JP2009162394A - Heat exchanger and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a heat exchanger capable of reducing its manufacturing cost and weight. <P>SOLUTION: The total heat exchange tubes 4 of this heat exchanger respectively have a pair of flat walls 13, 14 opposed to each other, and two side walls 15, 16 disposed over both side edges of the flat walls 13, 14. The heat exchange tubes 4 are formed by bending a brazing sheet having a brazing filler metal layer on at least one face in a state that the brazing filler metal layer is positioned at an outer side. Joint portions 24 extending in the longitudinal direction exist on one side edge portion of an outer face of the second flat wall 14 of the heat exchange tubes 4. All of the joint portions 24 of the heat exchange tubes 4 are positioned at the same side in the ventilating direction. The joint portions of the heat exchange tubes 4 are closed by the brazing filler metal. The amount of residue of flux at the side edge portion side where the joint portions 24 exist, of the outer faces of the heat exchange tubes 4 are more than that at the other side edge portion side. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a heat exchanger, and more particularly, to a heat exchanger used as, for example, a condenser, an evaporator, a heater core, an automobile oil cooler, an automobile radiator, and the like of a car air conditioner and a manufacturing method thereof.

  In this specification, the term “aluminum” includes aluminum alloys in addition to pure aluminum.

  For example, as a heat exchanger used in a condenser of a car air conditioner of a vehicle, a pair of header tanks formed of a material having a brazing filler metal layer on the outer surface and arranged at intervals from each other, Between a plurality of flat heat exchange tubes that are spaced apart in the length direction of the header tank and are arranged in the width direction in the direction of ventilation and that are brazed to the header tank at both ends, and adjacent heat exchange tubes And a corrugated fin brazed to a heat exchange pipe is widely used.

  The heat exchanger tube of the heat exchanger is required not only to have excellent heat exchange efficiency but also to have pressure resistance because a high-pressure gas refrigerant is introduced into the heat exchanger tube. Moreover, in order to reduce the size of the condenser, it is required that the tube wall of the heat exchange tube is thin and the tube height is low.

  As a heat exchange tube excellent in heat exchange efficiency used for the capacitor described above, for example, the one described in Patent Document 1 has been used. The heat exchange tube described in Patent Document 1 spans a pair of flat walls facing each other, two side walls provided across both side edges of both flat walls, and both flat walls between both side walls. A plurality of reinforcing walls extending in the lengthwise direction and spaced apart from each other, and having a plurality of parallel fluid passages therein, wherein the first side wall and the two flat walls Formed integrally, and the second side wall is formed by two side wall forming portions that are integrally formed on the side edge of each flat wall, project to the other flat wall side, and brazed so that the tips are brought into contact with each other Has been.

  Such a heat exchange tube is composed of a single metal plate as a whole, and connects two flat wall forming portions of the same width forming both flat walls, connecting the flat wall forming portions and forming a first side wall. And a side wall forming part that forms a second side wall and a side wall forming part that forms a second side wall, and a side wall forming part that forms a second side wall, and a side wall forming part that is formed integrally with the both side flat wall forming parts. A plate for heat exchange tube production having a reinforcing wall forming part is bent into a hairpin shape at the connecting part, the ends of both side wall forming parts are butted against each other and formed on one flat wall forming part The front end of the reinforcing wall forming portion formed and the front end of the reinforcing wall forming portion formed on the other flat wall forming portion are brought into contact with each other and brazed to each other. And the thickness of the 2nd side wall formed by making two side wall formation parts face each other and brazing is thinner than the thickness of the 1st side wall which consists of a connection part.

  However, when the heat exchange tube described in Patent Document 1 is used in the condenser as described above, if the flying stone hits the second side wall formed of the two side wall forming portions, the second side wall may be damaged by the impact. is there.

  Therefore, in order to solve such a problem, the present applicant previously provided a pair of flat walls facing each other and two side walls provided across both side edges of both flat walls. The first side wall is formed integrally with the two flat walls, the second side wall is formed by combining a plurality of side wall forming portions formed integrally with the side edges of the two flat walls, and the second side wall is A first side wall forming portion formed on a side edge portion of the first flat wall and projecting toward the second flat wall side and having a tip located at an intermediate portion of the height of the second side wall; and a side edge of the second flat wall A second side wall forming portion that is formed on the first flat wall and protrudes toward the first flat wall side and whose tip is located at the middle of the height of the second side wall and is abutted against the tip of the first side wall forming portion; Formed on the outer side in the width direction of the heat exchange pipe of the second side wall forming part in the wall and projecting to the first flat wall side, One end of the first flat wall is engaged with a side edge portion of the outer surface of the first flat wall, the front end portions of the first and second side wall forming portions, the outer surfaces of the first and second side wall forming portions, A third side wall forming part and a heat exchange pipe in which the third side wall forming part and the side edge of the first flat wall are brazed have been proposed (see Patent Document 2).

