US20150292817A1 - Heat exchanger - Google Patents
Heat exchanger Download PDFInfo
- Publication number
- US20150292817A1 US20150292817A1 US14/390,003 US201314390003A US2015292817A1 US 20150292817 A1 US20150292817 A1 US 20150292817A1 US 201314390003 A US201314390003 A US 201314390003A US 2015292817 A1 US2015292817 A1 US 2015292817A1
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- US
- United States
- Prior art keywords
- tubes
- heat exchanger
- header
- header tank
- brazing material
- 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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
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- 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
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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
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- 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
- F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
- F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
- F28F1/126—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element consisting of zig-zag shaped fins
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F19/00—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers
- F28F19/004—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers by using protective electric currents, voltages, cathodes, anodes, electric short-circuits
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F19/00—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers
- F28F19/02—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers by using coatings, e.g. vitreous or enamel coatings
- F28F19/06—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers by using coatings, e.g. vitreous or enamel coatings of metal
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
- F28F3/025—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like 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
- F28F9/0202—Header boxes having their inner space divided by partitions
- F28F9/0204—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions
- F28F9/0209—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions having only transversal partitions
- F28F9/0212—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions having only transversal partitions the partitions being separate elements attached to header boxes
-
- 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
- F28F2275/00—Fastening; Joining
- F28F2275/04—Fastening; Joining by brazing
Definitions
- the present invention relates to a parallel flow type of heat exchanger which is arranged at the front in an engine room of a vehicle and which is provided with porous tubes constituted by inner fin tubes.
- a structure which is comprised of a plurality of porous tubes which are fabricated by extrusion and are inserted at their two sides into header plates of header tanks at predetermined intervals and which is provided with outer fins for heat dissipation use between the porous tubes and other porous tubes has been employed.
- the porous tubes are being fabricated by, instead of extrusion, sheet forming for bending belt-shaped sheet members to form tubes and providing inner fins at the insides so as to simplify the method of production, lighten the weight, and reduce the costs.
- Porous tubes which are obtained by sheet forming for bending belt-shaped sheet members to form tubes and providing inner fins at the insides are called “inner fin tubes”.
- a heat exchanger which employs such inner fin tubes is disclosed in PLT 1.
- the biggest advantages of production of inner fin tubes by sheet forming of belt-shaped sheet members are the ease of reducing weight by suitably setting the sheet thickness and the greater degree of freedom of shaping than the extrusion method and therefore the enlarged heat conduction area etc. and consequent ability to improve the heat exchange performance of the heat exchanger.
- a heat exchanger which uses the inner fin tubes which are shown in PLT 1 etc. is for use for air-conditioning systems for vehicular use. Its configuration is shown simplified in FIG. 1 .
- the heat exchanger 1 is provided with a core part 2 , entry side header tank 3 , and exit side header tank 4 which are brazed together.
- the core part 2 is comprised of a plurality of inner fin tubes 10 and a plurality of outer fins 20 alternately stacked and reinforcing members constituted by side plates 25 at the end parts at the two sides in the stacking direction (up-down direction in figure).
- the air which is blown through the core part 2 is used to cool the refrigerant which flows through the insides of the inner fin tubes 10 .
- separators 26 are provided at the insides of the entry side header tank 3 and exit side header tank 4 . At the two end parts, caps 23 and 24 which close the opening parts of the header tanks are brazed. The insides of the entry side header tank 3 and exit side header tank 4 are separated by the separators 26 into a plurality of spaces. Further, the entry side header tank 3 has an inflow port 21 for the refrigerant, while the exit side header tank 4 has an outflow port 22 for the refrigerant.
- the refrigerant which flows from the inflow port 21 to the inside of the heat exchanger 1 flows through the insides of the entry side header tank 3 and exit side header tank 4 which are separated by the separators 26 and the insides of the inner fin tubes 10 as shown by the broken lines and discharged from the outflow part 22 .
- the number of the inner fin tubes 10 and the number of the separators 26 which are shown in FIG. 1 are examples and do not show the numbers and flow paths of refrigerant in an actual heat exchanger 1 .
- FIG. 2 explains the configuration of the inside of an inner fin tube 10 of the heat exchanger 1 which is shown in FIG. 1 and the flow path of refrigerant which flows through the inside of it.
- the inner fin tube 10 is comprised of a tube 11 formed with a cross-section wave-shaped inner fin 12 inserted in it.
- the tube 11 is a tube member with a horizontal cross-section of a flat shape (shape close to oval shape) perpendicular to the longitudinal direction (flow path direction of refrigerant) obtained by bending a thin (for example thickness 0.2 mm) aluminum belt-shaped sheet member.
- the tube 11 is comprised of a belt-shaped sheet member with a center part which is bent into an arc to form a curved end part 11 a and with parallel parts 11 p which extend from this curved end part 11 a to form a swaged part 11 b at the end part at the opposite side from the curved end part 11 a of the parallel parts 11 p.
- the two end parts of the belt-shaped sheet member are made different in lengths from the curved end part 11 a for swaging at the swaged part 11 b.
- the inner fin 12 like the tube 11 , is formed in a wave shape by rolling a thin (for example thickness 0.1 mm) aluminum belt-shaped sheet and providing flat plate parts 15 and 16 at the two end parts.
- the bent parts 14 of the wave parts of the inner fin 12 are brazed at the inside wall surface 13 of the tube 11
- the end part of the flat plate part 16 is brazed to the inside wall surface 14 of the curved end part 11 a.
- the end part of the flat plate part 15 of the inner fin 12 is joined with the tube 11 by swaging at the swaged part 11 b.
- FIG. 3 shows the state of a header tank of the heat exchanger 1 which is shown in FIG. 1 , for example, the exit side header tank 4 , to which the inner fin tubes 10 which are shown in FIG. 2 are connected.
- the exit side header tank 4 is formed by a header plate 41 through which the inner fin tubes 10 are inserted and a tank plate 42 which are joined together.
- the front end parts of the inner fin tubes 10 are inserted through the header plate 41 and stick out into the space inside the exit side header tank 4 .
- FIG. 4 is a view of the exit side header tank 4 which is shown in FIG. 3 as seen from the arrow L direction.
- the header plate 41 and the tank plate 42 are provided with a brazing material between them.
- the front end parts of the inner fin tubes 10 which are inserted into the header plate 41 are brazed to the header plate 41 by the brazing material which is arranged between the header plate 41 and the tank plate 42 .
- PLT 1 Japanese Patent Publication No. 2007-125590A
- FIG. 6 shows the vicinity of a swaged part 11 b of an inner fin tube 10 which is normally brazed.
- the tube 11 has parallel parts 11 p.
- the belt-shaped sheet member is bent at points at the same lengths from the not shown curved end part whereby slanted parts 11 c are formed.
- the slanted parts 11 c are bent at the parts of the belt-shaped sheet member which abut against each other.
- a flat plate part 15 of an inner fin 12 is sandwiched.
- the end part 11 e of the belt-shaped sheet member is folded back to the end part 11 f side to form the swaged part 11 b.
