JP2008012378A - Application method of flux, manufacturing method of flat pipe and manufacturing equipment for semifinished flat pipe - Google Patents
Application method of flux, manufacturing method of flat pipe and manufacturing equipment for semifinished flat pipe Download PDFInfo
- Publication number
- JP2008012378A JP2008012378A JP2006183289A JP2006183289A JP2008012378A JP 2008012378 A JP2008012378 A JP 2008012378A JP 2006183289 A JP2006183289 A JP 2006183289A JP 2006183289 A JP2006183289 A JP 2006183289A JP 2008012378 A JP2008012378 A JP 2008012378A
- Authority
- JP
- Japan
- Prior art keywords
- flat
- wall forming
- wall
- base plate
- forming portion
- 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.)
- Granted
Links
- 230000004907 flux Effects 0.000 title claims abstract description 76
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 53
- 238000000034 method Methods 0.000 title claims description 24
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 109
- 229910052751 metal Inorganic materials 0.000 claims abstract description 85
- 239000002184 metal Substances 0.000 claims abstract description 85
- 238000005452 bending Methods 0.000 claims abstract description 43
- 239000000725 suspension Substances 0.000 claims abstract description 39
- 239000007788 liquid Substances 0.000 claims abstract description 12
- 238000005219 brazing Methods 0.000 claims description 46
- 239000011265 semifinished product Substances 0.000 claims description 33
- 238000000576 coating method Methods 0.000 claims description 18
- 238000010438 heat treatment Methods 0.000 claims description 18
- 239000007769 metal material Substances 0.000 claims description 16
- 229910052782 aluminium Inorganic materials 0.000 claims description 14
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 14
- 239000000945 filler Substances 0.000 claims description 13
- 239000011248 coating agent Substances 0.000 claims description 12
- 238000005520 cutting process Methods 0.000 claims description 9
- 230000002787 reinforcement Effects 0.000 claims description 9
- 230000015572 biosynthetic process Effects 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 8
- 238000009423 ventilation Methods 0.000 claims description 4
- 230000004323 axial length Effects 0.000 claims description 3
- 238000003384 imaging method Methods 0.000 claims description 3
- 230000008016 vaporization Effects 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 239000000047 product Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 230000009972 noncorrosive effect Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
Images
Landscapes
- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
Description
この発明は、たとえば車両のカーエアコンに組み込まれるヒータコアとして好適に用いられる熱交換器の扁平管を製造する際に適用されるフラックスの塗布方法、扁平管の製造方法および扁平管半製品の製造装置に関する。 The present invention relates to a flux application method, a flat tube manufacturing method, and a flat tube semi-finished product manufacturing apparatus that are applied when manufacturing a flat tube of a heat exchanger suitably used as, for example, a heater core incorporated in a car air conditioner of a vehicle. About.
この明細書および特許請求の範囲において、「アルミニウム」という用語には、純アルミニウムの他にアルミニウム合金を含むものとする。 In this specification and claims, the term “aluminum” includes aluminum alloys in addition to pure aluminum.
エンジン冷却用の温水を用いて車室内を暖房するカーエアコン用ヒータコアとしては、互いに間隔をおいて配置された１対のヘッダタンクと、両ヘッダタンク間に、幅方向が通風方向を向くようにヘッダタンクの長さ方向に間隔をおいて配置され、かつ両端部が両ヘッダタンクに接続された複数の扁平管と、隣り合う扁平管どうしの間に配置されたコルゲートフィンとを備えた熱交換器が広く用いられている。 As a heater core for a car air conditioner that heats the vehicle interior using warm water for cooling the engine, a pair of header tanks spaced apart from each other and a width direction between the header tanks are directed to the ventilation direction. Heat exchange comprising a plurality of flat tubes arranged at intervals in the length direction of the header tank and having both ends connected to both header tanks and corrugated fins arranged between adjacent flat tubes A bowl is widely used.
従来、このような熱交換器の扁平管としては、たとえば互いに対向する１対の平坦壁と、両平坦壁の両側縁どうしに跨る２つの側壁と、両平坦壁の幅方向の中間部どうしに跨る補強壁とを備えたものが用いられている（特許文献１参照）。 Conventionally, as a flat tube of such a heat exchanger, for example, a pair of flat walls facing each other, two side walls straddling both side edges of both flat walls, and intermediate portions in the width direction of both flat walls are used. The thing provided with the reinforcement wall which straddles is used (refer patent document 1).
特許文献１記載の扁平管は、一方の平坦壁を形成する１つの第１平坦壁形成部、第１平坦壁形成部の両側縁に設けられかつ側壁を形成する２つの側壁形成部、両側壁形成部における第１平坦壁形成部とは反対側の側縁に設けられかつ他方の平坦壁を形成する２つの第２平坦壁形成部、および両第２平坦壁形成部における側壁形成部とは反対側の側縁に設けられかつ補強壁を形成する２つの補強壁形成部を有し、かつ片面にろう材層を有する１枚の金属素板を用意し、金属素板の両補強壁形成部を第２平坦壁形成部に対して同方向に曲げて補強壁用凸条を形成した後、両第２平坦壁形成部が第１平坦壁形成部に対して平行となるように、金属素板を両側壁形成部において曲げることにより、いずれか一方の補強壁用凸条を第１平坦壁形成部の内面に当接させるとともに、両補強壁用凸条どうしを係合させて折り曲げ体をつくり、ついで折り曲げ体を予め決められた長さに切断して扁平管半製品を形成し、その後少なくともいずれか一方の補強壁用凸条と第１平坦壁形成部および両補強壁用凸条どうしを、金属素板のろう材層を利用してろう付し、第１平坦壁形成部と両第２平坦壁形成部とにより１対の平坦壁を形成し、両側壁形成部により両側壁を形成し、さらに両補強壁用凸条により補強壁を形成することを含む方法により製造される。 The flat tube described in Patent Document 1 includes one first flat wall forming portion that forms one flat wall, two side wall forming portions that are provided on both side edges of the first flat wall forming portion and that form side walls, and both side walls. What are two second flat wall forming portions provided on the side edge of the forming portion opposite to the first flat wall forming portion and forming the other flat wall, and sidewall forming portions in both second flat wall forming portions? One metal base plate having two reinforcing wall forming portions provided on opposite side edges and forming a reinforcing wall and having a brazing filler metal layer on one side is prepared, and both reinforcing walls of the metal base plate are formed. After the portion is bent in the same direction with respect to the second flat wall forming portion to form the reinforcing wall ridge, the metal is formed so that both the second flat wall forming portions are parallel to the first flat wall forming portion. By bending the base plate at both side wall forming portions, either one of the reinforcing wall ridges can be inserted into the first flat wall forming portion. To make a bent body by engaging the two reinforcing wall projections, then cut the bent body into a predetermined length to form a flat tube semi-finished product, and then at least one of them The reinforcing wall ridges, the first flat wall forming portion and the two reinforcing wall ridges are brazed using the brazing material layer of the metal base plate, and the first flat wall forming portion and the two second flat walls are brazed. A pair of flat walls are formed by the forming portion, both side walls are formed by the both side wall forming portions, and a reinforcing wall is further formed by the convexes for both reinforcing walls.
ところで、特許文献１記載の方法で扁平管を製造する際には、金属素板の第１平坦壁形成部内面におけるいずれか一方の補強壁用凸条が当接する部分に、フラックスを塗布する必要がある。フラックスは、通常、粉末状のものを水に懸濁させてなるフラックス懸濁液の状態で塗布されるが、この場合、フラックス懸濁液が垂れ流れることにより、不要な部分にも付着するという問題がある。 By the way, when manufacturing a flat tube by the method of patent document 1, it is necessary to apply | coat a flux to the part which the protruding item | line for one reinforcement wall in the 1st flat wall formation part inner surface of a metal base plate contacts. There is. The flux is usually applied in the form of a flux suspension obtained by suspending a powdery material in water. In this case, the flux suspension hangs down and adheres to unnecessary portions. There's a problem.
そこで、このような問題を改善したフラックスの塗布方法として、金属部材を加熱した後、フラックス懸濁液を散布する方法が提案されている（特許文献２参照）。 Thus, as a flux coating method that has improved such problems, a method of spreading a flux suspension after heating a metal member has been proposed (see Patent Document 2).
