JP4782171B2 - Manufacturing method of heat exchanger - Google Patents

Description

The present invention relates to a method for manufacturing a heat exchanger .

FIG. 5 is an exploded perspective view of the internal structure of a conventional water heater.
A burner block (2) composed of a plurality of flat burners (21) (21) arranged in parallel is housed in a rectangular combustion box (3) and a front end opening of the combustion box (3) ( The upper half of 30) is closed by a front plate (32), and further, gas is supplied from the gas distributor (1) to the burner block (2).

  On the other hand, the heat exchanger (4) connected to the upper end opening (31) of the combustion box (3) includes a rectangular cylindrical outer frame (40) penetrating vertically, and the outer frame (40). A plurality of endothermic fins (41) and (41), and the endothermic fins (41) and (41) and the water pipes (42) and (42) penetrating the side walls of the outer frame (40), Copper pipes (not shown) and the like are connected to the upstream end (420) and the downstream end of the water flow pipes (42) and (42).

  A flange (40A) projects from the outer periphery of the lower end of the outer frame (40), and insertion slits (S1) (S1) are formed in the flange (40A). Then, when assembling the heat exchanger (4) and the combustion box (3), a packing is interposed at the joint between the two, and the above-described combustion box (3) with respect to the insertion slits (S1) (S1) The crimping tongues (S2) and (S2) that stand up at the upper edge are inserted and bent to thereby crimp the heat exchanger (4) and the combustion box (3) (see FIGS. 5 and 6).

On the other hand, the exhaust duct body (5) connected to the upper end opening (43) of the heat exchanger (4) is formed in a flat rectangular box shape that opens downward and forward, and the exhaust duct body (5 The crimping tongue piece (S3) (S3) hangs down from the outer peripheral flange (53) of the lower end opening (52). The crimping tongues (S3) and (S3) are crimped in such a manner that they are wound around the outer peripheral flange (44) at the upper end of the heat exchanger (4) from the outside. And the water heater main body constituted by the assembly of the combustion box (3), the heat exchanger (4) and the exhaust duct main body (5) combined in this way is appropriately attached to the casing (9) with a bracket or the like. The arrangement is fixed.
An exhaust port cover (6) is fixed to the exhaust port (51) at the downstream end of the exhaust duct body (5) with screws (b) (b). The projecting exhaust pipe (60) is loosely inserted into an exhaust window (91) provided in the front cover (90) of the casing (9) of the water heater.
Japanese Patent Laying-Open No. 2003-21319 (FIG. 1)

An object of the present invention is to solve the following problems with respect to the heat exchanger (4) incorporated in the water heater.
1. By improving the mechanical strength of the heat exchanger (4), it is possible to reduce the risk of damage to the heat exchanger due to impact during shipping and installation of the water heater, and to suppress deterioration over time.
2. Even if the water pipes (42) and (42) repeat thermal expansion and contraction in the length direction, damage to the heat exchanger can be prevented.

The technical means of the present invention for solving the above problems are as follows:
`` The water pipes (42) and (42) made of copper material are passed through the through holes (410) and (410) of the heat-absorbing fins (41) and (41) made of copper material, and in the through-holes, A first step of interposing a brazing material (100) (100) made of a phosphor copper material between the water pipes (42) (42) and the inner peripheries of the through holes (410) (410);
A water pipe (42) is attached to the first single plate that forms the right side wall (45) for heat exchange made of stainless material and the second single plate that forms the left side wall (46) for heat exchange made of stainless material. ) (42) the second step of penetrating both ends,
A third step of connecting the outer ends of adjacent water pipes (42) (42) to each other by U-shaped pipes (42A) (42A) made of a copper material ;
After the third step, the jig (18) supports the first and second single plates and the aggregates such as the water pipes (42) (42) and the heat absorption fins (41) (41). A fourth step of melting the brazing material (100) (100) by heating in a heating furnace ;
After the fourth step, a third sheet that forms the front wall (47) for heat exchange made of stainless material and a fourth sheet that forms the rear wall (48) for heat exchange made of stainless material. And a fifth step of attaching the plate and the first single plate and the second single plate in a detachable manner with screws .
In this, the left and right first and second single plates constituting the right side wall for heat exchange and the left side wall for heat exchange, and the third and third before and after constituting the front side wall for heat exchange and the rear side wall for heat exchange. 4 Since the single plate is made of a stainless material, the mechanical strength is improved as compared with the case of a copper material. Therefore, there is less concern that the heat exchanger will be damaged due to impact during shipping and installation of the water heater. Moreover, since each said single plate is comprised with the stainless steel material, heat resistance improves compared with a copper material, and aged deterioration can be suppressed.