- the end part 15 a of the flat plate part 15 sticks out from the short end part 11 f of the belt-shaped sheet member and is bent around the short end part 11 f side of the belt-shaped sheet member by the long end part 11 e of the folded back belt-shaped sheet member.
- FIG. 7 shows the swaged part 11 b of the inner fin tube 10 which is shown in FIG. 6 and shows the state where tube melting 5 occurs. If tube melting 5 occurs, the tube 11 is reduced in thickness, a hole is formed in the tube 11 at the part of the tube melting 5 , and refrigerant leaks out.
- FIG. 8 shows another example of an inner fin tube 10 .
- the inner fin tube 10 has an inner fin 12 inside of it.
- the tube 11 is swaged and closed by the swaged part 11 b.
- FIG. 9 shows the state where tube melting 6 and 7 occurs at the swaged part 11 b of the inner fin tube 10 which is shown in FIG. 8 .
- brazing material is arranged at the header tank side, at the time of brazing of the inner fin tube, the brazing material passes through the header plate to flow into the inner fin tube causing tube melting.
- Inflow of brazing material to the inner fin tube occurs due to the step difference at the swaged part of the tube which is formed by the bent sheet, so up to now measures have been taken such as welding together the swaged part or reducing the step difference at the swaged part.
- each of these measures leads to increased cost.
- special steps are required where the brazing temperature has to be strictly managed. Insufficient measures have been taken against the flow of brazing material to the inside of the inner fin tube.
- the present invention in consideration of the above problem, provides a heat exchanger which is brazed after tubes are assembled into the header tanks wherein tube melting at the time of attachment of the tubes to the header tanks can be prevented and productivity can be improved.
- the present invention provides a heat exchanger ( 1 ) which has a plurality of tubes ( 11 ) which are provided with refrigerant passages inside them and a pair of header tanks ( 3 , 4 ) to which end parts of the tubes ( 11 ) are brazed, wherein brazing materials ( 8 ) which are used for brazing to the header tanks ( 3 , 4 ) are arranged at the outer circumferential surfaces of the tubes ( 11 ), and the base materials of the metal sheet members which form the header tanks ( 3 , 4 ) are exposed at the inner circumferential surfaces and outer circumferential surfaces of the header tanks ( 3 , 4 ).
- the brazing material which is necessary for brazing a tube and a header tank is supplied from the outer circumferential surface of the tube, so tube melting at the time of brazing is prevented, and the heat exchanger is improved in productivity.
- FIG. 1 is a front view which shows the streamlined configuration of a heat exchanger of the comparative art.
- FIG. 2 is a perspective view which shows an inner fin tube which is used at the heat exchanger which is shown in FIG. 1 .
- FIG. 3 is a partial perspective view of a heat exchanger which shows the state where inner fin tubes which are shown in FIG. 2 are connected to a header plate of a header tank of the heat exchanger which is shown in FIG. 1 .
- FIG. 4 is a cross-sectional view of the header tank which is shown in FIG. 3 as seen from an arrow L direction.
- FIG. 5 is a partial perspective view which shows the state where the brazing material of the tank plate flows into the header plate through a separator and the brazing material flows into an inner fin tube.
- FIG. 6 is a partial enlarged cross-sectional view which shows a swaged part of an inner fin tube which is normally brazed.
- FIG. 7 is a partial enlarged cross-sectional view which shows the state where tube melting occurs at the swaged part of the inner fin tube which is shown in FIG. 6 .
- FIG. 8 is a cross-sectional view which shows another example of an inner fin tube.
- FIG. 9 is a partial enlarged cross-sectional view which shows the state where tube melting occurs at the swaged part of the inner fin tube which is shown in FIG. 8 .
- FIG. 10 is a cross-sectional view of an inner fin tube of a first embodiment of the present invention.
- FIG. 11 is a partial enlarged cross-sectional view which shows a part of a swaged part of the inner fin tube of FIG. 10 .
- FIG. 12A is a cross-sectional view of a brazing material-free header plate and tank plate which are used for an inner fin tube and heat exchanger of the first embodiment of the present invention
- FIG. 12B is a cross-sectional view of a modification of the first embodiment where there is a sacrificial material at the outside of the header plate of the brazing material-free header plate and tank plate which are shown in FIG. 12A
- FIG. 12C is a partial perspective view of a heat exchanger which shows an embodiment of providing a brazing material at one surface of a separator of an entry side and exit side header tank which is provided with a brazing material-free header plate and tank plate
- FIG. 12A is a cross-sectional view of a brazing material-free header plate and tank plate which are used for an inner fin tube and heat exchanger of the first embodiment of the present invention
- FIG. 12B is a cross-sectional view of a modification of the first embodiment where there is a sacrificial material at the outside of the header plate
- FIG. 12D is a cross-sectional view of an embodiment where the entry side and exit side header tanks are one-piece bodies and have cross-sections of circular shapes
- FIG. 12E is a cross-sectional view of an embodiment where the entry side and exit side header tanks are one-piece bodies and have cross-sections of oval shapes
- FIG. 12F is a cross-sectional view of an embodiment where the entry side and exit side header tanks are one-piece bodies and have cross-sections of irregular shapes
- FIG. 12G is an enlarged view of a principal part X of FIG. 12B .
- FIG. 13 is an assembled perspective view of a header plate and a brazing material-free separator which is used for the same which shows a second embodiment of the present invention.
- FIG. 14 is an assembled perspective view of a header plate and a brazing material-free separator which is used for the same which shows a modification of the second embodiment of the present invention.
- FIG. 15 is a side cross-sectional view and front view of a first specific example of a separator of a third embodiment of the present invention.
- FIG. 16 is a side cross-sectional view and front view of a second specific example of a separator of a third embodiment of the present invention.
- FIG. 17 is a front view of a third specific example of a separator of a third embodiment of the present invention.
- FIG. 18 is a front view of a fourth specific example of a separator of a third embodiment of the present invention.
- FIG. 19 is a front view of a fifth specific example of a separator of a third embodiment of the present invention.
- FIG. 20 is a front view of a sixth specific example of a separator of a third embodiment of the present invention.
- FIG. 10 shows an inner fin tube 10 of a first embodiment of the present invention. Further, FIG. 11 shows a part X of FIG. 10 enlarged.
- An inner fin tube 10 is comprised of a belt-shaped sheet member which is folded back to hold an inner fin 12 inside of it.
- the belt-shaped sheet member is formed by thin (for example thickness 0.2 mm) aluminum. It is folded back into an arc shape at a portion at slightly different distances from the two end parts to form a curved end part 11 a.
- the belt-shaped sheet member is folded back until becoming parallel to form parallel parts 11 p.
- the two end parts of the belt-shaped sheet member are bent at portions of the same distance from the curved end part 11 a to form predetermined lengths of slanted parts 11 c, then are further bent so that the two end parts become parallel.
- the belt-shaped sheet member is folded back as explained above to form the flat tube 11 .
- an inner fin 12 is housed whereby a flat shaped flow path of the medium is formed.