しかしながら、この方法でも、規定された塗布範囲および塗布量となるようにフラックスを正確に塗布することが困難であった。特に、特許文献１記載の扁平管の製造の際に、特許文献２記載の方法でフラックスを塗布した場合、過剰なフラックスが塗布されるとろう付後にフラックスが内部異物となるため、内部異物の量が多くなって流通抵抗が増大し、熱交換器用の扁平管としての性能が低下するという問題がある。
この発明の目的は、上記問題を解決し、規定された塗布範囲および塗布量となるようにフラックスを比較的正確に塗布しうるフラックスの塗布方法、扁平管の製造方法および扁平管半製品の製造装置を提供することにある。 An object of the present invention is to solve the above-mentioned problems and to apply a flux relatively accurately so as to achieve a prescribed application range and application amount, a method for manufacturing a flat tube, and a method for manufacturing a flat tube semi-finished product To provide an apparatus.
本発明は、上記目的を達成するために以下の態様からなる。 In order to achieve the above object, the present invention comprises the following aspects.
1)金属材に連続的にフラックスを塗布する方法であって、金属材を加熱した後、加熱された金属材にロールコータによりフラックス懸濁液を塗布し、金属材の有する熱によりフラックス懸濁液の液状成分を気化させることを含むフラックスの塗布方法。 1) A method in which a flux is continuously applied to a metal material. After the metal material is heated, a flux suspension is applied to the heated metal material by a roll coater, and the flux suspension is applied by the heat of the metal material. A method for applying a flux comprising vaporizing a liquid component of a liquid.
2)フラックス懸濁液の濃度が１０〜２０質量％である上記1)記載のフラックスの塗布方法。 2) The flux coating method according to 1) above, wherein the concentration of the flux suspension is 10 to 20% by mass.
3)金属材の加熱を、金属材の実体温度が１５０℃以上となるように行う上記1)または2)記載のフラックスの塗布方法。 3) The flux coating method according to 1) or 2) above, wherein the metal material is heated so that the substantial temperature of the metal material is 150 ° C. or higher.
4)互いに対向する１対の平坦壁と、両平坦壁の両側縁どうしに跨る２つの側壁と、両平坦壁の幅方向の中間部どうしに跨る補強壁とを備えた熱交換器用扁平管を製造する方法であって、一方の平坦壁を形成する１つの第１平坦壁形成部、第１平坦壁形成部の両側縁に設けられかつ側壁を形成する２つの側壁形成部、両側壁形成部における第１平坦壁形成部とは反対側の側縁に設けられかつ他方の平坦壁を形成する２つの第２平坦壁形成部、および両第２平坦壁形成部における側壁形成部とは反対側の側縁に設けられかつ補強壁を形成する２つの補強壁形成部を有する１枚の金属素板を用意し、金属素板の両補強壁形成部を第２平坦壁形成部に対して同方向に曲げて補強壁用凸条を形成した後、両第２平坦壁形成部が第１平坦壁形成部に対して平行となるように、金属素板を両側壁形成部において曲げることにより、少なくともいずれか一方の補強壁用凸条を第１平坦壁形成部の内面に当接させるとともに、両補強壁用凸条どうしを係合させて折り曲げ体をつくり、ついで折り曲げ体を予め決められた長さに切断して扁平管半製品を形成した後少なくともいずれか一方の補強壁用凸条と第１平坦壁形成部および両補強壁用凸条どうしをろう付し、第１平坦壁形成部と両第２平坦壁形成部とにより１対の平坦壁を形成し、両側壁形成部により両側壁を形成し、さらに両補強壁用凸条により補強壁を形成することを含む扁平管の製造方法において、
金属素板から折り曲げ体を得るまでの間に、金属素板を加熱し、加熱された金属素板の第１平坦壁形成部の内面における少なくともいずれか一方の補強壁用凸条をろう付する部分に、ロールコータによりフラックス懸濁液を塗布し、金属素板の有する熱によりフラックス懸濁液の液状成分を気化させることを特徴とする扁平管の製造方法。
4) A flat tube for a heat exchanger comprising a pair of flat walls facing each other, two side walls straddling both side edges of both flat walls, and a reinforcing wall straddling the middle part in the width direction of both flat walls. A method of manufacturing, one first flat wall forming part forming one flat wall, two side wall forming parts provided on both side edges of the first flat wall forming part and forming side walls, both side wall forming parts Two second flat wall forming portions provided on the side edge opposite to the first flat wall forming portion and forming the other flat wall, and opposite side wall forming portions in both second flat wall forming portions A metal base plate having two reinforcing wall forming portions that are provided on the side edges of the metal base plate and that forms the reinforcing wall is prepared, and both the reinforcing wall forming portions of the metal base plate are identical to the second flat wall forming portion. After forming the reinforcing wall projections by bending in the direction, both the second flat wall forming portions are in relation to the first flat wall forming portion. By bending the metal base plate at both side wall forming portions so as to form a row, at least one of the reinforcing wall protruding portions is brought into contact with the inner surface of the first flat wall forming portion, and both reinforcing wall protruding portions After forming a bent body by engaging each other and then cutting the bent body into a predetermined length to form a flat tube semi-finished product, at least one of the ridges for reinforcing wall and the first flat wall forming portion And brazing the ridges for both reinforcing walls, forming a pair of flat walls with the first flat wall forming portion and the two second flat wall forming portions, forming both side walls with the both side wall forming portions, In a method for manufacturing a flat tube, including forming a reinforcing wall with both reinforcing wall projections,
Before obtaining the bent body from the metal base plate, the metal base plate is heated, and at least one of the reinforcing wall projections on the inner surface of the first flat wall forming portion of the heated metal base plate is brazed. A method for producing a flat tube, wherein a flux suspension is applied to a portion by a roll coater, and a liquid component of the flux suspension is vaporized by heat of a metal base plate.
5)フラックス懸濁液の濃度が１０〜２０質量％である上記4)記載の扁平管の製造方法。 5) The method for producing a flat tube as described in 4) above, wherein the concentration of the flux suspension is 10 to 20% by mass.
6)金属素板の加熱を、金属素板の実体温度が１５０℃以上となるように行う上記4)または5)記載の扁平管の製造方法。 6) The method for producing a flat tube as described in 4) or 5) above, wherein the heating of the metal base plate is performed so that the substantial temperature of the metal base plate is 150 ° C. or higher.
7)折り曲げ体の状態において、補強壁用凸条が第２平坦壁形成部と直角をなす平板状であり、両補強壁用凸条の先端に、それぞれ補強壁用凸条と直角をなす屈曲部が形成されており、補強壁用凸条どうしが密着させられているとともに、両屈曲部が第１平坦壁形成部の内面に密着させられている上記4)〜6)のうちのいずれかに記載の扁平管の製造方法。 7) In the state of the bent body, the reinforcing wall ridges have a flat plate shape perpendicular to the second flat wall forming portion, and the ends of both reinforced wall ridges are bent at right angles to the reinforcing wall ridges, respectively. Any one of the above 4) to 6), in which the portion is formed, the protruding ridges for reinforcing walls are in close contact with each other, and both bent portions are in close contact with the inner surface of the first flat wall forming portion A method for producing a flat tube as described in 1. above.
8)金属素板の補強壁形成部の先端部を、金属素板と直角をなすように同方向に曲げて屈曲部を形成しておき、その後両補強壁形成部を第２平坦壁形成部に対して同方向に曲げて補強壁用凸条を形成する上記7)記載の扁平管の製造方法。 8) The bending portion is formed by bending the tip of the reinforcing wall forming portion of the metal base plate in the same direction so as to make a right angle to the metal base plate, and then both reinforcing wall forming portions are the second flat wall forming portion. The method for producing a flat tube according to 7) above, wherein the reinforcing wall projection is formed by bending in the same direction.
9)補強壁用凸条を形成した後に続く金属素板の両側壁形成部での曲げを途中で停止することにより、両補強壁用凸条間の間隔がロールコータにおける塗布ロールの軸方向の長さよりも大きくなっている折り曲げ中間体を形成し、この折り曲げ中間体の状態において、第１平坦壁形成部の内面にフラックス懸濁液を塗布する上記4)〜8)のうちのいずれかに記載の扁平管の製造方法。 9) By stopping the bending at both side wall forming portions of the metal base plate that follows the formation of the reinforcing wall ridges, the interval between the two reinforcing wall ridges is reduced in the axial direction of the coating roll in the roll coater. A folding intermediate body that is larger than the length is formed, and in this folded intermediate body, the flux suspension is applied to the inner surface of the first flat wall forming portion. The manufacturing method of the flat tube of description.