Further, since the through-holes of the water pipes (42) and (42) for the first and second single plates forming the right side wall for heat exchange and the left side wall for heat exchange are not substantially fixed, the water pipe (42 ) (42) even after repeated thermal expansion and contraction in the longitudinal direction, the thermal stress does not act on the penetrating portion, fear of heat exchanger is damaged is reduced.
That is, the endothermic fins (41) (41) and the water pipes (42) (42) made of copper material are brazed with the brazing material (100) (100) made of phosphorous copper material. The heat absorption fins (41) and (41) and the water pipes (42) and (42 ) are brazed in a heating furnace as follows .

That is, the water absorption pipes (42) and (42) are passed through the heat absorption fins (41) and (41), and the outer peripheral surfaces of the water flow pipes (42) and (42) and the heat absorption fins (41) (41) ), A brazing material is interposed as appropriate. Moreover, let the both ends of a water pipe (42) (42) penetrate the left and right 1st, 2nd single board (it is comprised with stainless steel) which comprises the right side wall for heat exchange, and the left side wall for heat exchange, The assembly of the pair of left and right first and second sheets, water pipes (42) and (42), and heat sink fins (41 and 41) in this state is heated in a heating furnace to melt the brazing material. . By melting the brazing material, the heat-absorbing fins (41) (41) and the water flow pipes (42) (42) are brazed, but the left and right first and second single plates are made of stainless steel. Even if brazing material flows into the through-holes of the water pipes (42) and (42) with respect to the first and second single plates, the first and second single plates and the water pipes (42) and (42) ) Is not substantially brazed. Since the brazing material combines the heat-absorbing fins (41) (41) and the water pipes (42) (42) made of copper material, the left and right stainless steel first and second single plates and the water pipes (42 ) (42) is not substantially bonded.
Therefore, when the water pipe (42) (42) repeats thermal expansion and contraction in the length direction along with gas combustion / extinguishment, the water pipe (42) (42) is the one piece in the penetrating portion. By sliding with respect to the plate, an excessive force does not act on the penetrating portion. Therefore, damage to the heat exchange part can be prevented.
Further, the third single plate forming the front wall for heat exchange, the fourth single plate forming the rear wall for heat exchange, and the first single plate and the second single plate are each made of screws. Since it is detachably attached, when the screw is removed, the front wall for heat exchange and the rear side wall for heat exchange can be removed, whereby the maintenance inside the heat exchange part can be easily performed.

A first single plate that forms the right side wall for heat exchange , a second single plate that forms the left side wall for heat exchange, a third single plate that forms the front side wall for heat exchange, and a rear side wall for the heat exchange Since the fourth single plate is made of a stainless material, the mechanical strength is improved as compared to the single plate of copper material. Moreover, heat resistance improves compared with the case where it comprises with a copper material, and aged deterioration can be prevented.
Further, as described above, since the left and right first and second single plates and the water pipes (42) and (42) are substantially in a non-bonded state, the water pipes ( 42) Even if (42) repeats thermal expansion and contraction in the length direction, excessive force does not act on the penetrating part of the water pipe (42) (42) with respect to the left and right first and second single plates. The damage to the heat exchanger can be prevented.
And since the front side wall for heat exchange and the rear side wall for heat exchange can be removed by removing the screw, maintenance inside the heat exchange part can be easily performed.