- the inner fin 12 is formed into a wave shape by rolling a thin (for example thickness 0.1 mm) aluminum belt-shaped sheet member in the same way as the tube 11 .
- flat plate parts 15 and 16 are provided at the two end parts.
- the bent parts 14 of the wave shaped parts of the inner fin 12 are brazed to the inside wall surface 13 of the tube 11 .
- the end part of the flat plate part 16 is also brazed to the inside wall surface 13 of the curved end part 11 a.
- the end part of the other flat plate part 15 of the inner fin 12 is sandwiched between the two end parts bent to become parallel.
- the two end parts 11 e and 11 f of the belt-shaped sheet member which sandwich the flat plate part 15 of the inner fin 12 in the first embodiment become longer at the end part 11 e than the end part 11 f. Accordingly, the end part 11 e is folded back to the end part 11 f side in a state sandwiching the flat plate part 15 and the end part 11 f and is swaged to join them whereby the swaged part 11 b is formed.
- a brazing material 8 is arranged (clad) at the outer surface as a whole at the thus formed inner fin tube 10 .
- the amount of this brazing material 8 becomes an amount which is required for brazing the inner fin tube 10 to the entry side and exit side header tanks 3 and 4 when inserting and brazing the two end parts of the inner fin tube 10 , as shown in FIG. 3 , to the entry side and exit side header tanks 3 and 4 .
- the inner circumferential surfaces N and outer circumferential surfaces S of the header plates 31 and 41 which form the entry side header tank 3 and the exit side header tank 4 , as shown in FIG. 12A are made brazing material-free. That is, the metal sheet members which form the header plates 31 and 41 are made sheet members with the base material exposed (bare materials) and can be made single layer members with no brazing material.
- the brazing material which is used when joining the inner fin tube 10 to the entry side and exit side header tanks 3 and 4 is supplied from the sufficient amount of brazing material 8 which was clad at the outer surface of the inner fin tube 10 (see FIG. 10 and FIG. 11 ).
- the brazing material is not present at the tank plates 32 and 42 , so the brazing material no longer flows from the tank plates 32 and 42 to the inner fin tube 10 and the tube melting of the inner fin tube 10 no longer occurs. As a result, the stability at the time of brazing the inner fin tube 10 is improved and the scope of application of the brazing temperature can be broadened.
- the brazing material which flows to the inside of the inner fin tube 10 is a sufficient amount of brazing material 8 which is clad over the entire outer surface of the inner fin tube 10 .
- the amount of the brazing material which is supplied to the brazing part of the inner fin tube 10 becomes sufficient, and the brazing fillet of the inner fin tube 10 can be made larger.
- a fillet commensurate with the amount of brazing material of the part itself is formed and the brazeability of parts other than the inner fin tube 10 is also improved.
- the brazing material which is at the entry side and exit side header tanks 3 and 4 flows into the inner fin tube 10 and where the brazing material which is at the entry side and exit side header tanks 3 and 4 and the brazing material of the inner fin tube 10 are connected.
- the size of the fillet radius of the fillet which is formed at the inner fin 12 and the size of the fillet radius which is formed at the tank plate 32 and header plate 31 become substantially equal.
- the amounts of brazing material at the entry side and exit side header tanks 3 and 4 are small, so the size of the fillet radius of the tank plate 32 and header plate 31 ends up becoming the same 0.1 mm or so as the fillet radius of the fillet which is formed at the inner fin 12 . That is, sometimes the size of the fillet radius which is formed at the tank plate 32 and the header plate 31 is extremely small and the gap at the part requiring brazing cannot be filled resulting in leakage.
- the “size of the fillet radius” which is referred to here envisions the case of using the generally widely used brazing material with 10 wt % of amount of Si.
- the surface of the inner fin tube 10 sometimes has an anticorrosion layer or sacrificial brazing material on which the brazing material layer is superposed arranged on it, but by making the header plates 31 and 41 brazing material-free, it is possible to prevent the inflow of brazing material from the entry side and the exit side header tanks 3 and 4 , so the flow of brazing material to the surface of the inner fin tube 10 is also prevented.
- the brazing material ends up obstructing the action of the anticorrosion layer, so by preventing the flow of brazing material to the surface of the inner fin tube 10 , it is possible to improve the corrosion resistance of the inner fin tube 10 .
- FIG. 12B shows an embodiment which provides the outer circumferential surfaces S of the header plates 31 and 41 with a sacrificial material (anticorrosion layer) 9 . In this case, as shown in FIG.
- the surfaces of the metal sheet members (for example, comprised of aluminum alloy etc.) at the inner circumferential surface N sides may be made states with the base materials 311 and 411 exposed and the surfaces of the metal sheet members at the outer circumferential surface S sides of the header plates 31 and 41 may be made states with the surfaces of the base materials 311 and 411 clad by the sacrificial material 9 .
- the header plates 31 and 41 are made brazing material-free, but one or both surfaces of the separators 26 may be provided with the brazing material 8 . In FIG. 12C , the brazing material 8 are shown shaded.
- the inner circumferential surfaces N and outer circumferential surfaces S of the entry side and exit side header tanks 3 and 4 may be made brazing material-free even in the case where the entry side and exit side header tanks 3 and 4 are single-piece pipes 30 not split into header plates 31 and 41 and tank plates 32 and 42 .
- the single-piece pipes 30 which are used for the entry side and exit side header tanks 3 and 4 are effective regardless of their cross-sectional shapes such as the circular shape which is shown in FIG. 12D , the oval shape which is shown in FIG. 12E , and the irregular shape which is shown in FIG. 12F .
- the materials which form the tanks may be exposed single layer types and may be provided at least at one of the inner circumferential surfaces N and outer circumferential surfaces S of the pipes 30 with a low potential sacrificial material (anticorrosion layer) 9 .
- the inner circumferential surface N of the pipe 30 which is shown in FIG. 12E is provided with the sacrificial material 9
- the outer circumferential surface S of the pipe 30 which is shown in FIG. 12F is provided with the sacrificial material 9 .
- the outer circumferential surface S of the pipe 30 which is shown in FIG. 12E may be provided with the sacrificial material and the inner circumferential surface N of the pipe 30 which is shown in FIG. 12F may be provided with the sacrificial material 9 needless to say. Whether the sacrificial material 9 is provided at the inner circumferential surface N of the pipe 30 or is provided at the outer circumferential surface S does not depend on the shape and structure of the pipe 30 . Further, both of the inner circumferential surface N and the outer circumferential surface S of the pipe 30 may be provided with the sacrificial material 9 .
- FIG. 13 shows a second embodiment of the heat exchanger of the present invention.
- the entry side header plate 31 and the exit side header plate 41 are made brazing material-free, and the separator 26 which is attached as a partition wall at the inside of the entry side header tank 3 and the exit side header tank 4 is made brazing material-free.
- the separator 26 of the second embodiment is used in the case of a structure where the header plates 31 and 41 have holes 33 and 43 (hole 33 at entry side header tank 3 and hole 43 at exit side header tank 4 ). That is, the metal sheet member which forms the separator 26 is made the exposed sheet member (bare material) where no brazing material is provided.