10)金属素板からの折り曲げ中間体の成形、および折り曲げ中間体からの折り曲げ体の成形を、それぞれロールフォーミング法により行う上記9)記載の扁平管の製造方法。 10) The method for producing a flat tube as described in 9) above, wherein the forming of the bent intermediate body from the metal base plate and the forming of the bent body from the bent intermediate body are each performed by a roll forming method.
11)金属素板が、片面にろう材層を有するアルミニウムブレージングシートからなり、ろう材層を持たない面にフラックス懸濁液を塗布する上記4)〜10)のうちのいずれかに記載の扁平管の製造方法。 11) The flat plate according to any one of 4) to 10) above, wherein the metal base plate is composed of an aluminum brazing sheet having a brazing filler metal layer on one side, and a flux suspension is applied to a surface not having the brazing filler metal layer. A method of manufacturing a tube.
12)扁平管半製品における少なくともいずれか一方の補強壁用凸条と第１平坦壁形成部とのろう付および両補強壁用凸条どうしのろう付を、熱交換器の製造の際の熱交換器形成部品のろう付と同時に行う上記4)〜11)のうちのいずれかに記載の扁平管の製造方法。 12) At the time of manufacturing the heat exchanger, brazing between at least one of the reinforcing wall projections and the first flat wall forming portion and between the reinforcing wall projections in the flat tube semi-finished product. The method for producing a flat tube according to any one of the above 4) to 11), which is performed simultaneously with brazing of the exchanger forming part.
13)互いに対向する１対の平坦壁と、両平坦壁の両側縁どうしに跨る２つの側壁と、両平坦壁の幅方向の中間部どうしに跨る補強壁とを備えた熱交換器用扁平管を製造する方法であって、一方の平坦壁を形成する１つの第１平坦壁形成部、第１平坦壁形成部の両側縁に設けられかつ側壁を形成する２つの側壁形成部、両側壁形成部における第１平坦壁形成部とは反対側の側縁に設けられかつ他方の平坦壁を形成する２つの第２平坦壁形成部、および両第２平坦壁形成部における側壁形成部とは反対側の側縁に設けられかつ補強壁を形成する２つの補強壁形成部を有する１枚の金属素板を用意し、金属素板の両補強壁形成部を第２平坦壁形成部に対して同方向に曲げて補強壁用凸条を形成した後、両第２平坦壁形成部が第１平坦壁形成部に対して平行となるように、金属素板を両側壁形成部において曲げることにより、両補強壁用凸条を第１平坦壁形成部の内面に当接させるとともに、両補強壁用凸条どうしを係合させて折り曲げ体をつくり、ついで折り曲げ体を予め決められた長さに切断して扁平管半製品を製造する装置であって、
片面にろう材層を有するアルミニウムブレージングシートからなる金属素板を巻き取ったコイルを装着する繰り出しロールと、繰り出しロールから繰り出された金属素板の補強壁形成部を、金属素板と直角をなすとともにろう材層が外側に来るように曲げて補強壁用凸条を形成し、ついで両第２平坦壁形成部が第１平坦壁形成部に対して平行となるように、金属素板を両側壁形成部において曲げるとともに、当該曲げを途中で停止することにより、両補強壁用凸条間の間隔がロールコータにおける塗布ロールの軸方向の長さよりも大きくなっている折り曲げ中間体を形成する第１のロールフォーミング装置と、第１ロールフォーミング装置の後流側に配置され、かつ折り曲げ中間体を加熱する加熱装置と、加熱装置の後流側に配置され、かつ折り曲げ中間体の第１平坦壁形成部の内面にフラックス懸濁液を塗布するロールコータと、ロールコータの後流側に配置され、かつ折り曲げ中間体の第２平坦壁形成部を第１平坦壁形成部と平行になるまで曲げることにより、両補強壁用凸条を第１平坦壁形成部の内面に当接させるとともに、補強壁用凸条どうしを密着させて折り曲げ体をつくる第２のロールフォーミング装置と、第２ロールフォーミング装置の後流側に配置され、かつ折り曲げ体を予め決められた長さに切断して扁平管半製品を得る切断装置とを備えている扁平管半製品の製造装置。
13) A flat tube for a heat exchanger having a pair of flat walls facing each other, two side walls straddling both side edges of both flat walls, and a reinforcing wall straddling the middle part in the width direction of both flat walls. A method of manufacturing, one first flat wall forming part forming one flat wall, two side wall forming parts provided on both side edges of the first flat wall forming part and forming side walls, both side wall forming parts Two second flat wall forming portions provided on the side edge opposite to the first flat wall forming portion and forming the other flat wall, and opposite side wall forming portions in both second flat wall forming portions A metal base plate having two reinforcing wall forming portions that are provided on the side edges of the metal base plate and that forms the reinforcing wall is prepared, and both the reinforcing wall forming portions of the metal base plate are identical to the second flat wall forming portion. After forming the reinforcing wall projections by bending in the direction, both the second flat wall forming portions are in relation to the first flat wall forming portion. By bending the metal base plate at both side wall forming portions so as to be in line, both reinforcing wall ridges are brought into contact with the inner surface of the first flat wall forming portion, and both reinforcing wall ridges are engaged with each other. An apparatus for manufacturing a flat tube semi-finished product by making a bent body and then cutting the bent body into a predetermined length,
A feeding roll for mounting a coil wound with a metal base plate made of an aluminum brazing sheet having a brazing filler metal layer on one side, and a reinforcing wall forming portion of the metal base plate fed from the feeding roll are perpendicular to the metal base plate. In addition, bends so that the brazing filler metal layer is on the outside to form reinforcing wall projections, and then the metal base plate is placed on both sides so that both second flat wall forming portions are parallel to the first flat wall forming portions. Bending at the wall forming portion and stopping the bending halfway forms a folding intermediate in which the interval between the two reinforcing wall ridges is larger than the axial length of the coating roll in the roll coater. 1 roll forming device, a heating device that is disposed on the downstream side of the first roll forming device and that heats the bending intermediate, and is disposed on the downstream side of the heating device, and A roll coater for applying a flux suspension to the inner surface of the first flat wall forming portion of the bending intermediate, and a second flat wall forming portion of the bending intermediate disposed on the downstream side of the roll coater. Bending the two reinforcing wall ridges to the inner surface of the first flat wall forming portion by bending them until they are parallel to the wall forming portion, and forming a bent body by bringing the reinforcing wall ridges into close contact with each other A flat tube semi-finished product comprising a roll forming device and a cutting device that is arranged on the downstream side of the second roll forming device and obtains a flat tube semi-finished product by cutting a bent body into a predetermined length. Manufacturing equipment.
14)第１ロールフォーミング装置が、補強壁用凸条を形成する前の段階において、補強壁形成部の先端部を、補強壁形成部と直角をなすように曲げるようになっており、第２ロールフォーミング装置が、折り曲げ体をつく際に、屈曲部を第１平坦壁形成部の内面に密着させるようになっている上記13)記載の扁平管半製品の製造装置。 14) The first roll forming device is configured to bend the distal end portion of the reinforcing wall forming portion so as to form a right angle with the reinforcing wall forming portion in the stage before forming the reinforcing wall projection. The flat tube semi-finished product manufacturing apparatus according to the above 13), wherein the roll forming device is adapted to bring the bent portion into close contact with the inner surface of the first flat wall forming portion when the bent body is formed.
15)第１平坦壁形成部の内面へのフラックスの塗布状況を確認する撮像手段を備えている上記13)または14)記載の扁平管半製品の製造装置。 15) The flat tube semi-finished product manufacturing apparatus according to 13) or 14) above, which includes an imaging unit for confirming a state of application of the flux to the inner surface of the first flat wall forming portion.
16)互いに間隔をおいて配置された１対のヘッダタンクと、両ヘッダタンク間に、幅方向が通風方向を向くようにヘッダタンクの長さ方向に間隔をおいて配置され、かつ両端部が両ヘッダタンクに接続された複数の扁平管と、隣り合う扁平管どうしの間に配置されたコルゲートフィンとを備えており、扁平管が上記4)〜12)のうちのいずれかに記載の方法により製造されているヒータコア。 16) A pair of header tanks spaced apart from each other, and between the header tanks, the header tanks are spaced apart in the length direction of the header tank so that the width direction faces the ventilation direction, and both end portions are The method according to any one of 4) to 12) above, comprising a plurality of flat tubes connected to both header tanks and corrugated fins disposed between adjacent flat tubes. Heater core manufactured by
上記1)〜3)のフラックスの塗布方法によれば、金属材を加熱した後、加熱された金属材にロールコータにより連続的にフラックス懸濁液を塗布し、金属材の有する熱によりフラックス懸濁液の液状成分を気化させるので、規定された塗布範囲および塗布量となるようにフラックスを正確に塗布することができる。 According to the flux application methods 1) to 3) above, after the metal material is heated, the flux suspension is continuously applied to the heated metal material by a roll coater, and the flux suspension is applied by the heat of the metal material. Since the liquid component of the turbid liquid is vaporized, the flux can be accurately applied so that the specified application range and application amount are obtained.