  The heat exchange tube described in Patent Document 2 is made of a single metal plate as a whole, two flat wall forming portions, a connecting portion that integrally connects both flat wall forming portions and forms a first side wall, The first and second side wall forming portions provided on the side edge opposite to the connecting portion in the flat wall forming portion so as to protrude from the flat wall forming portion, and the connecting portion in the first flat wall forming portion. A plate for manufacturing a heat exchange tube provided with an extension for a third side wall forming part provided by extending the opposite side edge is bent into a hairpin shape on both sides of the connecting part, and the first and first A second side wall forming part is abutted with each other; a third side wall forming part extension part is bent so as to cover the outer surfaces of the first and second side wall forming parts to form a third side wall forming part; Engage the tip of the side wall forming part with the side edge of the outer surface of the first flat wall forming part Making the bent body, and the first side wall forming portion and the second side wall forming portion of the bent body, the first and second side wall forming portions and the third side wall forming portion, and the third side wall forming portion and the first flat wall. It is manufactured by simultaneously brazing the forming part. And in the manufactured heat exchange pipe, it consists of a brazing part between the 1st flat wall which consists of a 1st flat wall formation part, and the front-end | tip part of the 3rd side wall formation part in a 2nd side wall, and length direction There will be a seam that extends.

  The heat exchanger provided with the heat exchange pipe described in Patent Document 2 is formed by alternately arranging the above-described bent bodies and fins used for manufacturing the heat exchange pipe, and a material having a brazing filler metal layer on the outer surface. Prepare a pair of header tank materials with multiple tube insertion holes, arrange both header tank materials at intervals, insert both ends of the folded body into the tube insertion holes of the header tank material, Temporarily fix the material, bent body, and fins to make a temporary fixed body, apply flux to the temporary fixed body, and place the temporary fixed body so that the width direction of the bent body faces in the vertical direction. In the state, the first side wall forming portion and the second side wall forming portion, the first and second side wall forming portions and the third side wall forming portion, and the third side wall forming portion and the first flat wall forming portion are brazed at the same time. To do To form a more heat exchange tubes, the header tank material to form a header tank, further header tank and the heat exchange tubes, is prepared by a method comprising brazing the fins heat exchanger tubes at the same time.

However, in the manufacturing method of the heat exchanger described above, since the direction of the bent body is not particularly determined, the bent bodies having different directions will be mixed, and as a result, when the temporary fixing body is laid and placed. There may be a bent body in which the first to third side wall forming portions are on the upper side. In this case, the following problems may occur. That is, in the above-described bent body for manufacturing the heat exchange tube of Patent Document 2, between the distal end portion of the third side wall forming portion and the outer surface of the first flat wall forming portion, in the length direction of the bent body. There will be a stretch seam. This seam may be a shallow shallow groove. Therefore, when the first to third side wall forming portions are on the upper side, the seam is also present on the upper side, and when the heat exchanger is manufactured, the molten brazing material that has melted from the header tank material is present. Due to the capillary phenomenon, it flows along the seam and flows along the contact portion between the bent body and the corrugated fin. As a result, it is necessary to increase the amount of brazing material covering the outer surface of the header tank material, which increases the material cost, which in turn increases the manufacturing cost of the heat exchanger and increases the weight of the heat exchanger. There's a problem.
JP-A-6-281373 JP 2006-78163 A

  An object of the present invention is to provide a heat exchanger that solves the above-described problems and can reduce the manufacturing cost and reduce the weight, and a method for manufacturing the heat exchanger.

  In order to achieve the above object, the present invention comprises the following aspects.

  1) A pair of header tanks formed of a material having a brazing filler metal layer on the outer surface and spaced apart from each other, and a distance in the length direction of the header tank and a width direction between the header tanks. Corrugated fins that are arranged in the direction of ventilation and that are brazed to the heat exchange pipes between the flat heat exchange pipes that are brazed to the header tank at both ends and adjacent heat exchange pipes And the heat exchange tube has a pair of flat walls facing each other and two side walls provided across both side edges of both flat walls, and at least one side of the brazing material layer A brazing sheet having a brazing material layer is bent so that the brazing material layer is on the outside, and there is a seam portion extending in the longitudinal direction on one side edge of the outer surface of one of the flat walls of the heat exchange tube. Heat A exchanger, joint portions of all the heat exchange tubes, the heat exchanger being located on the same side of the ventilating direction.

  2) The heat exchanger according to the above 1), wherein the joint portion is closed with a brazing material.

  3) The heat exchange described in 1) or 2) above, wherein the amount of brazing material on the side edge side where the seam portion exists on the outer surface of the heat exchange pipe is larger than the amount of brazing material on the other side edge side. vessel.

  4) The amount of flux residue on the side edge side where the seam portion on the outer surface of the heat exchange pipe is present is larger than the amount of flux residue on the other side edge side, any of the above 1) to 3) The heat exchanger according to crab.

In the heat exchanger of 4) above, the amount of flux residue on the side edge side where the seam portion exists on the outer surface of the heat exchange tube is 3 g / m ² or more than the amount of flux residue on the other side edge side. There may be many.