- the header plates 31 and 41 and the separator 26 are brazing material-free, but brazing material which is arranged at the tank plates 32 and 42 is supplied, whereby the header plates 31 and 41 and the separator 26 can be brazed.
- Tank brazing material flows through the fine clearances between the separator 26 and header plates 31 and 41 whereby these are brazed together.
- a brazing material with an amount of Si of 6 wt % or more is suitable as the brazing material of the tank plates 32 and 42 .
- FIG. 14 shows a modification of the separator 26 of the second embodiment of the present invention which is shown in FIG. 13 .
- the separator 26 of the modification is used in the case of a structure with grooves 34 and 44 at the two sides of the header plates 31 and 41 (groove 34 at entry side header tank 3 and groove 44 at exit side header tank 4 ).
- the metal sheet member which forms the separator 26 is made the exposed sheet member (bare material) where no brazing material is provided.
- the holes at the header plates 31 and 41 at the joining sides with the inner fin tubes are eliminated, and grooves 34 and 44 are provided for attachment of the separator 26 at the two sides of the header plates 31 and 41 . For this reason, the flow paths of inflow of the brazing material from the outsides of the header plates 31 and 41 are cut.
- FIG. 15 to FIG. 17 show the configurations of separators 26 of a third embodiment of the heat exchanger of the present invention.
- the figures give cross-sectional views and front views of separator 26 .
- the third embodiment provides the two surfaces of the separator 26 with structures for holding the brazing material in the case where the two surfaces of the entry side header tank 3 or exit side header tank 4 are provided with brazing material and thereby prevents the inflow of the brazing material to the inner fin tubes 10 .
- FIG. 15 shows a first specific example of the separator 26 .
- a separator 26 of the same type as the separator 26 which was explained in FIG. 13 is shown.
- the two surfaces of the separator 26 are provided with a plurality of parallel grooves 27 .
- FIG. 16 shows a second specific example of the separator 26 .
- a separator 26 of the same type as the separator 26 which was explained in FIG. 13 is shown.
- the two surfaces of the separator 26 are provided with a plurality of circular depressions 28 which are regularly arranged to the top and bottom and the left and right. These depressions 28 serve as brazing reservoirs in which melted brazing material is held.
- FIG. 17 shows a third specific example of the separator 26 .
- a separator 26 of the same type as the separator 26 which was explained in FIG. 13 is shown.
- the two surfaces of the separator 26 are provided with a plurality of oval depressions 29 which are regularly arranged to the top and bottom and the left and right. Oval depressions 29 may also be provided irregularly arranged.
- FIG. 18 to FIG. 20 show fourth to sixth specific examples of the separator 26 of the third embodiment of the heat exchanger of the present invention.
- the two surfaces of the separator 26 are provided at a slant with grooves 35 which cut the brazing material flow paths.
- the grooves 35 are provided at the separator 26 asymmetrically.
- the grooves 35 may also be ribs.
- the two surfaces of the separator 26 are provided with grooves 36 which cut the brazing material flow path at an angle symmetrically with respect to the centerline of the separator 26 .
- the grooves 36 may also be ribs.
- the two surfaces of the separator 26 are provided with not only the grooves 36 which were explained in the fifth example, but also ribs 37 which cut the brazing material flow paths at an angle symmetrically with respect to the centerline of the separator 26 .
- the ribs 37 may also be grooves.
- the brazing material which causes tube melting flows to an inner fin tube through a brazing part of a separator 26 and an inside of a tank. Therefore, as shown in the first to the sixth specific examples, by providing the two surfaces of the separator 26 with grooves 36 or ribs 37 , it is possible to reduce or delay the amount of brazing material which flows from the inside of the tank through the separator 26 to the inner fin tube. That is, the grooves 36 or ribs 37 which are provided at the two surfaces of the separator 26 can extend the flow paths from the inside of the tank to the inner fin tube and can increase the time it takes for the brazing material to reach the inner fin tube due to the large flow resistance of the brazing material. As a result, it is possible to reduce the temperature difference from the core part before the brazing material reaches the inner fin tube, so tube melting is reduced.
- the type and thickness of the brazing material which was actually used was a brazing material with a 4 wt % to 5 wt % amount of Si and with a clad rate of 20% (since the sheet thickness t was 0.2 mm, the film thickness was 40 ⁇ m).
- a usually used 10 wt % brazing material is also possible. The invention is effective even for a tube provided with a clad rate 10% (film thickness 20 ⁇ m) or so brazing material.
- the invention is effective even for a tube with an amount of Si of the brazing material 8 at the tube surface of 3.5 wt % to 10 wt %.
- the amount of the brazing material at the tube surface is preferably 3.5 wt % to 7.5 wt %.
- a heat exchanger which employs tubes which were produced by sheet bending wherein the brazing materials which are required at the time of brazing the tubes are supplied from the outer circumferential surfaces of the tubes, so tube melting at the time of brazing the tubes to the header tanks is prevented and the productivity of the heat exchanger is improved. Further, by making the separators which are provided at the inside of the header tanks brazing material-free or by providing the separators with structures for holding the brazing materials, tube melting at the time of brazing the tubes to the header tanks is prevented. Further, by combining the above-mentioned first to third embodiments, it is possible to further reduce the tube melting at the time of brazing the tubes to the header tanks.
- tubes with inner fins at their insides were explained, but it is also possible to use tubes in which no inner fins are arranged.
- the tubes which are brazed to the header plates are tubes of structures comprised of sheet members which are folded back and are superposed at their two end parts, the brazing materials are sucked in at the superposed parts due to the capillary phenomenon, so the brazing materials easily pool near the superposed parts, but it is possible to prevent tube melting by application of the present invention.
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Abstract
Description
- The present invention relates to a parallel flow type of heat exchanger which is arranged at the front in an engine room of a vehicle and which is provided with porous tubes constituted by inner fin tubes.
- In a heat exchanger which is applied to a refrigerant condenser of an air-conditioning system for automobile use, a structure which is comprised of a plurality of porous tubes which are fabricated by extrusion and are inserted at their two sides into header plates of header tanks at predetermined intervals and which is provided with outer fins for heat dissipation use between the porous tubes and other porous tubes has been employed. However, in recent years, due to the demand for reducing costs of heat exchangers, the most costly parts, the porous tubes, are being fabricated by, instead of extrusion, sheet forming for bending belt-shaped sheet members to form tubes and providing inner fins at the insides so as to simplify the method of production, lighten the weight, and reduce the costs.
- Porous tubes which are obtained by sheet forming for bending belt-shaped sheet members to form tubes and providing inner fins at the insides are called “inner fin tubes”. A heat exchanger which employs such inner fin tubes is disclosed in PLT 1. The biggest advantages of production of inner fin tubes by sheet forming of belt-shaped sheet members are the ease of reducing weight by suitably setting the sheet thickness and the greater degree of freedom of shaping than the extrusion method and therefore the enlarged heat conduction area etc. and consequent ability to improve the heat exchange performance of the heat exchanger.