上記2)および3)のフラックスの塗布方法によれば、ろう付に好適なフラックス懸濁液の濃度に応じて、金属材の実体温度をコントロールすることにより、フラックス懸濁液の液状成分の気化を調節することができる。 According to the flux application method of 2) and 3) above, the liquid component of the flux suspension is vaporized by controlling the solid temperature of the metal material according to the concentration of the flux suspension suitable for brazing. Can be adjusted.
上記4)〜12)の扁平管の製造方法によれば、金属素板の第１平坦壁形成部の内面に、規定された塗布範囲および塗布量となるようにフラックスを正確に塗布することができる。したがって、その後のろう付によって製造された扁平管においては、内部異物の量が少なくなって流通抵抗が低減し、熱交換器用の扁平管としての性能低下を抑制することができる。しかも、製造された扁平管の内部清浄度を向上させることができる。 According to the flat tube manufacturing method of the above 4) to 12), the flux can be accurately applied to the inner surface of the first flat wall forming portion of the metal base plate so as to have a prescribed application range and application amount. it can. Therefore, in the flat tube manufactured by the subsequent brazing, the amount of the internal foreign matter is reduced, the flow resistance is reduced, and the performance deterioration as the flat tube for the heat exchanger can be suppressed. And the internal cleanliness of the manufactured flat tube can be improved.
上記5)および6)の扁平管の製造方法によれば、ろう付に好適なフラックス懸濁液の濃度に応じて、金属素板の実体温度をコントロールすることにより、フラックス懸濁液の液状成分の気化を調節することができる。 According to the flat tube manufacturing method of 5) and 6) above, the liquid component of the flux suspension is controlled by controlling the solid temperature of the metal base plate according to the concentration of the flux suspension suitable for brazing. Can regulate the evaporation.
上記13)および14)の扁平管半製品の製造装置によれば、金属素板の第１平坦壁形成部の内面に、規定された塗布範囲および塗布量となるようにフラックスが塗布された扁平管半製品を、連続的に大量に製造することができる。しかも、その後のろう付によって製造された扁平管においては、内部異物の量が少なくなり、扁平管の性能低下を抑制することができる。 According to the flat tube semi-finished product manufacturing apparatus of 13) and 14) above, the flat surface in which the flux is applied to the inner surface of the first flat wall forming portion of the metal base plate so as to have the prescribed application range and application amount. Tube semi-finished products can be produced continuously in large quantities. And in the flat tube manufactured by the subsequent brazing, the quantity of an internal foreign material becomes small and the performance fall of a flat tube can be suppressed.
上記15)の扁平管半製品の製造装置によれば、折り曲げ体となった後には検査することができないフラックスの塗布状況を、確認することができる。 According to the flat tube semi-finished product manufacturing apparatus of the above 15), it is possible to confirm the application state of the flux that cannot be inspected after the bent body is formed.
以下、この発明の実施形態を、図面を参照して説明する。この実施形態は、この発明による扁平管の製造方法を、カーエアコンのヒータコアに用いられる扁平管の製造に適用したものである。 Embodiments of the present invention will be described below with reference to the drawings. In this embodiment, the method for producing a flat tube according to the present invention is applied to the production of a flat tube used for a heater core of a car air conditioner.
なお、図１および図２に関するヒータコアの説明において、図１の上下、左右を上下、左右といものとし、図１の紙面裏側（図２の上側）を前、これと反対側を後というものとする。 In the description of the heater core with reference to FIGS. 1 and 2, the top, bottom, left and right in FIG. 1 are referred to as up and down, and left and right, the back side of FIG. 1 (upper side in FIG. 2) is the front, and the opposite side is the back. To do.
図１はこの発明による熱交換器を適用したカーエアコン用ヒータコアの全体構成を示し、図２は要部の構成を示す。 FIG. 1 shows an overall configuration of a heater core for a car air conditioner to which a heat exchanger according to the present invention is applied, and FIG. 2 shows a configuration of a main part.
図１において、ヒータコア(1)は、上下方向に間隔をおいて配置されかつ左右方向に長いアルミニウム製上ヘッダタンク(2)および下ヘッダタンク(3)と、上下両ヘッダタンク(2)(3)間に設けられた熱交換コア部(4)とを備えており、上下両ヘッダタンク(2)(3)の左端部が熱交換コア部(4)よりも左方に突出させられ、上ヘッダタンク(2)の左方突出部に出口パイプ(5)が、下ヘッダタンク(3)の左方突出部に入口パイプ(6)がそれぞれ接続されている。 In FIG. 1, the heater core (1) has an aluminum upper header tank (2) and a lower header tank (3) which are spaced apart in the vertical direction and are long in the horizontal direction, and both upper and lower header tanks (2) (3 ) Between the upper and lower header tanks (2) and (3) are protruded to the left of the heat exchange core (4) An outlet pipe (5) is connected to the left protruding portion of the header tank (2), and an inlet pipe (6) is connected to the left protruding portion of the lower header tank (3).
上ヘッダタンク(2)は、下方が開口した左右方向に長い直方体状の箱形タンク本体(10A)と、タンク本体(10A)の開口端部にろう付されかつタンク本体(10A)の開口を閉鎖するヘッダプレート(10B)とよりなる。タンク本体(10A)は、片面にろう材層を有するアルミニウムブレージングシートからなる金属素板を、ろう材層が外面側に来るように折り曲げて必要箇所をろう付することにより形成され、ヘッダプレート(10B)は、片面にろう材層を有するアルミニウムブレージングシートからなる金属素板を、ろう材層が外面側に来るように折り曲げて必要箇所をタンク本体(10A)にろう付することにより形成されている。下ヘッダタンク(3)は上ヘッダタンク(2)を上下逆向きにしたものであり、同一物および同一部分には同一符号を付す。 The upper header tank (2) is a rectangular parallelepiped box-shaped tank body (10A) that is open at the bottom and brazed to the opening end of the tank body (10A) and opens the opening of the tank body (10A). It consists of a header plate (10B) that closes. The tank body (10A) is formed by brazing a metal base plate made of an aluminum brazing sheet having a brazing filler metal layer on one side so that the brazing filler metal layer comes to the outer surface side and brazing a required portion, and a header plate ( 10B) is formed by bending a metal base plate made of an aluminum brazing sheet having a brazing filler metal layer on one side so that the brazing filler metal layer is on the outer surface side and brazing the necessary part to the tank body (10A). Yes. The lower header tank (3) is obtained by turning the upper header tank (2) upside down, and the same components and the same parts are denoted by the same reference numerals.
熱交換コア部(4)は、幅方向が前後方向（通風方向）を向くように左右方向に間隔をおいて配置され、かつ上下両端部が上下両ヘッダタンク(2)(3)に接続された複数のアルミニウム製扁平管(7)と、隣り合う扁平管(7)どうしの間および左右両端の扁平管(7)の外側に配置されて扁平管(7)にろう付されたアルミニウム製ルーバ付きコルゲートフィン(8)と、左右両端のコルゲートフィン(8)の外側に配置されてコルゲートフィン(8)にろう付されたアルミニウムブレージングシート製サイドプレート(9)とからなる。扁平管(7)の上下両端部は、上下両ヘッダタンク(2)(3)に形成された管挿入穴（図示略）に挿入された状態で両ヘッダタンク(2)(3)にろう付されている。 The heat exchange core part (4) is arranged with a space in the left-right direction so that the width direction faces the front-rear direction (ventilation direction), and the upper and lower ends are connected to the upper and lower header tanks (2) (3). Aluminum louvers that are arranged between a plurality of flat aluminum tubes (7) and between the adjacent flat tubes (7) and outside the flat tubes (7) at both ends and brazed to the flat tubes (7) And a corrugated fin (8), and an aluminum brazing sheet side plate (9) brazed to the corrugated fin (8) and disposed outside the corrugated fins (8) at both left and right ends. The upper and lower ends of the flat tube (7) are brazed to both header tanks (2) and (3) while being inserted into the tube insertion holes (not shown) formed in the upper and lower header tanks (2) and (3). Has been.