  In the heat exchangers 1) to 4), the first side wall of the heat exchange tube is formed integrally with the two flat walls, and the second side wall is also formed integrally with the side edges of the two flat walls. Formed by combining a plurality of side wall forming parts, two flat wall forming parts, a connecting part that integrally connects both flat wall forming parts and forms a first side wall, and a connecting part in both flat wall forming parts; Is obtained by bending a plate-like body for manufacturing a heat exchange tube having a side wall forming portion provided on the opposite side edge portion into a hairpin shape at a connecting portion and caulking all side wall forming portions in combination. After obtaining the bent body, the heat exchange pipe is formed by brazing the plurality of side wall forming parts, and any one of the side wall forming parts forming the second side wall of the heat exchange pipe The brazing part between the forming part and one of the flat wall forming parts There may be seams. In the case of the heat exchanger, the second side wall of the heat exchange pipe is integrally formed on the edge of each flat wall opposite to the first side wall so as to protrude to the other flat wall side, and the tip part The first and second side wall forming portions brazed to each other, and the first and second side wall forming portions of either one of the flat walls are integrally formed on the outer side in the width direction of the heat exchange tube, and the first And an inclined surface which is brazed to the outer surface of the second side wall forming portion and whose tip is inclined toward the one flat wall side toward the outer side in the width direction of the heat exchange tube at the side edge portion of the other flat wall outer surface. A joint portion extending in the longitudinal direction of the heat exchange pipe exists between the tip end portion of the third side wall forming portion and the upper end portion in the inclined direction of the inclined surface. Have

5) A pair of header tanks formed of a material having a brazing filler metal layer on the outer surface and spaced from each other, and a distance in the length direction of the header tank and a width direction between the header tanks. Corrugated fins that are arranged in the direction of ventilation and that are brazed to the heat exchange pipes between the flat heat exchange pipes that are brazed to the header tank at both ends and adjacent heat exchange pipes And the heat exchange tube has a pair of flat walls facing each other and two side walls provided across both side edges of both flat walls, and at least one side of the brazing material layer A brazing sheet having a brazing material layer is bent so that the brazing material layer is on the outside, and there is a seam portion extending in the longitudinal direction on one side edge of the outer surface of one of the flat walls of the heat exchange tube. And The first side wall of the exchange pipe is formed integrally with both flat walls, and the second side wall of the heat exchange pipe projects to the edge of each flat wall opposite to the first side wall and to the other flat wall side. The first and second side wall forming portions formed integrally with each other and the end portions thereof are brazed to each other, and the width direction outer side portion of the heat exchange tube relative to the first and second side wall forming portions on either one of the flat walls And a third side wall forming part that is brazed to the outer surfaces of the first and second side wall forming parts and whose tip part is brazed to the side edge part of the other flat wall outer surface. A method of manufacturing an exchanger,
It consists of a brazing sheet having a brazing material layer on at least one side, two flat wall forming parts, a connecting part that integrally connects both flat wall forming parts and forms a first side wall, and a connecting part in both flat wall forming parts The first and second side wall forming portions provided so as to protrude from the flat wall forming portion on the side edge on the opposite side, and the side edge opposite to the connecting portion in the first flat wall forming portion are extended. And a tip part of the first and second side wall forming parts by bending the plate for heat exchange pipe production provided with the third side wall forming part extension part into a hairpin shape on both sides of the connecting part. Matching each other,
The third side wall forming part extension part is bent so as to cover the outer surfaces of the first and second side wall forming parts to form the third side wall forming part, and the tip of the third side wall forming part is set to the second flat wall forming part. Engaging the side edge of the outer surface to make a folded body,
Alternately arranging the folding bodies and fins;
Preparing a pair of header tank materials made of a material having a brazing filler metal layer on the outer surface and having a plurality of pipe insertion holes, and arranging the header tank materials at intervals;
Insert both ends of the entire folded body into the pipe insertion holes of the header tank material so that the first to third side wall forming portions are on the same side, and temporarily secure the header tank material, the folded body and the fins. And applying flux to the temporary fixing body,
The first side wall forming portion in the bent body is arranged in this state by placing the temporary fixing body so that the width direction of the bent body is directed in the vertical direction and the first to third side wall forming portions of the bent body are on the lower side. And a second side wall forming portion, a first side wall forming portion and a third side wall forming portion, and a third side wall forming portion and a first flat wall forming portion are simultaneously brazed to form a heat exchange tube, A method of manufacturing a heat exchanger, comprising: forming a header tank from a header tank material; and brazing the header tank and the heat exchange pipe, and the heat exchange pipe and the fin at the same time.

In addition, in the heat exchanger manufacturing method of 5) above, when the temporary fixing body is laid down, the amount of flux applied on the lower edge side of the outer surface of the folded body is greater than the amount of flux applied on the upper edge side. May be increased. In the case of the manufacturing method of the heat exchanger, when the temporary fixing body is laid down, the flux application amount on the lower edge side on the outer surface of the bent body is 3 g / m ² than the flux application amount on the upper edge side. May be more.