- A heat exchanger which uses the inner fin tubes which are shown in PLT 1 etc. is for use for air-conditioning systems for vehicular use. Its configuration is shown simplified in
FIG. 1 . The heat exchanger 1 is provided with acore part 2, entryside header tank 3, and exitside header tank 4 which are brazed together. Thecore part 2 is comprised of a plurality ofinner fin tubes 10 and a plurality ofouter fins 20 alternately stacked and reinforcing members constituted byside plates 25 at the end parts at the two sides in the stacking direction (up-down direction in figure). In the heat exchanger 1, the air which is blown through thecore part 2 is used to cool the refrigerant which flows through the insides of theinner fin tubes 10. - At the insides of the entry
side header tank 3 and exitside header tank 4, in this example,separators 26 are provided. At the two end parts,caps side header tank 3 and exitside header tank 4 are separated by theseparators 26 into a plurality of spaces. Further, the entryside header tank 3 has aninflow port 21 for the refrigerant, while the exitside header tank 4 has anoutflow port 22 for the refrigerant. Further, the refrigerant which flows from theinflow port 21 to the inside of the heat exchanger 1 flows through the insides of the entryside header tank 3 and exitside header tank 4 which are separated by theseparators 26 and the insides of theinner fin tubes 10 as shown by the broken lines and discharged from theoutflow part 22. Note that, the number of theinner fin tubes 10 and the number of theseparators 26 which are shown inFIG. 1 are examples and do not show the numbers and flow paths of refrigerant in an actual heat exchanger 1. -
FIG. 2 explains the configuration of the inside of aninner fin tube 10 of the heat exchanger 1 which is shown inFIG. 1 and the flow path of refrigerant which flows through the inside of it. Theinner fin tube 10 is comprised of atube 11 formed with a cross-section wave-shapedinner fin 12 inserted in it. Thetube 11 is a tube member with a horizontal cross-section of a flat shape (shape close to oval shape) perpendicular to the longitudinal direction (flow path direction of refrigerant) obtained by bending a thin (for example thickness 0.2 mm) aluminum belt-shaped sheet member. - Specifically, the
tube 11 is comprised of a belt-shaped sheet member with a center part which is bent into an arc to form acurved end part 11 a and withparallel parts 11 p which extend from thiscurved end part 11 a to form aswaged part 11 b at the end part at the opposite side from thecurved end part 11 a of theparallel parts 11 p. At this time, the two end parts of the belt-shaped sheet member are made different in lengths from thecurved end part 11 a for swaging at theswaged part 11 b. Theinner fin 12, like thetube 11, is formed in a wave shape by rolling a thin (for example thickness 0.1 mm) aluminum belt-shaped sheet and providingflat plate parts bent parts 14 of the wave parts of theinner fin 12 are brazed at theinside wall surface 13 of thetube 11, while the end part of theflat plate part 16 is brazed to theinside wall surface 14 of thecurved end part 11 a. On the other hand, the end part of theflat plate part 15 of theinner fin 12 is joined with thetube 11 by swaging at theswaged part 11 b. -
FIG. 3 shows the state of a header tank of the heat exchanger 1 which is shown inFIG. 1 , for example, the exitside header tank 4, to which theinner fin tubes 10 which are shown inFIG. 2 are connected. The exitside header tank 4 is formed by aheader plate 41 through which theinner fin tubes 10 are inserted and atank plate 42 which are joined together. The front end parts of theinner fin tubes 10 are inserted through theheader plate 41 and stick out into the space inside the exitside header tank 4.FIG. 4 is a view of the exitside header tank 4 which is shown inFIG. 3 as seen from the arrow L direction. Theheader plate 41 and thetank plate 42 are provided with a brazing material between them. The front end parts of theinner fin tubes 10 which are inserted into theheader plate 41 are brazed to theheader plate 41 by the brazing material which is arranged between theheader plate 41 and thetank plate 42. - PLT 1: Japanese Patent Publication No. 2007-125590A
- However, if brazing the front end parts of the
inner fin tubes 10 to theheader plates 41 by brazing material which is arranged between theheader plates 41 and thetank plates 42, there was the problem that the brazing material of theheader plates 41 flows into theinner fin tubes 10 and melts the tubes. Further, as shown inFIG. 5 , there was the problem that at the portions of the header tanks (here, the entry side header tank 3) provided with theseparators 26, the brazing material flows into theheader plates 31 through theseparators 26 and flows into - the
inner fin tubes 10 to melt the tubes. Here, tube melting will be explained in detail.FIG. 6 shows the vicinity of aswaged part 11 b of aninner fin tube 10 which is normally brazed. Thetube 11 hasparallel parts 11 p. The belt-shaped sheet member is bent at points at the same lengths from the not shown curved end part wherebyslanted parts 11 c are formed. Theslanted parts 11 c are bent at the parts of the belt-shaped sheet member which abut against each other. Between thelong end part 11 e and theshort end part 11 f of the belt-shaped sheet member, aflat plate part 15 of aninner fin 12 is sandwiched. In that state, theend part 11 e of the belt-shaped sheet member is folded back to theend part 11 f side to form theswaged part 11 b. In this example, theend part 15 a of theflat plate part 15 sticks out from theshort end part 11 f of the belt-shaped sheet member and is bent around theshort end part 11 f side of the belt-shaped sheet member by thelong end part 11 e of the folded back belt-shaped sheet member. - Further, the
long end part 11 e and oneslanted part 11 c of the belt-shaped sheet member are brazed together by abrazing material 51, while theflat plate part 15 of theinner fin 12 and the inside surfaces of theslanted parts 11 c are brazed together by thebrazing material 52. Further, thebent parts 14 of theinner fin 12 and theinner wall surface 13 of thetube 11 are brazed by thebrazing material 53.FIG. 7 shows theswaged part 11 b of theinner fin tube 10 which is shown inFIG. 6 and shows the state wheretube melting 5 occurs. Iftube melting 5 occurs, thetube 11 is reduced in thickness, a hole is formed in thetube 11 at the part of thetube melting 5, and refrigerant leaks out. -
FIG. 8 shows another example of aninner fin tube 10. Theinner fin tube 10 has aninner fin 12 inside of it. Thetube 11 is swaged and closed by theswaged part 11 b.FIG. 9 shows the state wheretube melting swaged part 11 b of theinner fin tube 10 which is shown inFIG. 8 . In this way, even if the shape of the inner fin tube differs, there was the problem that if brazing material is arranged at the header tank side, at the time of brazing of the inner fin tube, the brazing material passes through the header plate to flow into the inner fin tube causing tube melting. - Inflow of brazing material to the inner fin tube occurs due to the step difference at the swaged part of the tube which is formed by the bent sheet, so up to now measures have been taken such as welding together the swaged part or reducing the step difference at the swaged part. However, each of these measures leads to increased cost. Further, special steps are required where the brazing temperature has to be strictly managed. Insufficient measures have been taken against the flow of brazing material to the inside of the inner fin tube.
- The present invention, in consideration of the above problem, provides a heat exchanger which is brazed after tubes are assembled into the header tanks wherein tube melting at the time of attachment of the tubes to the header tanks can be prevented and productivity can be improved.