図２に示すように、扁平管(7)は、少なくとも片面にろう材層を有する帯状のアルミニウムブレージングシートを、ろう材層が外側に来るように中空状に曲げてろう付することにより形成されたものであり、互いに対向する左右両壁(11)(12)（１対の平坦壁）と、左右両壁(11)(12)の前後両側縁どうしにまたがる前後両側壁(13)(14)と、左右両壁(11)(12)の幅方向の中央部どうしに跨る１つの補強壁(15)とを備えている。右壁(12)は１つの右壁形成部(12A)（第１平坦壁形成部）からなり、左壁(11)は前後両側壁(13)(14)を介して右壁形成部(12A)の前後両側縁に一体に形成されるとともに、側壁(13)(14)とは反対側の縁部どうしが突き合わされた２つの左壁形成部(11A)(11B)（第２平坦壁形成部）からなる。補強壁(15)は、両左壁形成部(11A)(11B)における互いに突き合わされた縁部にそれぞれ右方に突出するように一体に形成され、かつ互いに密着させられた２つの補強壁用凸条(15A)からなる。両補強壁用凸条(15A)の先端（右端）に前後両側壁(13)(14)側に屈曲した屈曲部(15B)が一体に形成されているとともに当該屈曲部(15B)が右壁形成部(12A)の内面に密着した状態でろう付されている。両補強壁用凸条(15A)は左壁形成部(11A)(11B)と直角をなし、両屈曲部(15B)は補強壁用凸条(15A)と直角をなしている。 As shown in FIG. 2, the flat tube (7) is formed by brazing a brazed aluminum brazing sheet having a brazing filler metal layer on at least one side thereof into a hollow shape so that the brazing filler metal layer comes outside. Left and right walls (11), (12) (a pair of flat walls) facing each other, and both front and rear walls (13) (14) spanning the front and rear edges of both left and right walls (11), (12) ) And one reinforcing wall (15) straddling the center portions in the width direction of the left and right walls (11) and (12). The right wall (12) is composed of one right wall forming portion (12A) (first flat wall forming portion), and the left wall (11) is inserted into the right wall forming portion (12A via the front and rear side walls (13) and (14)). ) And two left wall forming portions (11A) and (11B) (second flat wall forming) that are integrally formed on both front and rear edges, and opposite edges of the side walls (13) and (14) are abutted. Part). The reinforcing wall (15) is for two reinforcing walls that are integrally formed so as to protrude rightward from each other at the edges of the left wall forming portions (11A) and (11B) and are in close contact with each other. Consists of ridges (15A). A bent portion (15B) bent toward the front and rear side walls (13) and (14) is integrally formed at the tip (right end) of both reinforcing wall projections (15A), and the bent portion (15B) is formed on the right wall. It is brazed in close contact with the inner surface of the forming part (12A). Both reinforcing wall ridges (15A) are perpendicular to the left wall forming portions (11A) and (11B), and both bent portions (15B) are perpendicular to the reinforcing wall ridges (15A).
扁平管(7)は、補強壁用凸条(15A)どうし、および屈曲部(15B)と右壁形成部(12A)とがろう付されていない点を除いては、図２に示す扁平管(7)と同一横断面形状である扁平管半製品をつくり、この扁平管半製品の所要部分をろう付することにより製造される。 The flat tube (7) is the flat tube shown in FIG. 2 except that the reinforcing wall projections (15A) and the bent portion (15B) and the right wall forming portion (12A) are not brazed. It is manufactured by making a flat tube semi-finished product having the same cross-sectional shape as (7) and brazing the required part of this flat tube semi-finished product.
扁平管半製品は、図３に示す方法により製造される。なお、以下に述べる扁平管半製品の製造方法に関する説明において、図３の上下、左右を上下、右というものとする。 The flat tube semi-finished product is manufactured by the method shown in FIG. In addition, in the description regarding the manufacturing method of the flat tube semi-finished product described below, the top and bottom and the left and right in FIG.
予め、片面にろう材層を有するアルミニウムブレージングシートからなる平坦な金属素板(20)を用意する。金属素板(20)は、１つの右壁形成部(12A)、右壁形成部(12A)の左右両側縁に設けられかつ前後両側壁(13)(14)を形成する２つの側壁形成部(21)(22)、両側壁形成部(21)(22)における右壁形成部(12A)とは反対側の側縁に設けられた２つの左壁形成部(11A)(11B)、および両左壁形成部(11A)(11B)における側壁形成部(21)(22)とは反対側の側縁に設けられかつ補強壁用凸条(15A)および屈曲部(15B)を形成する２つの補強壁形成部(23)からなる（図３(a)参照）。 A flat metal base plate (20) made of an aluminum brazing sheet having a brazing material layer on one side is prepared in advance. The metal base plate (20) is provided on the right and left side edges of the right wall forming part (12A) and the right wall forming part (12A) and has two side wall forming parts forming the front and rear side walls (13) and (14). (21) (22), two left wall forming portions (11A) (11B) provided on the side edge opposite to the right wall forming portion (12A) in the both side wall forming portions (21) (22), and 2 provided on the side edges of the left wall forming portions (11A) and (11B) opposite to the side wall forming portions (21) and (22) and forming the reinforcing wall projections (15A) and the bent portions (15B). It consists of two reinforcement wall formation parts (23) (refer Fig.3 (a)).
そして、金属素板(20)の両補強壁形成部(23)の先端部を補強壁形成部(23)に対して下方に直角に曲げて屈曲部(15B)を形成した後（図３(b)参照）、両補強壁形成部(23)を両左壁形成部(11A)(11B)に対して下方に直角に曲げて補強壁用凸条(15A)を形成する（図３(c)参照）。ついで、両左壁形成部(11A)(11B)が右壁形成部(12A)に対して直角よりも若干大きな鈍角をなすように、金属素板(20)を両側壁形成部(21)(22)において下方に曲げることにより、折り曲げ中間体(25)を得る（図３(d)参照）。 And after bending the front-end | tip part of both the reinforcement wall formation parts (23) of a metal base plate (20) at right angle downward with respect to the reinforcement wall formation part (23), a bending part (15B) is formed (FIG. 3 ( b)), both reinforcing wall forming portions (23) are bent downward at right angles to both left wall forming portions (11A) and (11B) to form reinforcing wall protrusions (15A) (FIG. 3 (c) )reference). Then, the metal base plate (20) is placed on both side wall forming portions (21) (21) (11B) so that both left wall forming portions (11A) (11B) form an obtuse angle slightly larger than a right angle with respect to the right wall forming portion (12A). The bent intermediate body (25) is obtained by bending downward in 22) (see FIG. 3 (d)).
ついで、折り曲げ中間体(25)を、折り曲げ中間体(25)の実体温度が１５０℃以上となるように加熱した後、右壁形成部(12A)の内面中央部における屈曲部(15B)をろう付する部分に、後述するロールコータ(33)の塗布ロール(40)によりフラックス懸濁液を塗布し、折り曲げ中間体(25)の有する熱によりフラックス懸濁液の液状成分を気化させてフラックスを定着させてフラックス塗膜(26)を形成する。フラックス懸濁液としては、たとえばＫＡｌＦ４と６０〜８５質量％、ＫＡｌＦ５・Ｈ２Ｏ１５〜４０質量％からなる非腐食性フラックス粉末を、水に懸濁させたものが用いられる。但し、ＫＡｌＦ４とＫＡｌＦ５・Ｈ２Ｏとの合計は１００質量％である。また、フラックス懸濁液中のフラックス濃度は１０〜２０質量％であることが好ましい。 Next, the folded intermediate body (25) is heated so that the substantial temperature of the folded intermediate body (25) is 150 ° C. or higher, and then the bent portion (15B) at the center of the inner surface of the right wall forming section (12A) is brazed. The flux suspension is applied to the part to be attached by a coating roll (40) of a roll coater (33) described later, and the flux suspension is vaporized by the heat of the folding intermediate (25) to generate the flux. Fix to form a flux coating (26). As the flux suspension, for example, a non-corrosive flux powder composed of KAlF 4 and 60 to 85% by mass and KAlF 5 · H 2 O 15 to 40% by mass is suspended in water. However, the total of KAlF 4 and KAlF 5 · H 2 O is 100% by mass. Moreover, it is preferable that the flux density | concentration in a flux suspension is 10-20 mass%.
