 21 A.
  • a pair of projecting portions 26 are integrally formed on the inside plate 8 at positions located at opposite sides of each tube insertion hole 18 with respect to the tube-width direction (vertical direction).
  • the projecting portions 26 project outward with respect to the left-right direction; i.e., toward the intermediate plate 9 , via inclined portions which are slightly inclined toward the tube-insertion-hole- 18 side and toward the intermediate plate 9 (outward with respect to the left-right direction).
  • the projecting portions 26 are formed by bending portions of the inside plate 8 corresponding to the opposite edges of each tube insertion hole 18 outward with respect to the left-right direction.
  • the vertically outer surfaces of the projecting portions 26 are inclined outward with respect to the left-right direction and toward the tube-insertion-hole- 18 side.
  • the inside plate 8 is formed, by press work, from an aluminum brazing sheet having a brazing material layer on each of opposite sides.
  • the intermediate plate 9 has communication holes 22 in the form of through-holes for allowing the tube insertion holes 18 of the inside plate 8 to communicate with the interiors of the outwardly bulging portions 11 A and 11 B of the outside plate 7 and in a number equal to the number of the tube insertion holes 18 .
  • the communication holes 22 positionally coincide with the respective tube insertion holes 18 of the inside plate 8 .
  • the width of the communication holes 22 of the intermediate plate 9 with respect to the vertical direction is greater than that of the tube insertion holes 18 of the inside plate 8 , except for the front and rear end portions of the communication holes.
  • the projecting portions 26 on the upper and lower sides of each tube insertion hole 18 of the inside palate 8 enter the corresponding communication hole 22 .
  • each communication hole 22 with respect to the vertical direction is generally equal to that of each tube insertion hole 18 .
  • Stepped portions 25 are formed on the peripheral wall surface of each communication hole 22 of the intermediate plate 9 at opposite end portions thereof with respect to the hole-length direction (front and rear end portions).
  • the stepped portions 25 are located at an intermediate position with respect to the plate-thickness direction of the intermediate plate 9 , and project inward with respect to the hole-length direction of the communication hole 22 .
  • An end surface of the flat tube 4 abuts the stepped portions 25 .
  • the projecting height of the stepped portion 25 of the intermediate plate 9 from the peripheral wall surface of the communication hole 22 is determined so as not to cover a refrigerant channel 4 a , which will be described later, of the flat tube 4 .
  • An upper-half group of tube insertion holes 18 of the inside plate 8 communicate with a first refrigerant flow section 11 a within the upper outwardly bulging portion 11 A of the outside plate 7 via an upper-half group of respective communication holes 22 of the intermediate plate 9 .
  • a lower-half group of tube insertion holes 18 communicate with a first refrigerant flow section 11 b within the lower outwardly bulging portion 11 B of the outside plate 7 via a lower-half group of respective communication holes 22 of the intermediate plate 9 .
  • the communication portions 23 are formed by cutting off central portions (with respect to the front-rear direction) of portions of the intermediate plate 9 between the adjacent communication holes 22 .
  • the communication portions 23 which connect the connection holes 22 facing the first refrigerant flow section 11 a of the outside plate 7 and the central portions (with respect to the front-rear direction) of the communication holes 22 (portions of the communication holes 22 corresponding to the communication portions 23 ) form in the intermediate plate 9 a second refrigerant flow section 9 a which communicates with the first refrigerant flow section 11 a of the outside plate 7 and through which refrigerant flows in the vertical direction.
  • the communication portions 23 which connect the connection holes 22 facing the first refrigerant flow section 11 b of the outside plate 7 and the central portions (with respect to the front-rear direction) of the communication holes 22 (portions of the communication holes 22 corresponding to the communication portions 23 ) form in the intermediate plate 9 a second refrigerant flow section 9 b which communicates with the first refrigerant flow section 11 b of the outside plate 7 and through which refrigerant flows in the vertical direction.
  • the right ends of the flat tubes 4 are positioned within the second refrigerant flow sections 9 a and 9 b of the intermediate plate 9 ; i.e., at a thicknesswise intermediate portion of the intermediate plate 9 .
  • the intermediate plate 9 is formed, by press work, from a bare aluminum material.
  • Respective portions of the three plates 7 , 8 , and 9 of the first header tank 2 which correspond to the outwardly bulging portions 11 A and 11 B form the inlet header section 10 A and the outlet header section 10 B.