  According to the heat exchangers of 1) to 3) above, the heat exchange pipe has a pair of flat walls facing each other and two side walls provided across both side edges of both flat walls. And a brazing sheet having a brazing filler metal layer on at least one side thereof and being bent so that the brazing filler metal layer is on the outside, and having a length on one side edge of the outer surface of one of the flat walls of the heat exchange tube. There is a joint portion extending in the direction, and the joint portions of all the heat exchange pipes are located on the same side in the ventilation direction. The two flat wall forming parts, the connecting part that integrally connects the two flat wall forming parts and forms the first side wall, and the side edge opposite to the connecting part in the two flat wall forming parts. Bulge from each flat wall forming part And a third side wall forming portion extension provided by extending a side edge of the first flat wall forming portion opposite to the connecting portion. The heat exchanger tube manufacturing plate-like body provided is bent into a hairpin shape on both sides of the connecting portion, and the leading end portions of the first and second side wall forming portions are butted together, an extension portion for the third side wall forming portion, A third side wall forming portion is formed by bending so as to cover the outer surfaces of the first and second side wall forming portions, and a tip end portion of the third side wall forming portion is engaged with a side edge portion of the outer surface of the first flat wall forming portion. Prepare a pair of header tank materials with a plurality of tube insertion holes using a material having a brazing filler metal layer on the outer surface, making a folded body, arranging the folded bodies and fins alternately, and separating both header tank materials Arranged at a distance, fully folded body Insert both ends into the pipe insertion hole of the header tank material so that the first to third side wall forming portions are on the same side, and temporarily fix the header tank material, the bent body and the fin to make a temporary fixing body, Apply the flux to the temporary fixing body, and arrange the temporary fixing body so that the width direction of the bent body faces in the vertical direction and the first to third side wall forming portions of the bent body are on the lower side. In the state, the first side wall forming portion and the second side wall forming portion, the first and second side wall forming portions and the third side wall forming portion, and the third side wall forming portion and the first flat wall forming portion are brazed at the same time. In the method of manufacturing a heat exchanger, including forming a heat exchange pipe, forming a header tank from a header tank material, and brazing the header tank and the heat exchange pipe, and the heat exchange pipe and the fin at the same time, Full fold Insert both ends of the rod body into the pipe insertion holes of the header tank material so that the first to third side wall forming portions are on the same side, and the width direction of the folded body faces the vertical direction, and the folded body When the temporary fixing body is placed so that the first to third side wall forming portions are on the lower side, when the heat exchanger is manufactured, the molten brazing material melted from the outer surface of the bent body flows downward due to gravity, and the bent body The seam forming the seam is filled with the brazing filler metal. Therefore, the molten brazing material melted from the material forming the header tank material at the time of manufacturing the heat exchanger is prevented from flowing along the seam forming the seam portion in the bent body due to the capillary phenomenon. As a result, the amount of brazing material covering the outer surface of the material forming the header tank material can be reduced, the material cost can be reduced, the manufacturing cost of the heat exchanger can be reduced, and the weight can be reduced. be able to.

  According to the heat exchanger of 4) above, the downward flow due to the gravity of the molten brazing material melted out from the outer surface of the bent body during the manufacture of the heat exchanger is effectively performed, and a seam portion in the bent body is formed. The seam is reliably filled with molten brazing material.

  According to the heat exchanger manufacturing method of 5) above, the molten brazing material that has melted from the outer surface of the bent body flows downward due to gravity, and the seam forming the seam portion in the bent body is filled with the molten brazing material. Therefore, the molten brazing material melted from the material forming the header tank material at the time of manufacturing the heat exchanger is prevented from flowing along the seam forming the seam portion in the bent body due to the capillary phenomenon. As a result, the amount of brazing material covering the outer surface of the material forming the header tank material can be reduced, the material cost can be reduced, the manufacturing cost of the heat exchanger can be reduced, and the weight can be reduced. be able to.

  Embodiments of the present invention will be described below with reference to the drawings. In this embodiment, the heat exchanger according to the present invention is applied to a condenser of a car air conditioner using a chlorofluorocarbon refrigerant.

  In the following description, the up and down, left and right in FIG. 1 are referred to as up and down and left and right, the downstream side in the ventilation direction (the direction indicated by the arrow X in FIG. 1, the upper side in FIG. 2) is the front, and the opposite side is the back. Shall. However, the description regarding the manufacturing method of the heat exchange pipe regarding FIG. 6 and FIG. 7 is excluded.

  FIG. 1 shows the overall configuration of a car air conditioner capacitor to which a heat exchanger according to the present invention is applied, and FIGS. 6 and 7 show a method for manufacturing a heat exchange tube used for a capacitor.

  1 and 2, a car air conditioner capacitor (1) includes a pair of aluminum header tanks (2) (3) extending in the vertical direction and spaced apart in the left-right direction, and both header tanks ( 2) Pipe insertion holes (2A) (3A) with the width direction facing the ventilation direction between (3) and spaced apart in the vertical direction and both ends formed in both header tanks (2) (3) ) Inserted into the header tanks (2) and (3) and brazed to the two aluminum flat heat exchange tubes (4), between the adjacent heat exchange tubes (4) and at the top and bottom ends. Aluminum corrugated fins (5) arranged outside the exchange pipe (4) and brazed to the heat exchange pipe (4), and corrugated fins (5) arranged outside the corrugated fins (5) at both upper and lower ends And a side plate (6) brazed.

  The left header tank (2) is divided into two upper and lower header parts (2a) and (2b) by a partition member (7) above the central part in the height direction, and the right header tank (3) is The upper and lower header parts (3a) and (3b) are partitioned by a partition member (7) below the central part. A fluid inlet (10A) is formed in the upper header portion (2a) of the left header tank (2), and an inlet member (8) having a fluid inflow passage (8a) communicating with the fluid inlet (10A) is formed in the upper header portion (2a). It is brazed. In addition, a fluid outlet (10B) is formed in the lower header portion (3b) of the right header tank (3), and an outlet member (9) having a fluid outlet path (9a) leading to the fluid outlet (10B) is connected to the lower header portion ( It is brazed to 3b).