ついで、金属素板(20)を、両左壁形成部(11A)(11B)が右壁形成部(12A)に対して平行となるように、金属素板(20)を両側壁形成部(21)(22)において曲げていき（図３(e)参照）、両補強壁用凸条(15A)先端の屈曲部(15B)を右壁形成部(12A)の内面に密着させるとともに、両補強壁用凸条(15A)どうしを密着させて折り曲げ体(27)をつくり（図３(f)参照）、折り曲げ体(27)を予め決められた長さに切断する。こうして扁平管半製品が製造される。上述した金属素板(20)のすべての曲げは、ロールフォーミングにより行われる。 Next, the metal base plate (20) is placed on both side wall forming portions (20A) so that both left wall forming portions (11A) and (11B) are parallel to the right wall forming portion (12A). 21) Bending in (22) (see Fig. 3 (e)), the bent portion (15B) at the tip of both reinforcing wall projections (15A) is brought into close contact with the inner surface of the right wall forming portion (12A). The ridges (15A) for reinforcing walls are brought into close contact with each other to form a bent body (27) (see FIG. 3 (f)), and the bent body (27) is cut into a predetermined length. A flat tube semi-finished product is thus manufactured. All the bending of the metal base plate (20) described above is performed by roll forming.
その後、扁平管半製品の補強壁用凸条(15A)先端の屈曲部(15B)と右壁形成部(12A)および両補強壁用凸条(15A)どうしをろう付することにより扁平管(7)が製造される。 After that, the flat tube (15A) is bent by brazing the bent portion (15B) at the tip of the flat tube semi-finished product (15A) and the right wall forming portion (12A) and the two reinforcing wall convex strips (15A). 7) is manufactured.
扁平管半製品から扁平管(7)を製造するための補強壁用凸条(15A)先端の屈曲部(15B)と右壁形成部(12A)とのろう付、および両補強壁用凸条(15A)どうしのろう付は、ヒータコア(1)の製造の際に他の部品のろう付と同時に行われる。 Reinforcement wall projections (15A) for manufacturing flat tubes (7) from semi-finished flat tube products Brazing between the bent portion (15B) at the tip and the right wall forming portion (12A), and projections for both reinforcement walls (15A) The brazing between the two parts is performed simultaneously with the brazing of the other parts when the heater core (1) is manufactured.
すなわち、上下のタンク本体(10A)およびヘッダプレート(10B)と、所要数の扁平管半製品およびコルゲートフィン(8)と、１対のサイドプレート(9)と、出口パイプ(5)および入口パイプ(6)とを組み合わせて、全部品を適当な治具を用いて仮止めする。その後、これらを所定温度に加熱し、扁平管半製品の補強壁用凸条(15A)先端の屈曲部(15B)と右壁形成部(12A)、および両補強壁用凸条(15A)どうしをろう付し、右壁壁形成部(12A)と両左壁形成部(11A)(11B)とにより１対の平坦壁(12)(11)を形成し、両側壁形成部(21)(22)により両側壁(13)(14)を形成し、さらに両補強壁用凸条(15A)により補強壁(15)を形成することにより扁平管(7)をつくり、さらにタンク本体(10A)をヘッダプレート(10B)をろう付して上下のヘッダタンク(2)(3)を形成するとともに、扁平管(7)とヘッダタンク(2)(3)、扁平管(7)とコルゲートフィン(8)、コルゲートフィン(8)とサイドプレート(9)、ならびにヘッダタンク(2)(3)と出口パイプ(5)および入口パイプ(2)(3)とを同時にろう付する。こうして、ヒータコア(1)が製造される。 That is, upper and lower tank bodies (10A) and header plates (10B), a required number of flat tube semi-finished products and corrugated fins (8), a pair of side plates (9), an outlet pipe (5) and an inlet pipe In combination with (6), temporarily fix all parts using an appropriate jig. Thereafter, these are heated to a predetermined temperature, and the reinforcing wall projections (15A) of the flat tube semi-finished product (15A), the bent portion (15B) and the right wall forming portion (12A), and both reinforcing wall projections (15A) A pair of flat walls (12) and (11) are formed by the right wall wall forming portion (12A) and both left wall forming portions (11A) and (11B), and both side wall forming portions (21) ( 22) forms both side walls (13) and (14), and further forms a reinforcing wall (15) with both reinforcing wall projections (15A) to form a flat tube (7), and further the tank body (10A) The header plate (10B) is brazed to form the upper and lower header tanks (2) (3), and the flat tube (7) and header tank (2) (3), flat tube (7) and corrugated fin ( 8) The corrugated fin (8) and the side plate (9), and the header tank (2) (3), the outlet pipe (5) and the inlet pipe (2) (3) are brazed simultaneously. Thus, the heater core (1) is manufactured.
扁平管半製品は、図４に示す製造装置を用いて製造される。 A flat tube semi-finished product is manufactured using the manufacturing apparatus shown in FIG.
扁平管半製品の製造装置は、ろう材層面が外側を向くように金属素板(20)を巻き取ったコイル(20A)を装着する繰り出しロール(30)と、繰り出しロール(30)から繰り出された金属素板(20)を、上述した折り曲げ中間体(25)の状態まで曲げる第１ロールフォーミング装置(31)と、第１ロールフォーミング装置(31)の後流側に配置され、かつ折り曲げ中間体(25)を加熱する加熱装置(32)と、加熱装置(32)の後流側に配置され、かつ折り曲げ中間体(25)の右壁形成部(12A)の内面における両屈曲部(15B)が密着する部分を含む帯状部分にフラックス懸濁液を塗布するロールコータ(33)と、折り曲げ中間体(25)の右壁形成部(12A)内面へのフラックスの塗布状況を確認するカメラ(34)と、ロールコータ(33)の後流側に配置され、かつ折り曲げ中間体(25)の両左壁形成部(11A)(11B)を右壁形成部(12A)と平行になるまで曲げることにより、両補強壁用凸条(15A)どうしを密着させるとともに、両屈曲部(15B)を右壁形成部(12A)内面に密着させて折り曲げ体(27)をつくる第２ロールフォーミング装置(35)と、第２ロールフォーミング装置(35)の後流側に配置され、かつ折り曲げ体(27)を予め決められた長さに切断して扁平管半製品を得る切断装置(36)とを備えている。この製造装置を使用し、上述した方法により、扁平管半製品が連続的に製造される。 The flat tube semi-finished product manufacturing device is fed from a feed roll (30) and a feed roll (30) to which a coil (20A) wound with a metal base plate (20) is wound so that the brazing material layer surface faces outward. The first metal plate (20) is disposed on the downstream side of the first roll forming device (31) and the first roll forming device (31), and is bent in the middle. A heating device (32) for heating the body (25), and both bent portions (15B) on the inner surface of the right wall forming portion (12A) of the bending intermediate body (25), which is disposed on the downstream side of the heating device (32). ) And a roll coater (33) that applies the flux suspension to the belt-like part including the part where it adheres, and a camera that confirms the flux application condition on the inner surface of the right wall forming part (12A) of the bending intermediate (25) ( 34) and the left side wall forming portion (11A) (11B) of the folded intermediate body (25) disposed on the wake side of the roll coater (33) and forming the right wall By bending until it becomes parallel to the portion (12A), both the reinforcing wall projections (15A) are brought into close contact with each other, and both bent portions (15B) are brought into close contact with the inner surface of the right wall forming portion (12A) to be bent ( 27) and the second roll forming device (35), and the second roll forming device (35) are arranged on the downstream side of the second roll forming device (35), and the bent body (27) is cut into a predetermined length to cut the flat tube half And a cutting device (36) for obtaining a product. Using this manufacturing apparatus, flat tube semi-finished products are continuously manufactured by the method described above.
加熱装置(32)は加熱室を備えており、折り曲げ中間体(25)が、たとえば２００℃以上となされた加熱室内を所定時間かけて通過するようになっている。 The heating device (32) includes a heating chamber, and the bending intermediate (25) passes through the heating chamber set at, for example, 200 ° C. or more for a predetermined time.
ロールコータ(33)は、折り曲げ中間体(25)にフラックス懸濁液を塗布する塗布ロール(40)と、フラックス懸濁液を入れておくタンク(41)と、一部がタンク(41)内のフラックス懸濁液中に浸漬されかつフラックス懸濁液を塗布ロール(40)に供給するピックアップロール(42)とを備えている。塗布ロール(40)の軸方向の長さは、折り曲げ中間体(25)の両補強壁用凸条(15A)間の間隔よりも短くなっている。 The roll coater (33) includes a coating roll (40) for applying the flux suspension to the bending intermediate (25), a tank (41) for storing the flux suspension, and a part of the inside of the tank (41). A pickup roll (42) that is immersed in the flux suspension and supplies the flux suspension to the coating roll (40). The length of the coating roll (40) in the axial direction is shorter than the distance between the two reinforcing wall projections (15A) of the bending intermediate body (25).