  • the two first refrigerant flow sections 11 a and 11 b of the outside plate 7 and the two second refrigerant flow sections 9 a and 9 b of the intermediate plate 9 form the internal refrigerant flow spaces of the inlet header section 10 A and the outlet header section 10 B.
  • the second header tank 3 has substantially the same construction as the first header tank 2 , and like members and portions are designated by like reference numerals (see FIG. 2 ).
  • the two header tanks 2 and 3 are disposed such that the respective inside plates 8 face each other.
  • the outside plate 7 of the second header tank 3 has dome-like outwardly bulging portions provided in a number one fewer than the outwardly bulging portions 11 A and 11 B of the first header tank 2 ; herein, a single dome-like outwardly bulging portion 24 , which extends from an upper end portion to a lower end portion of the outside plate 7 and is opposed to the outwardly bulging portions 11 A and 11 B of the first header tank 2 .
  • a peripheral portion around a rightward-facing opening of the outwardly bulging portion 24 is brazed to the intermediate plate 9 , whereby the intermediate plate 9 covers the rightward-facing opening of the outwardly bulging portion 24 .
  • the interior of the outwardly bulging portion 24 serves as a first refrigerant flow section 24 a whose upper and lower ends are closed and through which refrigerant flows in the vertical direction.
  • the outwardly bulging portion 24 has neither a refrigerant inlet nor a refrigerant outlet.
  • All of the tube insertion holes 18 of the inside plate 8 of the second header tank 3 are formed within a vertical range corresponding to the outwardly bulging portion 24 of the outside plate 7 .
  • All of the tube insertion holes 18 of the inside plate 8 communicate with the first refrigerant flow section 24 a within the outwardly bulging portion 24 of the outside plate 7 via all of the communication holes 22 of the intermediate plate 9 .
  • All of the communication holes 22 of the intermediate plate 9 communicate with one another via communication portions 23 , which are formed by cutting off central portions (with respect to the front-rear direction) of portions of the intermediate plate 9 between the adjacent communication holes 22 .
  • the communication portions 23 and the central portions (with respect to the front-rear direction) of the communication holes 22 form in the intermediate plate 9 a second refrigerant flow section 9 c which communicates with the refrigerant flow section 24 a of the outside plate 7 and through which refrigerant flows in the vertical direction.
  • Respective portions of the three plates 7 , 8 , and 9 of the second header tank 3 which correspond to the outwardly bulging portion 24 form intermediate header sections 20 , the number of which is one fewer than the two header sections 10 A and 10 B of the first header tank 2 ; here, a single intermediate header section 20 , in such a manner that the intermediate header section 20 faces the two header sections 10 A and 10 B of the first header tank 2 .
  • the refrigerant flow section 24 a of the outside plate 7 and the second refrigerant flow section 9 c of the intermediate plate 9 form the internal refrigerant flow space of the intermediate header section 20 .
  • the remaining portion of the second header tank 3 has the same structure as the first header tank 2 , and like members and portions are denoted by the same reference numerals.
  • the tube height which is the thickness of each flat tube 4 as measured in the vertical direction, is represented by T (mm); the distance between each of the opposite longitudinal end surfaces of each flat tube 4 and the outer surface of the corresponding intermediate plate 9 is represented by L (mm); and the width of each communication hole 22 of the intermediate plate 9 , except for the narrow portions at the front and rear ends thereof, is represented by W (mm).
  • the gas cooler 1 must satisfy the relations L ⁇ 0.7 T and 1.1 T ⁇ W ⁇ 2.5 T (see FIG. 6 ).
  • the pressure loss increases when the supercritical refrigerant flows from the first refrigerant flow section 24 a into the second refrigerant flow section 9 c , flows within the communication holes 22 in the longitudinal direction thereof, and flows into the flat tubes 4 from portions of the second ends of the flat tubes 4 facing the inner surface of the corresponding outside plate 7 .
  • the pressure loss increases, the performance of the gas cooler 1 deteriorates. Further, the pressure loss increases at the outlet header section 10 B of the first header tank 2 and an upper half portion of the intermediate header section 20 of the second header tank 3 .