The best mode for carrying out the present invention will be described below with reference to the accompanying drawings.
The hot water heater shown in FIGS. 1 and 2 includes a gas combustion chamber (3A), a heat exchanger (4A) as an arrangement of a heat exchanger (4) above the gas combustion chamber (3A), and an upper part of the heat exchanger (4). The exhaust duct portion (56) formed between the rectifying blades (55) horizontally disposed on the top and the duct ceiling wall (54) above the rectifying blades (55) is provided in this order from below. Yes.

Details of each part will be described below.
[Gas combustion chamber (3A)]
The gas combustion chamber (3A) is an arrangement part of the burner block (2), the combustion chamber right side wall (33) and the combustion chamber left side wall (34), the combustion chamber front side wall (35) and the combustion chamber. It is formed in a rectangular box shape that is open upward and surrounded by a rear wall (36) for use and a bottom wall (37) for combustion chamber. As shown in FIGS. 1 and 3, both side edges (E) of the entire region from the combustion chamber bottom wall (37) to the duct ceiling wall (54) described later through the combustion chamber rear wall (36). (E) is a single plate constituting the left side wall for combustion chamber (34), the left side wall for heat exchange (46) and the left side wall for duct (58) described later, and the right side wall for combustion chamber (33). A crimping portion (H) (see FIG. 3) is fixed to a peripheral edge portion (G) of a single plate constituting a heat exchange right side wall (45) and a duct right side wall (57) which will be described later.
As shown in FIGS. 1 and 2, the discharge port of the supply fan (F) is connected to the supply port (370) opened in the bottom wall (37) for the combustion chamber.

The burner block (2) disposed in the gas combustion chamber (3A) includes a flat burner (21) (21) group arranged side by side in the left-right direction, and a burner that houses the flat burner (21) (21) group. Composed of the case (20), the left and right side walls (34) and (33) for the combustion chamber, the lower part of the front side wall (35) for the combustion chamber, which will be described later, and the tip standing piece (373) of the bottom wall (37) for the combustion chamber The gas distributor (1) for supplying gas to the flat burners (21) (21) is fixed with screws (19) (19).
The left and right ends of the combustion chamber front side wall (35) are fixed to the combustion chamber right side wall (33) and the combustion chamber left side wall (34) with screws (28) and (28). The combustion chamber front side wall (35) has an ignition device (39) for igniting the burner block (2), and a flame detector for detecting the flame generated in the flat burners (21) (21) group. (38) and an ignition confirmation window (29) are provided.

[Heat exchange part (4A)]
The heat exchange part (4A) is an arrangement part of the heat exchanger (4), and as shown in FIGS. 1 to 3, the heat exchanger (4) has a right side wall (45 ) And the left side wall for heat exchange (46), the front side wall for heat exchange (47) and the rear side wall for heat exchange (48) facing in the front-rear direction, and the right side wall for heat exchange (45) to each for heat exchange. A large number of heat-absorbing fins (41) and (41) arranged in parallel in a rectangular space surrounded by the rear side wall (48), and further, a water pipe (42) (42) passing through the heat-absorbing fins (41) and (41). 42). Further, both ends of the water pipes (42) and (42) penetrate the heat exchange right side wall (45) and the heat exchange left side wall (46) outwardly, and the U-shaped pipes outside the penetrating outside. (42A).

  The right side wall for heat exchange (45) is composed of a single plate with the right side wall for combustion chamber (33) and the right side wall for duct (57), which will be described later, and the left side wall for heat exchange (46) is combusted as described above. The left side wall for the chamber (34) and the left side wall for the duct (58) to be described later and a single plate, the front wall for heat exchange (47) is the front side wall for the combustion chamber (35) and the exhaust port cover to be described later. (6) and a single plate, and the heat exchange rear side wall (48) is composed of a single plate with the combustion chamber rear side wall (36) and the duct rear side wall (542) described later. Yes. Each of these single plates is made of a stainless material. On the other hand, the endothermic fins (41) and (41), the water pipes (42) and (42), and the U-shaped pipes (42A) and (42A) constituting the heat exchanger (4) are made of a copper material, and the endothermic fins ( 41) (41), the water pipes (42) and (42), and the U-shaped pipes (42A) and (42A) are brazed with a brazing material made of a phosphor copper material.