カメラ(34)は画像処理装置（図示略）に接続されており、画像処理装置は、カメラ(34)により撮像されたフラックス塗布部の画像を記録し、フラックス塗膜(26)の有無を連続的に判別する機能を有している。 The camera (34) is connected to an image processing device (not shown), and the image processing device records the image of the flux application part imaged by the camera (34) and continuously indicates the presence or absence of the flux coating (26). It has a function to discriminate automatically.
右壁形成部(12A)内面に、たとえば幅５mm、膜厚３０μｍのフラックス塗膜(26)を形成する場合、フラックス懸濁液中のフラックス濃度を１５質量％、加熱装置(32)の加熱室内の雰囲気温度を２００〜２５０℃、折り曲げ中間体(25)が加熱装置(32)の加熱室内を通過する時間を１秒とすればよい。 For example, when a flux coating (26) having a width of 5 mm and a film thickness of 30 μm is formed on the inner surface of the right wall forming part (12A), the flux concentration in the flux suspension is 15% by mass, the heating chamber of the heating device (32). The atmospheric temperature may be 200 to 250 ° C., and the time required for the folding intermediate (25) to pass through the heating chamber of the heating device (32) may be 1 second.
(1)：ヒータコア（熱交換器）
(2)(3)：ヘッダタンク
(7)：扁平管
(8)：コルゲートフィン
(11)：左壁（平坦壁）
(11A)(11B)：左壁形成部（第１平坦壁形成部）
(12)：右壁（平坦壁）
(12A)：右壁形成部（第２平坦壁形成部）
(13)(14)：側壁
(15)：補強壁
(15A)：補強壁用凸条
(15B)：屈曲部
(20)：金属素板
(20A)：コイル
(21)(22)：側壁形成部
(23)：補強壁形成部
(25)：折り曲げ中間体
(26)：フラックス塗膜
(27)：折り曲げ体
(30)：繰り出しロール
(31)：第１ロールフォーミング装置
(32)：加熱装置
(33)：ロールコータ
(34)：カメラ（撮像手段）
(35)：第２ロールフォーミング装置
(36)：切断装置
(40)：塗布ロール
(1): Heater core (heat exchanger)
(2) (3): Header tank
(7): Flat tube
(8): Corrugated fin
(11): Left wall (flat wall)
(11A) (11B): Left wall forming part (first flat wall forming part)
(12): Right wall (flat wall)
(12A): Right wall forming part (second flat wall forming part)
(13) (14): Side wall
(15): Reinforcement wall
(15A): Convex ridge for reinforcing wall
(15B): Bent part
(20): Metal base plate
(20A): Coil
(21) (22): Side wall forming part
(23): Reinforcing wall forming part
(25): Bending intermediate
(26): Flux coating
(27): Folded body
(30): Feeding roll
(31): First roll forming device
(32): Heating device
(33): Roll coater
(34): Camera (imaging means)
(35): Second roll forming device
(36): Cutting device
(40): Application roll
Claims (16)
金属素板から折り曲げ体を得るまでの間に、金属素板を加熱し、加熱された金属素板の第１平坦壁形成部の内面における少なくともいずれか一方の補強壁用凸条をろう付する部分に、ロールコータによりフラックス懸濁液を塗布し、金属素板の有する熱によりフラックス懸濁液の液状成分を気化させることを特徴とする扁平管の製造方法。 A flat tube for a heat exchanger having a pair of flat walls facing each other, two side walls straddling both side edges of both flat walls, and a reinforcing wall straddling intermediate portions in the width direction of both flat walls is manufactured. A first flat wall forming portion that forms one flat wall, two side wall forming portions that are provided on both side edges of the first flat wall forming portion and that form side walls, Two second flat wall forming portions provided on the side edge opposite to the one flat wall forming portion and forming the other flat wall, and a side opposite to the side wall forming portion in both second flat wall forming portions One metal base plate having two reinforcing wall forming portions provided at the edge and forming a reinforcing wall is prepared, and both reinforcing wall forming portions of the metal base plate are in the same direction with respect to the second flat wall forming portion. After forming the reinforcing wall projections by bending, both the second flat wall forming portions are flat with respect to the first flat wall forming portion. By bending the metal base plate at the both side wall forming portions so that at least one of the reinforcing wall protruding strips is brought into contact with the inner surface of the first flat wall forming portion, both the reinforcing wall protruding strips are Are engaged with each other to form a bent body, and then the bent body is cut into a predetermined length to form a flat tube semi-finished product. The two reinforcing wall ridges are brazed to each other, a pair of flat walls are formed by the first flat wall forming portion and the two second flat wall forming portions, and both side walls are formed by the both side wall forming portions. In a method for manufacturing a flat tube, including forming a reinforcing wall with a reinforcing wall projection,
Before obtaining the bent body from the metal base plate, the metal base plate is heated, and at least one of the reinforcing wall projections on the inner surface of the first flat wall forming portion of the heated metal base plate is brazed. A method for producing a flat tube, wherein a flux suspension is applied to a portion by a roll coater, and a liquid component of the flux suspension is vaporized by heat of a metal base plate.
片面にろう材層を有するアルミニウムブレージングシートからなる金属素板を巻き取ったコイルを装着する繰り出しロールと、繰り出しロールから繰り出された金属素板の補強壁形成部を、金属素板と直角をなすとともにろう材層が外側に来るように曲げて補強壁用凸条を形成し、ついで両第２平坦壁形成部が第１平坦壁形成部に対して平行となるように、金属素板を両側壁形成部において曲げるとともに、当該曲げを途中で停止することにより、両補強壁用凸条間の間隔がロールコータにおける塗布ロールの軸方向の長さよりも大きくなっている折り曲げ中間体を形成する第１のロールフォーミング装置と、第１ロールフォーミング装置の後流側に配置され、かつ折り曲げ中間体を加熱する加熱装置と、加熱装置の後流側に配置され、かつ折り曲げ中間体の第１平坦壁形成部の内面にフラックス懸濁液を塗布するロールコータと、ロールコータの後流側に配置され、かつ折り曲げ中間体の第２平坦壁形成部を第１平坦壁形成部と平行になるまで曲げることにより、両補強壁用凸条を第１平坦壁形成部の内面に当接させるとともに、補強壁用凸条どうしを密着させて折り曲げ体をつくる第２のロールフォーミング装置と、第２ロールフォーミング装置の後流側に配置され、かつ折り曲げ体を予め決められた長さに切断して扁平管半製品を得る切断装置とを備えている扁平管半製品の製造装置。 A flat tube for a heat exchanger having a pair of flat walls facing each other, two side walls straddling both side edges of both flat walls, and a reinforcing wall straddling intermediate portions in the width direction of both flat walls is manufactured. A first flat wall forming portion that forms one flat wall, two side wall forming portions that are provided on both side edges of the first flat wall forming portion and that form side walls, Two second flat wall forming portions provided on the side edge opposite to the one flat wall forming portion and forming the other flat wall, and a side opposite to the side wall forming portion in both second flat wall forming portions One metal base plate having two reinforcing wall forming portions provided at the edge and forming a reinforcing wall is prepared, and both reinforcing wall forming portions of the metal base plate are in the same direction with respect to the second flat wall forming portion. After forming the reinforcing wall projections by bending, both the second flat wall forming portions are flat with respect to the first flat wall forming portion. By bending the metal base plate at both side wall forming portions so that both the reinforcing wall convex strips are brought into contact with the inner surface of the first flat wall forming portion, the two reinforcing wall convex strips are engaged with each other. An apparatus for manufacturing a flat tube semi-finished product by making a bent body and then cutting the bent body into a predetermined length,
A feeding roll for mounting a coil wound with a metal base plate made of an aluminum brazing sheet having a brazing filler metal layer on one side, and a reinforcing wall forming portion of the metal base plate fed from the feeding roll are perpendicular to the metal base plate. In addition, bends so that the brazing filler metal layer is on the outside to form reinforcing wall projections, and then the metal base plate is placed on both sides so that both second flat wall forming portions are parallel to the first flat wall forming portions. Bending at the wall forming portion and stopping the bending halfway forms a folding intermediate in which the interval between the two reinforcing wall ridges is larger than the axial length of the coating roll in the roll coater. 1 roll forming device, a heating device that is disposed on the downstream side of the first roll forming device and that heats the bending intermediate, and is disposed on the downstream side of the heating device, and A roll coater for applying a flux suspension to the inner surface of the first flat wall forming portion of the bending intermediate, and a second flat wall forming portion of the bending intermediate disposed on the downstream side of the roll coater. Bending the two reinforcing wall ridges to the inner surface of the first flat wall forming portion by bending them until they are parallel to the wall forming portion, and forming a bent body by bringing the reinforcing wall ridges into close contact with each other A flat tube semi-finished product comprising a roll forming device and a cutting device that is arranged on the downstream side of the second roll forming device and obtains a flat tube semi-finished product by cutting a bent body into a predetermined length. Manufacturing equipment.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2006183289A JP5033366B2 (en) | 2006-07-03 | 2006-07-03 | Flat tube manufacturing method and flat tube semi-finished product manufacturing apparatus |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2006183289A JP5033366B2 (en) | 2006-07-03 | 2006-07-03 | Flat tube manufacturing method and flat tube semi-finished product manufacturing apparatus |