- To solve the above problem, the present invention provides a heat exchanger (1) which has a plurality of tubes (11) which are provided with refrigerant passages inside them and a pair of header tanks (3, 4) to which end parts of the tubes (11) are brazed, wherein brazing materials (8) which are used for brazing to the header tanks (3, 4) are arranged at the outer circumferential surfaces of the tubes (11), and the base materials of the metal sheet members which form the header tanks (3, 4) are exposed at the inner circumferential surfaces and outer circumferential surfaces of the header tanks (3, 4).
- According to the heat exchanger of the present invention, the brazing material which is necessary for brazing a tube and a header tank is supplied from the outer circumferential surface of the tube, so tube melting at the time of brazing is prevented, and the heat exchanger is improved in productivity.
- Further, reference notations attached above are examples which show the correspondence with specific examples of the later explained embodiments.
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FIG. 1 is a front view which shows the streamlined configuration of a heat exchanger of the comparative art. -
FIG. 2 is a perspective view which shows an inner fin tube which is used at the heat exchanger which is shown inFIG. 1 . -
FIG. 3 is a partial perspective view of a heat exchanger which shows the state where inner fin tubes which are shown inFIG. 2 are connected to a header plate of a header tank of the heat exchanger which is shown inFIG. 1 . -
FIG. 4 is a cross-sectional view of the header tank which is shown inFIG. 3 as seen from an arrow L direction. -
FIG. 5 is a partial perspective view which shows the state where the brazing material of the tank plate flows into the header plate through a separator and the brazing material flows into an inner fin tube. -
FIG. 6 is a partial enlarged cross-sectional view which shows a swaged part of an inner fin tube which is normally brazed. -
FIG. 7 is a partial enlarged cross-sectional view which shows the state where tube melting occurs at the swaged part of the inner fin tube which is shown inFIG. 6 . -
FIG. 8 is a cross-sectional view which shows another example of an inner fin tube. -
FIG. 9 is a partial enlarged cross-sectional view which shows the state where tube melting occurs at the swaged part of the inner fin tube which is shown inFIG. 8 . -
FIG. 10 is a cross-sectional view of an inner fin tube of a first embodiment of the present invention. -
FIG. 11 is a partial enlarged cross-sectional view which shows a part of a swaged part of the inner fin tube ofFIG. 10 . -
FIG. 12A is a cross-sectional view of a brazing material-free header plate and tank plate which are used for an inner fin tube and heat exchanger of the first embodiment of the present invention,FIG. 12B is a cross-sectional view of a modification of the first embodiment where there is a sacrificial material at the outside of the header plate of the brazing material-free header plate and tank plate which are shown inFIG. 12A ,FIG. 12C is a partial perspective view of a heat exchanger which shows an embodiment of providing a brazing material at one surface of a separator of an entry side and exit side header tank which is provided with a brazing material-free header plate and tank plate,FIG. 12D is a cross-sectional view of an embodiment where the entry side and exit side header tanks are one-piece bodies and have cross-sections of circular shapes,FIG. 12E is a cross-sectional view of an embodiment where the entry side and exit side header tanks are one-piece bodies and have cross-sections of oval shapes,FIG. 12F is a cross-sectional view of an embodiment where the entry side and exit side header tanks are one-piece bodies and have cross-sections of irregular shapes, andFIG. 12G is an enlarged view of a principal part X ofFIG. 12B . -
FIG. 13 is an assembled perspective view of a header plate and a brazing material-free separator which is used for the same which shows a second embodiment of the present invention. -
FIG. 14 is an assembled perspective view of a header plate and a brazing material-free separator which is used for the same which shows a modification of the second embodiment of the present invention. -
FIG. 15 is a side cross-sectional view and front view of a first specific example of a separator of a third embodiment of the present invention. -
FIG. 16 is a side cross-sectional view and front view of a second specific example of a separator of a third embodiment of the present invention. -
FIG. 17 is a front view of a third specific example of a separator of a third embodiment of the present invention. -
FIG. 18 is a front view of a fourth specific example of a separator of a third embodiment of the present invention. -
FIG. 19 is a front view of a fifth specific example of a separator of a third embodiment of the present invention. -
FIG. 20 is a front view of a sixth specific example of a separator of a third embodiment of the present invention. - Below, referring to the drawings, embodiments of the present invention will be explained. In the embodiments, parts which are configured the same are assigned the same reference notations and explanations will be omitted. Parts of the embodiments of the present invention which are the same in configuration as the comparative art forming the basis of the present invention are assigned the same reference notations and explanations are omitted.
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FIG. 10 shows aninner fin tube 10 of a first embodiment of the present invention. Further,FIG. 11 shows a part X ofFIG. 10 enlarged. Aninner fin tube 10 is comprised of a belt-shaped sheet member which is folded back to hold aninner fin 12 inside of it. The belt-shaped sheet member is formed by thin (for example thickness 0.2 mm) aluminum. It is folded back into an arc shape at a portion at slightly different distances from the two end parts to form acurved end part 11 a. The belt-shaped sheet member is folded back until becoming parallel to formparallel parts 11 p. The two end parts of the belt-shaped sheet member are bent at portions of the same distance from thecurved end part 11 a to form predetermined lengths ofslanted parts 11 c, then are further bent so that the two end parts become parallel. - The belt-shaped sheet member is folded back as explained above to form the
flat tube 11. At the inside, aninner fin 12 is housed whereby a flat shaped flow path of the medium is formed. Theinner fin 12 is formed into a wave shape by rolling a thin (for example thickness 0.1 mm) aluminum belt-shaped sheet member in the same way as thetube 11. At the two end parts,flat plate parts bent parts 14 of the wave shaped parts of theinner fin 12 are brazed to theinside wall surface 13 of thetube 11. The end part of theflat plate part 16 is also brazed to theinside wall surface 13 of thecurved end part 11 a. On the other hand, the end part of the otherflat plate part 15 of theinner fin 12 is sandwiched between the two end parts bent to become parallel. - The two
end parts flat plate part 15 of theinner fin 12 in the first embodiment become longer at theend part 11 e than theend part 11 f. Accordingly, theend part 11 e is folded back to theend part 11 f side in a state sandwiching theflat plate part 15 and theend part 11 f and is swaged to join them whereby the swagedpart 11 b is formed. In the first embodiment, abrazing material 8 is arranged (clad) at the outer surface as a whole at the thus formedinner fin tube 10. The amount of thisbrazing material 8 becomes an amount which is required for brazing theinner fin tube 10 to the entry side and exitside header tanks inner fin tube 10, as shown inFIG. 3 , to the entry side and exitside header tanks - In this case, the inner circumferential surfaces N and outer circumferential surfaces S of the