Next, a manufacturing operation of the heat exchanger (4) for describing the embodiment of the present invention will be described .
As shown in FIG. 4, the water pipes (42) and (42) are passed through the through holes (410) and (410) of the heat sink fins (41) and (41), and the water pipes (42) (42) ( 42) and a linear brazing material (100) (100) are interposed between the inner peripheries of the through holes (410) and (410). In addition, water pipes are connected to the right side wall (45) for heat exchange and the left side wall (46) for heat exchange that constitute a part of the left and right single plates (the first and second single plates, which are the specific matters of the invention described above ). (42) Pass through both ends of (42) and connect the outer ends of adjacent water pipes (42) (42) with U-shaped pipes (42A) (42A). , And assemblies such as the water pipes (42) and (42) and the heat absorption fins (41) and (41) are supported by the jig (18). Then, this assembly is heated in a heating furnace to melt the brazing materials (100) (100). Then, the endothermic fins (41) (41) and the water pipes (42) (42) are brazed by the melting of the brazing material (100) (100), but the right side wall (45) for heat exchange or the heat exchange. Since each single plate constituting the left side wall (46) is made of stainless steel, the right side wall (45) for heat exchanger and the left side wall (46) for heat exchanger of the water pipes (42) (42) Even if the molten brazing material (100) flows into the penetration part, the right side wall for heat exchange (45), the left side wall for heat exchange (46), and the water pipes (42) (42) are substantially It is never brazed. Accordingly, when the water pipe (42) (42) repeats thermal expansion and contraction in the length direction along with the point / fire extinguishing of the burner block (2) described later, the water pipe (42) (42) ( 42) slides with respect to the left and right side walls (46) and (45) for heat exchange, so that a mechanical load does not act on the penetrating portion. Therefore, it is possible to prevent damage to the heat exchange part (4A).

[Exhaust duct part (56)]
As shown in FIG. 1, the exhaust duct portion (56) provided above the heat exchanging portion (4A) includes a duct right side wall (57), a duct left side wall (58), and a duct rear side wall ( 542) and a duct ceiling wall (54). The entire range from the duct ceiling wall (54) to the duct rear wall (542) to the combustion chamber bottom wall (37) is manufactured by bending a single plate made of stainless steel. .
Between the top and bottom of the duct ceiling wall (54) and the heat exchanger (4), rectifying blades (55) are horizontally provided. As shown in FIGS. 2 and 3, the duct ceiling wall (54) The exhaust passage (59) is formed between the inner surface of the portion connected to the duct rear side wall (542) and the rectifying blade (55).

  As shown in FIG. 2, the range from the duct ceiling wall (54) to the arcuate rear end (540) is formed in a forward inclined posture toward the downstream end (front end) of the exhaust passage (59). In addition, the range from the upper surface to the rear surface of the rectifying blade (55) is parallel to the range from the duct ceiling wall (54) to the arcuate rear end (540). As shown in FIG. 1, the rectifying blade (55) has both side surfaces (560) and (560) fixed to the right and left side walls (58) and (57) for the duct with screws (b) and (b). ing.

[Exhaust port cover (6)]
The exhaust port cover (6) connected to the exhaust port (51) at the downstream end of the exhaust duct part (56), the heat exchange front side wall (47) and the combustion chamber front side wall (35) below the An exhaust pipe (60) penetrating forward and backward is formed by drawing the front part of the upper part of the single plate together with a single plate (a third single plate as a specific matter of the invention described above ). ing. The tip of the exhaust tube (60) is loosely inserted into an exhaust window (91) provided in the front lid (90) covering the front end opening of the case body (92) constituting the casing (9). In addition, the front lid (90) is detachably attached to the front end opening of the case body (92) with screws (95) (95).