  • the pressure loss increases when the supercritical refrigerant flows from the portions of the first ends of the flat tubes 4 facing the inner surface of the corresponding outside plate 7 into the communication holes 22 of the intermediate plate 9 , flows within the communication holes 22 in the longitudinal direction thereof to enter the second refrigerant flow section 9 b , and then flows into the first refrigerant flow section 11 b via the second refrigerant flow section 9 b .
  • the pressure loss increases when the supercritical refrigerant flows from the portions of the second ends of the flat tubes 4 facing the inner surface of the corresponding outside plate 7 into the communication holes 22 of the intermediate plate 9 , flows within the communication holes 22 in the longitudinal direction thereof to enter the second refrigerant flow section 9 c , and then flows into the first refrigerant flow section 24 a via the second refrigerant flow section 9 c .
  • the upper limit of L is 2.5 T.
  • W is preferably set to a large value, because when the value of W is small, pressure loss changes sharply with a change in L and when the value of W is large, pressure loss changes mildly with a change in L.
  • the value of W is excessively large, the joint area between the outer surface of the intermediate plate 9 and the inner surface of the outside plate 7 decreases, and the withstanding pressure of the header tanks 2 and 3 decreases.
  • the width W of the communication holes 22 must be chosen within the range of 1.1 T to 2.5 T.
  • the first and second header tanks 2 and 3 are manufactured as follows. That is, after the three plates 7 , 8 , and 9 are stacked in layers, the straight engagement portions 21 A are bent to form the engagement portions 21 , which are engaged with the outside plate 7 so as to form a provisionally fixed assembly. After that, the provisionally fixed assembly is heated to a predetermined temperature so as to braze the three plates 7 , 8 , and 9 together by use of the brazing material layers of the outside plate 7 and the inside plate 8 , braze the cover walls 19 to the front and rear end surfaces of the intermediate plate 9 and the outside plate 7 , and further braze the engagement portions 21 to the outside plate 7 . Thus are manufactured the two header tanks 2 and 3 .
  • each flat tube 4 includes mutually opposed flat upper and lower walls 31 and 32 (a pair of flat walls); front and rear side walls 33 and 34 which extend over front and rear side ends, respectively, of the upper and lower walls 31 and 32 ; and a plurality of reinforcement walls 35 which are provided at predetermined intervals between the front and rear side walls 33 and 34 and extend longitudinally and between the upper and lower walls 31 and 32 .
  • the flat tube 4 internally has a plurality of refrigerant channels 4 a arranged in the width direction thereof.
  • the front side wall 33 has a dual structure and includes an outer side-wall-forming elongated projection 36 which is integrally formed with the front side end of the upper wall 31 in a downward raised condition and extends along the entire height of the flat tube 4 ; an inner side-wall-forming elongated projection 37 which is located inside the outer side-wall-forming elongated projection 36 and is integrally formed with the upper wall 31 in a downward raised condition; and an inner side-wall-forming elongated projection 38 which is integrally formed with the front side end of the lower wall 32 in an upward raised condition.
  • the outer side-wall-forming elongated projection 36 is brazed to the two inner side-wall-forming elongated projections 37 and 38 and the lower wall 32 while a lower end portion thereof is engaged with a front side edge portion of the lower surface of the lower wall 32 .
  • the two inner side-wall-forming elongated projections 37 and 38 are brazed together while butting against each other.
  • the rear side wall 34 is integrally formed with the upper and lower walls 31 and 32 .
  • a projection 38 a is integrally formed on the tip end face of the inner side-wall-forming projection 38 of the lower wall 32 and extends in the longitudinal direction of the inner side-wall-forming projection 38 along the entire length thereof.
  • a groove 37 a is formed on the tip end face of the inner side-wall-forming elongated projection 37 of the upper wall 31 and extends in the longitudinal direction of the inner side-wall-forming elongated projection 37 along the entire length thereof.
  • the projection 38 a is press-fitted into the groove 37 a.
  • the reinforcement walls 35 are formed such that reinforcement-wall-forming elongated projections 40 and 41 , which are integrally formed with the upper wall 31 in a downward raised condition, and reinforcement-wall-forming elongated projections 42 and 43 , which are integrally formed with the lower wall 32 in an upward raised condition, are brazed together while the reinforcement-wall-forming elongate projections 40 and 41 butt against the reinforcement-wall-forming elongated projections 43 and 42 , respectively.
  • the upper wall 31 has the reinforcement-wall-forming elongated projections 40 and 41 , which are of different projecting heights and are arranged alternately in the front-rear direction.