Related Child Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2012110301A Division JP2012196713A (en) | 2012-05-14 | 2012-05-14 | Method for manufacturing flat pipe and manufacturing apparatus of flat pipe semifinished product |
| JP2012110308A Division JP2012193950A (en) | 2012-05-14 | 2012-05-14 | Flat tube for heat exchanger |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2008012378A true JP2008012378A (en) | 2008-01-24 |
| JP5033366B2 JP5033366B2 (en) | 2012-09-26 |
Family
ID=39069949
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2006183289A Expired - Fee Related JP5033366B2 (en) | 2006-07-03 | 2006-07-03 | Flat tube manufacturing method and flat tube semi-finished product manufacturing apparatus |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP5033366B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2010008018A (en) * | 2008-06-30 | 2010-01-14 | Showa Denko Kk | Heat exchange pipe with inner fin and heat exchanger using it |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH07303858A (en) * | 1994-05-13 | 1995-11-21 | Nippon Light Metal Co Ltd | Brazing slurry application method |
| JPH10193094A (en) * | 1996-12-27 | 1998-07-28 | Showa Alum Corp | Flux coating device |
| JP2002178074A (en) * | 2000-12-13 | 2002-06-25 | Zexel Valeo Climate Control Corp | Device and method of manufacturing heat exchanger tube |
| JP3414354B2 (en) * | 2000-03-16 | 2003-06-09 | 株式会社デンソー | tube |
| JP2004167601A (en) * | 2002-10-30 | 2004-06-17 | Showa Denko Kk | Semiprocessed flat tube and its manufacturing method, flat tube, heat-exchanger using flat tube and its manufacturing method |
| JP2005037062A (en) * | 2003-07-15 | 2005-02-10 | Toyo Radiator Co Ltd | Aluminum heat exchanger |
-
2006
- 2006-07-03 JP JP2006183289A patent/JP5033366B2/en not_active Expired - Fee Related
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH07303858A (en) * | 1994-05-13 | 1995-11-21 | Nippon Light Metal Co Ltd | Brazing slurry application method |
| JPH10193094A (en) * | 1996-12-27 | 1998-07-28 | Showa Alum Corp | Flux coating device |
| JP3414354B2 (en) * | 2000-03-16 | 2003-06-09 | 株式会社デンソー | tube |
| JP2002178074A (en) * | 2000-12-13 | 2002-06-25 | Zexel Valeo Climate Control Corp | Device and method of manufacturing heat exchanger tube |
| JP2004167601A (en) * | 2002-10-30 | 2004-06-17 | Showa Denko Kk | Semiprocessed flat tube and its manufacturing method, flat tube, heat-exchanger using flat tube and its manufacturing method |
| JP2005037062A (en) * | 2003-07-15 | 2005-02-10 | Toyo Radiator Co Ltd | Aluminum heat exchanger |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2010008018A (en) * | 2008-06-30 | 2010-01-14 | Showa Denko Kk | Heat exchange pipe with inner fin and heat exchanger using it |
Also Published As
| Publication number | Publication date |
|---|---|
| JP5033366B2 (en) | 2012-09-26 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| EP1065466B1 (en) | Flat turbulator for a tube and method of making same | |
| CN104204709B (en) | Heat exchanger | |
| JPH0560482A (en) | Heat exchanger manufacturing method | |
| JP2012196713A (en) | Method for manufacturing flat pipe and manufacturing apparatus of flat pipe semifinished product | |
| JP2016017666A (en) | Heat exchanger and its process of manufacture | |
| JP5033366B2 (en) | Flat tube manufacturing method and flat tube semi-finished product manufacturing apparatus | |
| JP2009063229A (en) | Heat exchanger and its manufacturing method | |
| JP2010008018A (en) | Heat exchange pipe with inner fin and heat exchanger using it | |
| JP2012193950A (en) | Flat tube for heat exchanger | |
| JP5352276B2 (en) | Manufacturing method of heat exchanger | |
| JP2009216287A (en) | Heat exchanger | |
| JP2011163700A (en) | Heat exchanger | |
| JP4804895B2 (en) | Manufacturing method of heat exchanger | |
| US20060219398A1 (en) | Heat exchanger | |
| JP6959111B2 (en) | Flat multi-channel pipe made of extruded aluminum pipe and its manufacturing method | |
| CN101511501A (en) | Method for manufacturing a heat exchanger tube | |
| JP2009008277A (en) | Heat exchanger and its manufacturing method | |
| CN100476340C (en) | Brazing structure and manufacturing method thereof | |
| JP2002181480A (en) | Heat exchanger | |
| JP4736847B2 (en) | Heat exchanger and manufacturing method thereof | |
| JP4861844B2 (en) | Heat exchanger and manufacturing method thereof | |
| JP2002178074A (en) | Device and method of manufacturing heat exchanger tube | |
| JP2006038335A (en) | Core part for heat exchanger | |
| JP2006317027A (en) | Flat tube for heat exchanger | |
| JP2008008603A (en) | Heat exchanger |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| A621 | Written request for application examination |
Free format text: JAPANESE INTERMEDIATE CODE: A621 Effective date: 20090402 |
|
| A977 | Report on retrieval |
Free format text: JAPANESE INTERMEDIATE CODE: A971007 Effective date: 20110524 |
|
| A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20110621 |
|
| A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20110816 |
|
| A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20120313 |
|
| A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20120514 |
|
| A711 | Notification of change in applicant |
Free format text: JAPANESE INTERMEDIATE CODE: A711 Effective date: 20120514 |
|
| RD03 | Notification of appointment of power of attorney |
Free format text: JAPANESE INTERMEDIATE CODE: A7423 Effective date: 20120514 |
|
| TRDD | Decision of grant or rejection written | ||
| A01 | Written decision to grant a patent or to grant a registration (utility model) |
Free format text: JAPANESE INTERMEDIATE CODE: A01 Effective date: 20120606 |
|
| A01 | Written decision to grant a patent or to grant a registration (utility model) |
Free format text: JAPANESE INTERMEDIATE CODE: A01 |
|
| A61 | First payment of annual fees (during grant procedure) |
Free format text: JAPANESE INTERMEDIATE CODE: A61 Effective date: 20120702 |
|
| R150 | Certificate of patent or registration of utility model |
Free format text: JAPANESE INTERMEDIATE CODE: R150 Ref document number: 5033366 Country of ref document: JP Free format text: JAPANESE INTERMEDIATE CODE: R150 |
|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20150706 Year of fee payment: 3 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| S533 | Written request for registration of change of name |
Free format text: JAPANESE INTERMEDIATE CODE: R313533 |
|
| R350 | Written notification of registration of transfer |
Free format text: JAPANESE INTERMEDIATE CODE: R350 |
|
| S111 | Request for change of ownership or part of ownership |
Free format text: JAPANESE INTERMEDIATE CODE: R313113 |
|
| R360 | Written notification for declining of transfer of rights |
Free format text: JAPANESE INTERMEDIATE CODE: R360 |
|
| R360 | Written notification for declining of transfer of rights |
Free format text: JAPANESE INTERMEDIATE CODE: R360 |
|
| R371 | Transfer withdrawn |
Free format text: JAPANESE INTERMEDIATE CODE: R371 |
|
| S111 | Request for change of ownership or part of ownership |
Free format text: JAPANESE INTERMEDIATE CODE: R313113 |
|
| R350 | Written notification of registration of transfer |
Free format text: JAPANESE INTERMEDIATE CODE: R350 |
|
| LAPS | Cancellation because of no payment of annual fees |