Also, the peripheral edge of the single plate constituting the exhaust port cover (6) and the heat exchange front side wall (47) etc. is heat exchanged by the aforementioned screws (28) (28) and other screws (470) (470). The right single plate constituting the right side wall (45) for the duct and the right side wall (57) for the duct, and the single plate on the left side constituting the left side wall for heat exchange (46) and the left side wall (58) for the duct In addition, it is fixed in a removable state with respect to the standing upright piece (543) of the duct ceiling wall (54). Therefore, by removing the screws (470) (470) and removing the single plate constituting the exhaust port cover (6), the heat exchange front side wall (47), and the combustion chamber front side wall (35), heat exchange is performed. Maintenance inside the vessel (4) can be performed easily.
In this case, the exhaust pipe (60) is formed by drawing a single plate constituting the front wall (47) for heat exchange and the exhaust port cover (6), whereby an independent exhaust port cover (6 ) Is unnecessary. Therefore, the number of parts can be reduced, and the parts management can be simplified.

[Actual use]
In this case, when the hot water supply operation is started by burning the burner block (2), the combustion exhaust from the burner block (2) passes through the heat exchanger (4) and the bottom surface of the rectifying blade (55) is inclined ( 550), the gap between the rear end of the rectifying blade (55) and the arcuate rear end (540) of the ceiling wall (54) for the duct → the exhaust passage (59) → the exhaust port (51) → the exhaust port cover It flows in the route of (6) and is released into the atmosphere.
On the other hand, the heated water flowing through the water pipes (42) and (42) is heated and heated by the combustion exhaust gas passing through the heat exchanger (4) and then supplied to a hot water supply place (not shown).

The disassembled perspective view of the internal structure of a water heater provided with the heat exchanger (4) manufactured with the manufacturing method which concerns on embodiment of this invention 1 is a longitudinal sectional view of the water heater in FIG. Partial sectional view of the water heater in FIG. Sectional drawing explaining the manufacturing method of the heat exchanger (4) which concerns on embodiment of this invention An exploded perspective view of the internal structure of a water heater for explaining a conventional example Illustration of conventional example

Explanation of symbols

(2) ・ ・ ・ Burner block
(3A) ・ ・ ・ Gas combustion chamber
(4A) ・ ・ ・ Heat exchange part
(6) ... Exhaust port cover
(9) ... Casing
(35) ・ ・ ・ Front side wall for heat exchange
(41) ... Endothermic fin
(42) ... Water pipe
(45) ・ ・ ・ Right wall for heat exchange
(46) ... Left side wall for heat exchange
(48) ・ ・ ・ Back wall for heat exchange
(51) ... Exhaust port
(54) ・ ・ ・ Duct ceiling wall
(56) ... Exhaust duct
(57) ・ ・ ・ Right side wall for duct
(58) ・ ・ ・ Left wall for duct
(59) ... Exhaust passage
(60) ・ ・ ・ Tip tube
(91) ... Exhaust window
(542) ・ ・ ・ Duct rear wall

Claims (1)

The water absorption pipes (42) and (42) made of copper material are passed through the through holes (410) and (410) of the heat-absorbing fins (41) and (41) made of copper material, and through the through-holes. A first step of interposing a brazing material (100) (100) made of phosphorous copper material between the water pipe (42) (42) and the inner periphery of the through hole (410) (410);
A water pipe (42) is attached to the first single plate that forms the right side wall (45) for heat exchange made of stainless material and the second single plate that forms the left side wall (46) for heat exchange made of stainless material. ) (42) the second step of penetrating both ends,
A third step of connecting the outer ends of adjacent water pipes (42) (42) to each other by U-shaped pipes (42A) (42A) made of a copper material ;
After the third step, the jig (18) supports the first and second single plates and the aggregates such as the water pipes (42) (42) and the heat absorption fins (41) (41). A fourth step of melting the brazing material (100) (100) by heating in a heating furnace ;
After the fourth step, a third sheet that forms the front wall (47) for heat exchange made of stainless material and a fourth sheet that forms the rear wall (48) for heat exchange made of stainless material. A heat exchanger manufacturing method comprising: a fifth step of attaching a plate and the first single plate and the second single plate with screws .

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