  • the lower wall 32 has the reinforcement-wall-forming elongated projections 42 and 43 , which are of different projecting heights and are arranged alternately in the front-rear direction.
  • the reinforcement-wall-forming elongated projections 40 of a long projecting height of the upper wall 31 and the respective reinforcement-wall-forming elongated projections 43 of a short projecting height of the lower wall 32 are brazed together.
  • the reinforcement-wall-forming elongated projections 41 of a short projecting height of the upper wall 31 and the respective reinforcement-wall-forming elongated projections 42 of a long projecting height of the lower wall 32 are brazed together.
  • the reinforcement-wall-forming elongated projections 40 and 42 of a long projecting height of the upper and lower walls 31 and 32 are called the first reinforcement-wall-forming elongated projections.
  • the reinforcement-wall-forming elongated projections 41 and 43 of a short projecting height of the upper and lower walls 31 and 32 are called the second reinforcement-wall-forming elongated projections.
  • a groove 44 ( 45 ) is formed on the tip end face of the second reinforcement-wall-forming elongated projection 41 ( 43 ) of the upper wall 31 (lower wall 32 ) and extends in the longitudinal direction of the second reinforcement-wall-forming elongated projection 41 ( 43 ) along the entire length thereof.
  • a tip end portion of the first reinforcement-wall-forming elongated projection 42 ( 40 ) of the lower wall 32 (upper wall 31 ) is fitted into the groove 44 ( 45 ) of the second reinforcement-wall-forming elongated projection 41 ( 43 ) of the upper wall 31 (lower wall 32 ). While tip end portions of the first reinforcement-wall-forming elongated projections 40 and 42 of the upper and lower walls 31 and 32 , respectively, are fitted into the respective grooves 45 and 44 , the reinforcement-wall-forming elongated projections 40 and 43 are brazed together, and the reinforcement-wall-forming elongated projections 41 and 42 are brazed together.
  • the flat tube 4 is manufactured by use of a tube-forming metal sheet 50 as shown in FIG. 11( a ).
  • the tube-forming metal sheet 50 is formed, by rolling, from an aluminum brazing sheet having a brazing material layer on each of opposite sides.
  • the tube-forming metal sheet 50 includes a flat upper-wall-forming portion 51 (flat-wall-forming portion); a flat lower-wall-forming portion 52 (flat-wall-forming portion); a connection portion 53 connecting the upper-wall-forming portion 51 and the lower-wall-forming portion 52 and adapted to form the rear side wall 34 ; the inner side-wall-forming elongated projections 37 and 38 , which are integrally formed with the side ends of the upper-wall-forming and lower-wall-forming portions 51 and 52 opposite the connection portion 53 in an upward raised condition and which are adapted to form an inner portion of the front side wall 33 ; an outer side-wall-forming-elongated-projection forming portion 54 , which extends outward from the side end of the upper-wall-forming portion 51 opposite
  • the first reinforcement-wall-forming elongated projections 40 of the upper-wall-forming portion 51 and the second reinforcement-wall-forming elongated projections 43 of the lower-wall-forming portion 52 are located symmetrically with respect to the centerline of the width direction of the connection portion 53 .
  • the second reinforcement-wall-forming elongated projections 41 of the upper-wall-forming portion 51 and the first reinforcement-wall-forming elongated projections 42 of the lower-wall-forming portion 52 are located symmetrically with respect to the centerline of the width direction of the connection portion 53 .
  • the projection 38 a is formed on the tip end face of the inner side-wall-forming elongated projection 38 of the lower-wall-forming portion 52
  • the groove 37 a is formed on the tip end face of the inner side-wall-forming elongated projection 37 of the upper-wall-forming portion 51
  • the groove 44 ( 45 ) into which a tip end portion of the first reinforcement-wall-forming elongated projection 42 ( 40 ) of the lower-wall-forming portion 52 (upper-wall-forming portion 51 ) is fitted, is formed on the tip end face of the second reinforcement-wall-forming elongated projection 41 ( 43 ) of the upper-wall-forming portion 51 (lower-wall-forming portion 52 ).