  The left and right header tanks (2) and (3) are made of an aluminum pipe having a brazing filler metal layer on at least the outer surface, for example, a base plate made of an aluminum brazing sheet having a brazing filler metal layer on both sides is formed into a cylindrical shape, and both side edges A header tank body (11) having a plurality of heat exchange insertion holes, and a header tank body (11) brazed to both ends of the header tank body (11). An aluminum closing member (12) for closing the opening. Detailed illustration of the header tank body (11) is omitted. Further, the header tank body (11) may be made of an aluminum extruded tube having a brazing material sprayed on the outer peripheral surface.

  As shown in FIGS. 3 to 5, the heat exchange pipe (4) is made of aluminum, is opposed to each other with a space in the vertical direction, and has a pair of flat walls (13), (14) having the same thickness. A first side wall (15) straddling one side edge of both flat walls (13) and (14) and integrally formed with both flat walls (13) and (14), and both flat walls (13) and (14) A second side wall (16) formed by combining a plurality of side wall forming portions integrally formed on the other side edge portions of the flat walls (13) and (14). It consists of a plurality of reinforcing walls (17) that extend across the flat walls (13), (14) between the side walls (15), (16) and are spaced apart from each other and extend in the length direction. And a plurality of fluid passages (18) arranged in parallel. Although not shown in the figure, all the reinforcing walls (17) are provided with a plurality of communication holes through which the adjacent fluid passages (18) pass so as to form a staggered arrangement as viewed from above. Yes.

  The second side wall (16) includes a first side wall forming part (19) formed integrally with the first flat wall (13) and a second side wall forming part (integrally formed with the second flat wall (14) ( 21) and a third side wall forming portion (22) formed integrally with the first flat wall (13) in combination and brazed.

  The first side wall forming portion (19) is integrally formed on the first flat wall (13) so as to protrude toward the second flat wall (14). The second side wall forming portion (21) is formed integrally with the second flat wall (14) so as to protrude toward the first flat wall (13), and the tip projects into the tip of the first side wall forming portion (19). It is brazed to the first side wall forming portion (19) in the combined state. The tip portions of the first and second side wall forming portions (19) and (21) are butted against each other. That is, the front end portion of the first side wall forming portion (19) of the first flat wall (13) has a shape in which the outer half in the front-rear direction is cut away, and the second flat wall (14) has the second end. The tip of the two side wall forming portion (21) is shaped such that the front half in the front-rear direction is cut away, and the protruding portion (19a) of the first side wall forming portion (19) is the second side wall forming portion ( 21) fits into the cutout part (21b), and the protruding part (21a) of the second side wall forming part (21) fits into the cutout part (19b) of the first side wall forming part (19).

  The third side wall forming portion (22) is formed integrally with the first flat wall (13) so as to protrude toward the second flat wall (14) on the outer side in the front-rear direction than the first side wall forming portion (19). The front and rear ends of the first and second side wall forming portions (19) and (21) are formed at the front and rear outer edges of the second flat wall (14) outer surface. The entire outer surface of the first and second side wall forming portions (19), (21) and the second flat surface in a state of being engaged with the inclined surface (23) inclined toward the first flat wall (13) toward It is brazed to the inclined surface (23) of the wall (14). And on one surface to which the corrugated fin (5) of the heat exchange pipe (4) is brazed, there is a tip of the third side wall forming part (22) and an inclined surface (23 of the second flat wall (14)). ) And a first side wall (15) side end portion, and a seam portion (24) including a brazed portion extending in the length direction of the heat exchange pipe (4) exists over the entire length. The seam portion (24) may have a shallow groove shape.

  The reinforcing wall (17) includes reinforcing ribs (25) and (26) integrally formed so as to protrude from the first flat wall (13) toward the second flat wall (14), and the second flat wall ( 14) Reinforcing wall ridges (27) and (28), which are integrally formed so as to protrude from the first flat wall (13) side, are formed by brazing the ends of each other with each other butted together. ing. On the first flat wall (13) and the second flat wall (14), two types of reinforcing wall projections (25) (26) and (27) (28) with different thicknesses are alternately arranged in the front-rear direction. The thick reinforcing wall projection (25) on the first flat wall (13) and the thin reinforcing wall projection (28) on the second flat wall (14) are brazed. The thin reinforcing wall projections (26) on the first flat wall (13) and the thick reinforcing wall projections (27) on the second flat wall (14) are brazed. . Hereinafter, the thick reinforcing wall ridges (25) and (27) of the flat walls (13) and (14) are referred to as first reinforcing wall ridges, respectively, and the thin reinforcing wall ridges (26) ( 28) shall be called the second reinforcing wall projections. The first reinforcing wall ridges (25) and (27) of the two flat walls (13) and (14) are respectively extended in the length direction thereof, and the second flat walls (14) and (13) are secondly Concave grooves (29) and (31) into which the tip ends of the reinforcing wall projections (28) and (26) fit are formed over the entire length. And the front-end | tip part of the 2nd reinforcement wall convex line | wire (28) of a 2nd flat wall (14) is in the groove | channel (29) of the 1st reinforcement wall convex line | wire (25) of a 1st flat wall (13). The tip of the second reinforcing wall projection (26) of the first flat wall (13) is inserted into the groove (31) of the first reinforcing wall projection (27) of the second flat wall (14), respectively. In the press-fitted state, both reinforcing wall projections (25) (28) and (26) (27) are brazed.