header plates side header tank 3 and the exitside header tank 4, as shown inFIG. 12A , are made brazing material-free. That is, the metal sheet members which form theheader plates inner fin tube 10 to the entry side and exitside header tanks brazing material 8 which was clad at the outer surface of the inner fin tube 10 (seeFIG. 10 andFIG. 11 ). The brazing material is not present at thetank plates tank plates inner fin tube 10 and the tube melting of theinner fin tube 10 no longer occurs. As a result, the stability at the time of brazing theinner fin tube 10 is improved and the scope of application of the brazing temperature can be broadened. - As explained above, the brazing material which flows to the inside of the
inner fin tube 10 is a sufficient amount ofbrazing material 8 which is clad over the entire outer surface of theinner fin tube 10. For this reason, the amount of the brazing material which is supplied to the brazing part of theinner fin tube 10 becomes sufficient, and the brazing fillet of theinner fin tube 10 can be made larger. Further, a fillet commensurate with the amount of brazing material of the part itself is formed and the brazeability of parts other than theinner fin tube 10 is also improved. - Here, consider the case of the comparative art where the brazing material which is at the entry side and exit
side header tanks inner fin tube 10 and where the brazing material which is at the entry side and exitside header tanks inner fin tube 10 are connected. In this case, the size of the fillet radius of the fillet which is formed at theinner fin 12 and the size of the fillet radius which is formed at thetank plate 32 andheader plate 31 become substantially equal. However, in this case, the amounts of brazing material at the entry side and exitside header tanks tank plate 32 andheader plate 31 ends up becoming the same 0.1 mm or so as the fillet radius of the fillet which is formed at theinner fin 12. That is, sometimes the size of the fillet radius which is formed at thetank plate 32 and theheader plate 31 is extremely small and the gap at the part requiring brazing cannot be filled resulting in leakage. - As opposed to this, if making the inner circumferential surfaces N and outer circumferential surfaces S of the
header plates tank plate 32 andheader plate 31 and the brazing material of thefillet inner fin 12 can be broken. As a result, it is possible to form a large fillet at the joint of thetank plate 32 andheader plate 31 or the joint of thetank plate 32 and acap 24. That is, it is possible to form a large fillet of the fillet radius 0.3 mm to 0.6 mm or so which can inherently be obtained at the joint of thetank plate 32 andheader plate 31 or the joint of thetank plate 32 and acap 24, the gap can be easily filled, and the brazeability can be improved. Note that, the “size of the fillet radius” which is referred to here envisions the case of using the generally widely used brazing material with 10 wt % of amount of Si. - Further, the surface of the
inner fin tube 10 sometimes has an anticorrosion layer or sacrificial brazing material on which the brazing material layer is superposed arranged on it, but by making theheader plates side header tanks inner fin tube 10 is also prevented. The brazing material ends up obstructing the action of the anticorrosion layer, so by preventing the flow of brazing material to the surface of theinner fin tube 10, it is possible to improve the corrosion resistance of theinner fin tube 10. - Further, it is possible to use as the material of the
header plates 31 and 41 a metal material which does not contain a brazing material and provide the inner circumferential surfaces N or outer circumferential surfaces S of theheader plates FIG. 12B shows an embodiment which provides the outer circumferential surfaces S of theheader plates FIG. 12G , as theheader plates header plates sacrificial material 9. Furthermore, as shown inFIG. 12C , theheader plates separators 26 may be provided with thebrazing material 8. InFIG. 12C , thebrazing material 8 are shown shaded. - Still further, the inner circumferential surfaces N and outer circumferential surfaces S of the entry side and exit
side header tanks side header tanks piece pipes 30 not split intoheader plates tank plates piece pipes 30 which are used for the entry side and exitside header tanks FIG. 12D , the oval shape which is shown inFIG. 12E , and the irregular shape which is shown inFIG. 12F . Further, even when the entry side and exitside header tanks piece pipes 30, the materials which form the tanks may be exposed single layer types and may be provided at least at one of the inner circumferential surfaces N and outer circumferential surfaces S of thepipes 30 with a low potential sacrificial material (anticorrosion layer) 9. In the entry side and exitside header tanks FIG. 12D toFIG. 12F , the inner circumferential surface N of thepipe 30 which is shown inFIG. 12E is provided with thesacrificial material 9, while the outer circumferential surface S of thepipe 30 which is shown inFIG. 12F is provided with thesacrificial material 9. - Note that, in the entry side and exit
side header tanks FIG. 12D toFIG. 12F as well, the outer circumferential surface S of thepipe 30 which is shown inFIG. 12E may be provided with the sacrificial material and the inner circumferential surface N of thepipe 30 which is shown inFIG. 12F may be provided with thesacrificial material 9 needless to say. Whether thesacrificial material 9 is provided at the inner circumferential surface N of thepipe 30 or is provided at the outer circumferential surface S does not depend on the shape and structure of thepipe 30. Further, both of the inner circumferential surface N and the outer circumferential surface S of thepipe 30 may be provided with thesacrificial material 9. -
FIG. 13 shows a second embodiment of the heat exchanger of the present invention. In the second embodiment, the entryside header plate 31 and the exitside header plate 41 are made brazing material-free, and theseparator 26 which is attached as a partition wall at the inside of the entryside header tank 3 and the exitside header tank 4 is made brazing material-free. Theseparator 26 of the second embodiment is used in the case of a structure where theheader plates side header tank 3 and hole 43 at exit side header tank 4). That is, the metal sheet member which forms theseparator 26 is made the exposed sheet member (bare material) where no brazing material is provided. - In the case of this arrangement, the
header plates separator 26 are brazing material-free, but brazing material which is arranged at thetank plates header plates separator 26 can be brazed. Tank brazing material flows through the fine clearances between theseparator 26 andheader plates tank plates -
FIG. 14 shows a modification of theseparator 26 of the second embodiment of the present invention which is shown inFIG. 13 . Theseparator 26 of the modification is used in the case of a structure with grooves 34 and 44 at the two sides of theheader plates 31 and 41 (groove 34 at entryside header tank 3 and groove 44 at exit side header tank 4). In the modification of the second embodiment as well, the metal sheet member which forms theseparator 26 is made the exposed sheet member (bare material) where no brazing material is provided. Further, in the modification of the second embodiment, the holes at theheader plates separator 26 at the two sides of theheader plates header plates - If, in this way, making the metal sheet member which forms the separator 26 a sheet member with the base material exposed and not providing a brazing material, that is, making it brazing material-free, it is possible to cut the flow paths of brazing material to the
header plates -
FIG. 15 toFIG. 17 show the configurations ofseparators 26 of a third embodiment of the heat exchanger of the present invention. The figures give cross-sectional views and front views ofseparator 26. The third embodiment provides the two surfaces of theseparator 26 with structures for holding the brazing material in the case where the two surfaces of the entryside header tank 3 or exitside header tank 4 are provided with brazing material and thereby prevents the inflow of the brazing material to theinner fin tubes 10. -