  • the inner side-wall-forming elongated projections 37 and 38 and the reinforcement-wall-forming elongated projections 40 , 41 , 42 , and 43 are integrally formed, by rolling, on one side of the aluminum brazing sheet whose opposite sides are clad with a brazing material, whereby a brazing material layer (not shown) is formed on the opposite side surfaces and tip end faces of the inner side-wall-forming elongated projections 37 and 38 and the reinforcement-wall-forming elongated projections 40 , 41 , 42 , and 43 ; on the peripheral surfaces of the grooves 44 and 45 of the second reinforcement-wall-forming elongated projections 41 and 43 ; and on the vertically opposite surfaces of the upper-wall-forming and lower-wall-forming portions 51 and 52 and the outer side-wall-forming-elongated-projection forming portion 54 .
  • the tube-forming metal sheet 50 is gradually folded at opposite side edges of the connection portion 53 by a roll forming process (see FIG. 11( b )) until a hairpin form is assumed.
  • the inner side-wall-forming elongated projections 37 and 38 are caused to butt against each other; tip end portions of the first reinforcement-wall-forming elongated projections 40 and 42 are fitted into the respective grooves 45 and 44 of the second reinforcement-wall-forming elongated projections 43 and 41 ; and the projection 38 a is press-fitted into the groove 37 a.
  • the outer side-wall-forming-elongated-projection forming portion 54 is folded along the outer surfaces of the inner side-wall-forming elongated projections 37 and 38 , and a tip end portion thereof is deformed so as to be engaged with the lower-wall-forming portion 52 , thereby yielding a folded member 55 (see FIG. 11( c )).
  • the folded member 55 is heated at a predetermined temperature so as to braze together tip end portions of the inner side-wall-forming elongated projections 37 and 38 ; to braze together tip end portions of the first and second reinforcement-wall-forming elongated projections 40 and 43 ; to braze together tip end portions of the first and second reinforcement-wall-forming elongated projections 42 and 41 ; and to braze the outer side-wall-forming-elongated-projection forming portion 54 to the inner side-wall-forming elongated projections 37 and 38 and to the lower-wall-forming portion 52 .
  • the flat tube 4 is manufactured the flat tube 4 .
  • right end portions of an upper-half group of flat tubes 4 are connected to the first header tank 2 so as to communicate with the interior of the upper outwardly bulging portion 11 A, and left end portions are connected to the second header tank 3 so as to communicate with the interior of the outwardly bulging portion 24 .
  • right end portions of a lower-half group of flat tubes 4 are connected to the first header tank 2 so as to communicate with the interior of the lower outwardly bulging portion 11 B, and left end portions are connected to the second header tank 3 so as to communicate with the interior of the outwardly bulging portion 24 .
  • Each of the corrugated fins 5 is made in a wavy form from a brazing sheet; herein, an aluminum brazing sheet, having a brazing material layer on each of opposite sides.
  • the gas cooler 1 is manufactured by the steps of: preparing the aforementioned two provisionally fixed assemblies to be manufactured into the header tanks 2 and 3 , a plurality of the aforementioned folded members 55 , and a plurality of corrugated fins 5 ; arranging the two provisionally fixed assemblies in such a manner as to be spaced apart from each other with the inside plates 8 facing each other; arranging alternately the folded members 55 and the corrugated fins 5 ; inserting opposite end portions of the folded members 55 through the respective tube insertion holes 18 of the inside plates 8 and into the respective communication holes 22 of the intermediate plates 9 of the two provisionally fixed assemblies, and causing the end surfaces of the opposite end portions to abut the respective stepped portions 25 of the intermediate plate 9 ; arranging the side plates 6 externally of the respective opposite-end corrugated fins 5 ; arranging the inlet member 13 and the outlet member 16 on the outwardly bulging portions 11 A and 11 B, respectively, of the outside plate 7 used to form the first header tank 2 ; and brazing necessary portions of the
  • the gas cooler 1 together with a compressor, an evaporator, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between refrigerant from the gas cooler and refrigerant from the evaporator, constitutes a supercritical refrigeration cycle.
  • the refrigeration cycle is installed in a vehicle, for example, in an automobile, as a car air conditioner.
  • CO 2 from a compressor flows through the refrigerant inflow channel 14 of the inlet member 13 and enters the first refrigerant flow section 11 a of the upper outwardly bulging portion 11 A of the first header tank 2 through the refrigerant inlet 12 . Then, the CO 2 dividedly flows into the refrigerant channels 4 a of all the flat tubes 4 in communication with the upper outwardly bulging portion 11 A via the upper-side second refrigerant flow section 9 a and the communication holes 22 of the intermediate plate 9 .