The total heat exchange pipe (4) is arranged such that the second side wall (16) is located on the same side, that is, the rear side, and the joint part (24) is located on the same side in the ventilation direction, that is, the rear side. . On the outer surface of the heat exchange tube (4), the brazing material (33) used at the time of manufacturing the capacitor (1) and the flux residue (34) are present so as to cover the entire outer surface. The amount of brazing material (33) on the rear edge side where the seam portion (24) exists on the outer surface of the heat exchange pipe (4) is larger than the amount of brazing material (33) on the front edge side. The seam portion (24) is completely closed by the brazing material (33). Further, the amount of the flux residue (34) on the rear edge side where the seam portion (24) exists on the outer surface of the heat exchange pipe (4) is preferably more than the amount of the flux residue (34) on the front edge side. Is 3 g / m ² or more. Although brazing material and flux residue are also present on the outer surface of the heat exchange tube (4), illustration thereof is omitted.

  The capacitor (1) is manufactured by the method described below.

  First, a pair of cylindrical aluminum header tank body materials having a brazing filler metal layer at least on the outer surface, a closing member (12), a plurality of aluminum corrugated fins (5), a side plate (6), an inlet member (8), And an outlet member (9). A plurality of pipe insertion holes are formed in the header tank body material.

  Further, a bent body (40A) for making the heat exchange tube (4) is obtained by the method described below using the plate (40) for producing the heat exchange tube shown in FIG. In the description of FIGS. 6 and 7 regarding the method of manufacturing the heat exchange tube, the upper and lower sides and the left and right sides of FIGS.

  The plate (40) for producing a heat exchange tube is formed by rolling a rolling base plate made of an aluminum brazing sheet having a brazing filler metal layer on both sides, and both flat walls (13) (14 The first flat wall forming portion (41) and the second flat wall forming portion (42) having the same width and the same thickness as each other, and the flat wall forming portions (41) (42) are integrated with each other. And a connecting portion (43) that forms the first side wall (15) and the connecting portion (43) on the opposite side of the first flat wall forming portion (41) and the second flat wall forming portion (42). First and second side wall forming portions (19) and (21) which are integrally formed in a raised shape above the side edge and form the second side wall (16), and a connecting portion (43 in the first flat wall forming portion (41)) ), A third side wall forming portion extension (44) formed by extending the side edge opposite to the right side, the first flat wall forming portion (41) and the second flat wall forming portion (42). ) To the left and right A plurality of first and second reinforcing wall projections (25), (26), (27), and (28) that are integrally formed in an upwardly protruding shape at a predetermined interval, and a first flat wall forming portion ( 41) first reinforcing wall ridge (25), second flat wall forming portion (42) second reinforcing wall ridge (28), and second flat wall forming portion (42) first reinforcing wall. The ridges for use (27) and the ridges (26) for the second reinforcing wall of the first flat wall forming part (41) are symmetrical with respect to the longitudinal center line of the connecting part (43). It is in.

  An inclined surface (23) inclined upward toward the left is formed on the left edge of the lower surface of the second flat wall forming portion (42) on the second side wall forming portion (21) side. The first and second side wall forming portions (19) and (21) of the flat wall forming portions (41) and (42) are respectively provided with a protruding portion (19a) (21a) and a notch portion (19b) (21b) at the tip portion. Of the first side wall forming part (19) of the first flat wall forming part (41) and the second side wall forming part (21) of the second flat wall forming part (42). The notch (21b), the notch (19b) of the first side wall forming part (19) of the first flat wall forming part (41) and the second side wall forming part of the second flat wall forming part (42) ( The protruding portions (21a) of 21) are in positions that are line-symmetric with respect to the center line in the left-right direction of the connecting portion (43). Further, the dimensions of the first and second side wall forming portions (19) and (21), that is, the height, the overall thickness, and the thicknesses of the protruding portions (19a) and (21a) are the same. A groove in which the second reinforcing wall projection (28) of the second flat wall forming portion (42) is press-fitted into the front end surface of the first reinforcing wall protruding strip (25) of the first flat wall forming portion (41). (29) is formed, and the second reinforcing wall projection (26) of the first flat wall forming portion (41) is formed on the front end surface of the first reinforcing wall projection (27) of the second flat wall forming portion (42). ) Is pressed into the groove (31). Dimensions of the first reinforcing wall ridges (25) of the first flat wall forming portion (41) and the first reinforcing wall ridges (27) of the second flat wall forming portion (42), that is, height and thickness. The widths of the grooves (29) and (31) and the depths of the grooves (29) and (31) are the same. The dimensions of the second reinforcing wall projection (26) of the first flat wall forming portion (41) and the second reinforcing wall projection (28) of the second flat wall forming portion (42), that is, the height and The wall thickness is the same. The thickness of the third side wall forming portion extension (44) is equal to the thickness of the upper second flat wall forming portions (42) and (22).