FIG. 15 shows a first specific example of theseparator 26. Aseparator 26 of the same type as theseparator 26 which was explained inFIG. 13 is shown. In the first specific example of theseparator 26, the two surfaces of theseparator 26 are provided with a plurality ofparallel grooves 27.FIG. 16 shows a second specific example of theseparator 26. Aseparator 26 of the same type as theseparator 26 which was explained inFIG. 13 is shown. In the second specific example of theseparator 26, the two surfaces of theseparator 26 are provided with a plurality ofcircular depressions 28 which are regularly arranged to the top and bottom and the left and right. Thesedepressions 28 serve as brazing reservoirs in which melted brazing material is held. Thedepressions 28 may also be provided irregularly arranged.FIG. 17 shows a third specific example of theseparator 26. Aseparator 26 of the same type as theseparator 26 which was explained inFIG. 13 is shown. In the third specific example of theseparator 26, the two surfaces of theseparator 26 are provided with a plurality ofoval depressions 29 which are regularly arranged to the top and bottom and the left and right.Oval depressions 29 may also be provided irregularly arranged. - If in this way providing the two surfaces of the
separator 26 with grooves or holes, even if the two surfaces of the entryside header tank 3 and the exitside header tank 4 are provided with brazing material, the excess brazing material can be held at the grooves or holes and flow of excess brazing material to the header plate side can be prevented. As a result, excess brazing material no longer flows into the inner fin tubes and tube melting can be prevented. -
FIG. 18 toFIG. 20 show fourth to sixth specific examples of theseparator 26 of the third embodiment of the heat exchanger of the present invention. In the fourth specific example which is shown inFIG. 18 , the two surfaces of theseparator 26 are provided at a slant withgrooves 35 which cut the brazing material flow paths. Thegrooves 35 are provided at theseparator 26 asymmetrically. Thegrooves 35 may also be ribs. In the fifth specific example which is shown inFIG. 19 , the two surfaces of theseparator 26 are provided withgrooves 36 which cut the brazing material flow path at an angle symmetrically with respect to the centerline of theseparator 26. Thegrooves 36 may also be ribs. In the sixth specific example which is shown inFIG. 20 , the two surfaces of theseparator 26 are provided with not only thegrooves 36 which were explained in the fifth example, but alsoribs 37 which cut the brazing material flow paths at an angle symmetrically with respect to the centerline of theseparator 26. Theribs 37 may also be grooves. - The brazing material which causes tube melting flows to an inner fin tube through a brazing part of a
separator 26 and an inside of a tank. Therefore, as shown in the first to the sixth specific examples, by providing the two surfaces of theseparator 26 withgrooves 36 orribs 37, it is possible to reduce or delay the amount of brazing material which flows from the inside of the tank through theseparator 26 to the inner fin tube. That is, thegrooves 36 orribs 37 which are provided at the two surfaces of theseparator 26 can extend the flow paths from the inside of the tank to the inner fin tube and can increase the time it takes for the brazing material to reach the inner fin tube due to the large flow resistance of the brazing material. As a result, it is possible to reduce the temperature difference from the core part before the brazing material reaches the inner fin tube, so tube melting is reduced. - In the embodiments which were explained above, the type and thickness of the brazing material which was actually used was a brazing material with a 4 wt % to 5 wt % amount of Si and with a clad rate of 20% (since the sheet thickness t was 0.2 mm, the film thickness was 40 μm). However, in the present invention, as the brazing material which is clad at the tube surface, a usually used 10 wt % brazing material is also possible. The invention is effective even for a tube provided with a clad
rate 10% (film thickness 20 μm) or so brazing material. That is, the invention is effective even for a tube with an amount of Si of thebrazing material 8 at the tube surface of 3.5 wt % to 10 wt %. However, the amount of the brazing material at the tube surface is preferably 3.5 wt % to 7.5 wt %. - As explained above, in the present invention, there is provided a heat exchanger which employs tubes which were produced by sheet bending wherein the brazing materials which are required at the time of brazing the tubes are supplied from the outer circumferential surfaces of the tubes, so tube melting at the time of brazing the tubes to the header tanks is prevented and the productivity of the heat exchanger is improved. Further, by making the separators which are provided at the inside of the header tanks brazing material-free or by providing the separators with structures for holding the brazing materials, tube melting at the time of brazing the tubes to the header tanks is prevented. Further, by combining the above-mentioned first to third embodiments, it is possible to further reduce the tube melting at the time of brazing the tubes to the header tanks.
- Note that, in the above-mentioned embodiments, examples of using tubes with inner fins at their insides as the tubes which were brazed to the header plates were explained, but it is also possible to use tubes in which no inner fins are arranged. In particular, if the tubes which are brazed to the header plates are tubes of structures comprised of sheet members which are folded back and are superposed at their two end parts, the brazing materials are sucked in at the superposed parts due to the capillary phenomenon, so the brazing materials easily pool near the superposed parts, but it is possible to prevent tube melting by application of the present invention.
- Further, in the above-mentioned embodiments, the example of use of aluminum as the material of the inner fin tubes and inner fins was explained, but in all of the above embodiments, it is possible to use aluminum alloy as the material of the inner fin tubes and inner fins.
Claims (21)
Applications Claiming Priority (5)
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JP2012085849 | 2012-04-04 | ||
JP2012-085849 | 2012-04-04 | ||
JP2013-077780 | 2013-04-03 | ||
JP2013077780A JP6197338B2 (en) | 2012-04-04 | 2013-04-03 | Heat exchanger |
PCT/JP2013/060354 WO2013151138A1 (en) | 2012-04-04 | 2013-04-04 | Heat exchanger |
Related Parent Applications (1)
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PCT/JP2013/060354 A-371-Of-International WO2013151138A1 (en) | 2012-04-04 | 2013-04-04 | Heat exchanger |
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US16/285,981 Division US20190186849A1 (en) | 2012-04-04 | 2019-02-26 | Parallel Flow Type Heat Exchanger |
Publications (1)
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US20150292817A1 true US20150292817A1 (en) | 2015-10-15 |
Family
ID=49300616
Family Applications (2)
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US14/390,003 Abandoned US20150292817A1 (en) | 2012-04-04 | 2013-04-04 | Heat exchanger |
US16/285,981 Abandoned US20190186849A1 (en) | 2012-04-04 | 2019-02-26 | Parallel Flow Type Heat Exchanger |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US16/285,981 Abandoned US20190186849A1 (en) | 2012-04-04 | 2019-02-26 | Parallel Flow Type Heat Exchanger |
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US (2) | US20150292817A1 (en) |
JP (1) | JP6197338B2 (en) |
CN (1) | CN104204709B (en) |
DE (1) | DE112013001903T5 (en) |
WO (1) | WO2013151138A1 (en) |
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US20210307198A1 (en) * | 2020-03-27 | 2021-09-30 | Auras Technology Co., Ltd. | Liquid cooling module and its liquid cooling head |
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US20220381515A1 (en) * | 2019-11-28 | 2022-12-01 | Mitsubishi Electric Corporation | Heat exchanger and air-conditioning apparatus |
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Also Published As
Publication number | Publication date |
---|---|
CN104204709B (en) | 2017-10-27 |
JP2013231579A (en) | 2013-11-14 |
DE112013001903T5 (en) | 2015-01-08 |
CN104204709A (en) | 2014-12-10 |
JP6197338B2 (en) | 2017-09-20 |
US20190186849A1 (en) | 2019-06-20 |
WO2013151138A1 (en) | 2013-10-10 |
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