  • the CO 2 in the refrigerant channels 4 a flows leftward through the refrigerant channels 4 a and enters the first refrigerant flow section 24 a of the outwardly bulging portion 24 of the second header tank 3 .
  • the CO 2 in the first refrigerant flow section 24 a of the outwardly bulging portion 24 flows downward through the first refrigerant flow section 24 a and through the second refrigerant flow section 9 c of the intermediate plate 9 ; dividedly flows into the refrigerant channels 4 a of all the flat tubes 4 in communication with the lower outwardly bulging portion 11 B via the second refrigerant flow section 9 c and the communication holes 22 ; flows rightward through the refrigerant channels 4 a ; and enters the first refrigerant flow section 11 b of the lower outwardly bulging portion 11 B via the lower-side second refrigerant flow section 9 b and the communication holes 22 of the intermediate plate 9 of the first header tank 2 .
  • the CO 2 flows out of the gas cooler 1 via the refrigerant outlet 15 and the refrigerant outflow channel 17 of the outlet member 16 .
  • the CO 2 While flowing through the refrigerant channels 4 a of the flat tubes 4 , the CO 2 is subjected to heat exchange with the air flowing through the air-passing clearances in the direction of arrow X shown in FIGS. 1 and 12 , thereby being cooled.
  • results shown in FIG. 13 demonstrate that in each gas cooler 1 , an increase in pressure loss can be suppressed when the relation L ⁇ 0.7 T is satisfied, where T represents the tube height in mm of the flat tubes 4 . Further, the results demonstrate that the smaller the width W of the communication holes 22 of the intermediate plate 9 , the greater the degree to which a change in pressure loss with a change in L becomes sharp, and the greater the width W, the greater the degree to which a change in pressure loss with a change in L becomes mild.
  • Gas coolers 1 were fabricated, while the width W of the communication holes 22 of the intermediate plate 9 was changed to various values, and the relation between the width W and the withstanding pressure of the header tanks 2 and 3 was investigated.
  • the gas coolers 1 are identical in terms of the dimensions of the components and portions, other than the width W.
  • FIG. 14 shows the results of the test.
  • the heat exchanger of the present invention is applied to a gas cooler of a supercritical refrigeration cycle.
  • the heat exchanger of the present invention may be applied to an evaporator of the above-mentioned supercritical refrigeration cycle.
  • This evaporator together with a compressor, a gas cooler, a pressure-reducing device, and an intermediate heat exchanger for performing heat exchange between refrigerant from the gas cooler and refrigerant from the evaporator, constitutes a supercritical refrigeration cycle which uses a supercritical refrigerant such as CO 2 .
  • This refrigeration cycle is installed in a vehicle, for example, in an automobile, as a car air conditioner.
  • each of the header tanks 2 and 3 is formed by stacking three types of plates; i.e., the outside plate 7 , the inside plate 8 , and the intermediate plate 9 , one sheet each.
  • the present invention is not limited thereto, and two or more intermediate plates 9 may be stacked.
  • the refrigerant is not limited thereto, but ethylene, ethane, nitrogen oxide, or the like may be alternatively used.
  • the above-described embodiment uses, for forming the flat tube 4 , a folded member 55 which is formed by bending a tube-forming metal sheet in the form of an aluminum brazing sheet having a brazing material layer on each of opposite sides.
  • a folded member 55 which is formed by bending a tube-forming metal sheet in the form of an aluminum brazing sheet having a brazing material layer on each of opposite sides.
  • the present invention is not limited thereto.
  • an aluminum extrudate having a brazing material layer on its outer surface may be used to form the flat tube 4 .

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  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Geometry (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
  • Details Of Heat-Exchange And Heat-Transfer (AREA)
US11/736,724 2006-04-28 2007-04-18 Heat exchanger Abandoned US20070251682A1 (en)

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JP2006124789A JP4724594B2 (ja) 2006-04-28 2006-04-28 熱交換器

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US10041738B2 (en) 2009-02-27 2018-08-07 Electrolux Home Products, Inc. Evaporator fins in contact with end bracket
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US20100218925A1 (en) * 2009-02-27 2010-09-02 Electrolux Home Products, Inc. Evaporator fins in contact with end bracket
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