  The first flat wall forming portion (41), the second flat wall forming portion (42), and the connecting portion (43) are obtained by rolling a rolling base plate made of an aluminum brazing sheet provided with a brazing filler metal layer on both sides. The first and second side wall forming portions (19) and (21), the third side wall forming portion extension (44), and the reinforcing wall ridges (25), (26), (27), and (28) are integrally formed. As a result, the entire surface excluding the side surface of the second side wall forming portion (21) of the second flat wall forming portion (42) and the tip end surface of the third side wall forming portion extension (44) is made of the brazing material layer. Covered.

  Then, as shown in FIG. 7, the heat exchange tube manufacturing plate (40) is sequentially bent on the left and right sides of the connecting portion (43) by roll forming (see FIG. 7 (a)), and finally. Folded into a hairpin shape to fit the protrusions (19a) and (21a) of the first and second side wall forming portions (19) and (21) with the notch portions (21b) and (19b), and the convexity for the second reinforcing wall The tips of the strips (26) and (28) are press-fitted into the concave grooves (31) and (29) of the first reinforcing wall projections (27) and (25).

  Next, the third side wall forming part extension (44) is bent so that it extends along the outer surfaces of the first and second side wall forming parts (19) and (21), and the tip part thereof is the second flat wall forming part ( 42) is engaged with the inclined surface (23) to form a third side wall forming portion (22) to obtain a bent body (40A) (see FIG. 7B). Here, in the bent body (40A), the tip of the third side wall forming part (22) and the outer surface of the first flat wall forming part (41), that is, the tip of the third side wall forming part (22) and the inclined surface ( A seam (45) extending in the length direction of the bent body (40A) exists between the upper end of the inclined direction of 23).

Next, a pair of header tank body materials having pipe insertion holes (2A) and (3A) are arranged at intervals, and a closing member (12) is arranged at both ends of both header tank body materials to remove the header tank material. prepare. Further, the folded bodies (40A) and the fins (5) are alternately arranged, and both ends of the folded body (40A) are inserted into the pipe insertion holes (2A) (3A) of the header tank material. At this time, the entire folded body (40A) is arranged so that the seam (45) is located in the same direction. Further, a side plate (6) is disposed outside the corrugated fins (5) at both ends, and an inlet member (8) and an outlet member (9) are further disposed. Next, the header tank material composed of the header tank body material and the closing member (12), the bent body (40A), the corrugated fin (5), the side plate (6), the inlet member (8) and the outlet member (9) are temporarily mounted. Stop and make a temporary fixing body, and apply flux to the temporary fixing body. Next, the temporary fixing body is laid in the brazing furnace so that the first to third side wall forming portions (19), (21), and (22) of the bent body (40A), that is, the seam (45) is on the lower side. Arrange in the state. At this time, the flux application amount on the lower edge side on the outer surface of the bent body (40A) is set to be larger than the flux application amount on the upper edge side. Preferably, the flux application amount on the lower edge side on the outer surface of the bent body (40A) is set to be 3 g / m ² or more larger than the flux application amount on the upper edge side.

  Thereafter, the temporary fixing body is heated to a predetermined temperature in the brazing furnace to braze the tips of the first and second side wall forming portions (19) and (21) to each other, and the third side wall forming portion (22 ) Is brazed to the outer surfaces of the first and second side wall forming portions (19) and (21) and the inclined surface (23) of the second flat wall forming portion (42) to form the second side wall (16). Further, the reinforcing wall (17) is formed by brazing the tip portions of both reinforcing wall projections (25) (28) and (26) (27) using the brazing material layer, and the connecting portion (43) forms the first side wall (15), the first flat wall forming portion (41) forms the first flat wall (13), and the second flat wall forming portion (42) forms the second flat wall (14). ) To form a heat exchange tube (4). At the same time, the header tank (2) (3) is manufactured from the header tank body material and the header tank material consisting of the closure member (12), and the heat exchange pipe (4), header tank (2) (3), heat exchange The pipe (4) and the corrugated fin (5), the corrugated fin (5) and the side plate (6), and the header tank (2) (3), the inlet member (8) and the outlet member (9) are simultaneously brazed. It is attached. Thus, the capacitor (1) is manufactured.

  At the time of brazing all the components at the time of manufacturing the capacitor (1) described above, the molten brazing material melted from the outer surface of the bent body (40A) flows downward due to gravity, and the seam portion (24) in the bent body (40A). The seam (45) that forms is filled with molten brazing material. Accordingly, it is possible to prevent the molten brazing material that has melted from the header tank body material during the production of the capacitor (1) from flowing along the joint (45) due to the capillary phenomenon. As a result, it becomes possible to reduce the amount of brazing material covering the outer surface of the material forming the header tank (2) (3), the material cost can be reduced, and the manufacturing cost of the capacitor (1) can be reduced. At the same time, the weight of the capacitor (1) can be reduced.

It is a whole perspective view showing an embodiment of a capacitor to which a heat exchanger of this invention is applied. It is the AA line expanded sectional view which abbreviate | omitted a part of FIG. FIG. 3 is an enlarged sectional view taken along line B-B in FIG. 2. FIG. 4 is a partially enlarged view of FIG. 3. It is a cross-sectional view which expands and shows a part of heat exchange pipe | tube of the capacitor | condenser of FIG. It is a front view of the plate for a heat exchange tube manufacturing used for manufacturing the heat exchange tube of the capacitor | condenser of FIG. It is a figure which shows a part of process of manufacturing the heat exchange pipe | tube of the capacitor | condenser of FIG.

Explanation of symbols

(1): Capacitor (heat exchanger)
(2) (3): Header tank
(4): Heat exchange pipe
(5): Corrugated fin
(13): First flat wall
(14): Second flat wall
(15): First side wall
(16): Second side wall
(19): First side wall forming part
(21): Second side wall forming part
(22): Third side wall forming part
(23): Inclined surface
(24): Seam
(33): Brazing material
(34): Flux residue
(40): Plate for heat exchanger tube production
(40A): Folded body
(41): First flat wall forming portion
(42): Second flat wall forming part
(43): Connection part
(44): Extension part for third side wall forming part

Claims (5)

A pair of header tanks formed of a material having a brazing filler metal layer on the outer surface and spaced apart from each other, and a distance in the length direction of the header tank between the header tanks and a ventilation direction in the width direction A plurality of flat heat exchange pipes that are disposed toward the opposite ends and brazed to the header tank, and corrugated fins that are disposed between adjacent heat exchange pipes and brazed to the heat exchange pipes. The heat exchange pipe has a pair of flat walls facing each other and two side walls provided across both side edges of both flat walls, and has a brazing material layer on at least one side. The brazing sheet is formed by bending the brazing material layer so that the brazing material layer is on the outside, and there is a seam portion extending in the length direction on one side edge of the outer surface of one of the flat walls of the heat exchange tube. Heat exchange A vessel, joint portions of all the heat exchange tubes, the heat exchanger being located on the same side of the ventilating direction. The heat exchanger according to claim 1, wherein the joint portion is closed with a brazing material. The heat exchanger according to claim 1 or 2, wherein the amount of brazing material on the side edge portion side where the seam portion exists on the outer surface of the heat exchange tube is larger than the amount of brazing material on the other side edge portion side. The amount of the flux residue on the side edge portion side where the seam portion on the outer surface of the heat exchange pipe exists is larger than the amount of the flux residue on the other side edge portion side. Heat exchanger. A pair of header tanks formed of a material having a brazing filler metal layer on the outer surface and spaced apart from each other, and a distance in the length direction of the header tank between the header tanks and a ventilation direction in the width direction A plurality of flat heat exchange pipes that are disposed toward the opposite ends and brazed to the header tank, and corrugated fins that are disposed between adjacent heat exchange pipes and brazed to the heat exchange pipes. The heat exchange pipe has a pair of flat walls facing each other and two side walls provided across both side edges of both flat walls, and has a brazing material layer on at least one side. The brazing sheet is formed by bending the brazing material layer so that the brazing material layer is on the outside, and there is a seam portion extending in the length direction on one side edge of the outer surface of one of the flat walls of the heat exchange tube. ,heat The first side wall of the exchange tube is formed integrally with the two flat walls, and the second side wall of the heat exchange tube projects to the edge of each flat wall opposite to the first side wall and to the other flat wall side. The first and second side wall forming portions formed integrally with each other and the end portions thereof are brazed to each other, and the width direction outer side portion of the heat exchange tube relative to the first and second side wall forming portions on either one of the flat walls And a third side wall forming part that is brazed to the outer surfaces of the first and second side wall forming parts and whose tip part is brazed to the side edge part of the other flat wall outer surface. A method of manufacturing an exchanger,
It consists of a brazing sheet having a brazing material layer on at least one side, two flat wall forming parts, a connecting part that integrally connects both flat wall forming parts and forms a first side wall, and a connecting part in both flat wall forming parts The first and second side wall forming portions provided so as to protrude from the flat wall forming portion on the side edge on the opposite side, and the side edge opposite to the connecting portion in the first flat wall forming portion are extended. And a tip part of the first and second side wall forming parts by bending the plate for heat exchange pipe production provided with the third side wall forming part extension part into a hairpin shape on both sides of the connecting part. Matching each other,
The third side wall forming part extension part is bent so as to cover the outer surfaces of the first and second side wall forming parts to form the third side wall forming part, and the tip of the third side wall forming part is set to the second flat wall forming part. Engaging the side edge of the outer surface to make a folded body,
Alternately arranging the folding bodies and fins;
Preparing a pair of header tank materials made of a material having a brazing filler metal layer on the outer surface and having a plurality of pipe insertion holes, and arranging the header tank materials at intervals;
Insert both ends of the entire folded body into the pipe insertion holes of the header tank material so that the first to third side wall forming portions are on the same side, and temporarily secure the header tank material, the folded body and the fins. And applying flux to the temporary fixing body,
The first side wall forming portion in the bent body is arranged in this state by placing the temporary fixing body so that the width direction of the bent body is directed in the vertical direction and the first to third side wall forming portions of the bent body are on the lower side. And a second side wall forming portion, a first side wall forming portion and a third side wall forming portion, and a third side wall forming portion and a first flat wall forming portion are simultaneously brazed to form a heat exchange tube, A method of manufacturing a heat exchanger, comprising: forming a header tank from a header tank material; and brazing the header tank and the heat exchange pipe, and the heat exchange pipe and the fin at the same time.

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