Flat joint and method for manufacturing the same

Abstract

This invention discloses a flat connector and its manufacturing method, comprising a flat tube section, a main tube section, and a circular tube section connected in sequence. The main tube section is curved and has a circular cross-section with an outer diameter of D. The flat tube section has an elliptical cross-section with a major axis of a and a minor axis of b. The circular tube section has a circular cross-section with a diameter of d, where a ≤ d. This invention achieves increased heat dissipation, reduced costs, and high assembly efficiency without increasing the size of the equipment.

Description

Technical Field

[0001] This invention relates to the technical field of copper pipe fitting processing, and more particularly to a flat connector and its preparation method. Background Technology

[0002] The internal structure of radiators for vehicles and large equipment consists of circular copper or aluminum tubes combined with heat dissipation fins. Heat is mainly transferred to the heat dissipation fins by the flow of heat dissipation medium from the tubes. The heat dissipation effect is mainly affected by the contact surface between the copper tubes and the fins, as well as the heat dissipation fins themselves.

[0003] In the industry, increasing the diameter of copper pipes can improve heat dissipation, but this results in larger radiators, which is detrimental to equipment layout and fails to achieve efficient heat dissipation. Improving heat dissipation without increasing the size of the radiator and related components aligns with the industry's demand for low-carbon and environmentally friendly development.

[0004] By flattening round tubes into elliptical structures and installing them inside heat sink fins, and by modifying the inlet / outlet and adapter joints into elliptical structures, heat dissipation can be increased without increasing the size of the equipment. However, there are currently no mature methods or equipment for processing flat connectors in the industry. Summary of the Invention

[0005] In view of the aforementioned problems with existing copper pipes, this paper aims to provide a flat connector and its manufacturing method.

[0006] The specific technical solution is as follows: A flat connector includes: a flat tube portion, a main tube portion, and a round tube portion connected in sequence, wherein the main tube portion is bent, the cross-section of the main tube portion is circular, the outer diameter of the cross-section of the main tube portion is D, the cross-section of the flat tube portion is elliptical, and the cross-section of the round tube portion is circular.

[0007] The aforementioned flat connector, wherein the outer periphery of the end of the round tube portion has a rolled edge.

[0008] In the aforementioned flat connector, the major axis of the cross-section of the flat tube portion is a, the minor axis is b, and the diameter of the round tube portion is d, wherein a ≤ d.

[0009] A method for preparing a flat connector, wherein the method comprises: Step S1: Bending, select a blank copper tube with a diameter of (a+b) / 2, and use a bending machine to bend the blank copper tube into a bent tube; Step S2: Cleaning of semi-finished products, using cleaning agents to clean the bent pipe; Step S3: Shaping, flaring one end of the bent pipe to form the round pipe section, and flattening the other end of the bent pipe using a flattening tool, and flaring it twice to form the flat pipe section; Step S4: Flattening the ends, flattening the round tube portion and the flat tube portion formed after flaring, and forming a semi-finished product; Step S5: Cleaning of semi-finished products, using the cleaning agent to clean the semi-finished products; Step S6: Edge rolling and shaping, the end of the round tube is rolled and shaped outwards; Step S7: Flattening and shaping, flattening and shaping the rolled edge on the round tube to form the finished product; Step S8: Finished product cleaning, the finished product is cleaned using the cleaning agent.

[0010] In the above preparation method, the cleaning materials include: stainless steel balls, water, cleaning agent, and brightener.

[0011] In the above-described preparation method, the flattening fixture includes an upper mold device and a lower mold device, wherein the upper mold device and the lower mold device cooperate to form a forming cavity, and the forming cavity is used to accommodate the bent tube; The lower mold device includes: a first inner mold and a first outer mold, the first outer mold being sleeved on the outer periphery of the first inner mold, the first outer mold having a first outer mold forming cavity, the first inner mold having a first inner mold forming cavity, the first outer mold forming cavity being connected to the first inner mold forming cavity, and a first elastic component being provided at the bottom of the first outer mold, the first outer mold floating longitudinally through the first elastic component; The upper mold device includes: a second inner mold and a second outer mold, the second outer mold being sleeved on the outer periphery of the second inner mold, the second outer mold having a second outer mold forming cavity, the second inner mold having a second inner mold forming cavity, the second outer mold forming cavity being connected to the second inner mold forming cavity, the top of the second outer mold being provided with a second elastic component, and the second outer mold floating longitudinally through the second elastic component.

[0012] In the above-described preparation method, the first outer mold has a first receiving cavity, the first inner mold is located in the first receiving cavity, the inner wall of the first receiving cavity has a first outer mold step, the outer wall of the first inner mold has a first inner mold step, and the first outer mold step and the first inner mold step are mutually limiting and engaging; The second outer mold has a second receiving cavity, the second inner mold is located in the second receiving cavity, the inner wall of the second receiving cavity has a second outer mold step, the outer wall of the second inner mold has a second inner mold step, and the second outer mold step and the second inner mold step are mutually limiting and engaging.

[0013] In the above-described preparation method, at least two guide components are provided between the first outer mold and the second outer mold, and each guide component includes a guide pin hole and a guide pin that cooperate with each other. At least two positioning components are provided between the first outer mold and the second outer mold. Each positioning component includes two positioning holes and a steel ball. The two positioning holes are respectively provided on the first outer mold and the second outer mold. The first outer mold forming cavity and the second outer mold forming cavity are symmetrically arranged, the first inner mold forming cavity and the second inner mold forming cavity are symmetrically arranged, and the first elastic component and the second elastic component are symmetrically arranged.

[0014] In the above preparation method, the first elastic component and the second elastic component include: a plurality of elastic elements, the bottom of the first outer mold has a plurality of first mounting cavities, the plurality of elastic elements are respectively installed in the plurality of first mounting cavities, and the compression stroke L of each elastic element is ≥1.5*(D-b) / 2.

[0015] In the above preparation method, in step S3, the two flaring processes respectively include: a first flaring and a second flaring, wherein the other end of the bent tube is flared for the first time to form an elliptical opening, and the elliptical opening is flared for the second time to form a flat tube portion at the other end of the bent tube; The major axis of the elliptical opening is aX, where X = 0.3mm~0.4mm.

[0016] In the above preparation method, in step S6, the edge curling and shaping adopts a split edge curling forming fixture, which includes a core sleeve and a mandrel. The core sleeve is sleeved on the outside of the mandrel. The inner circumference of the end of the core sleeve has a first arc groove, the outer circumference of the mandrel has a second arc groove, and the first outer mold forming cavity has a third arc groove. The first arc groove, the second arc groove and the third arc groove are connected in sequence. The first and second circular arc grooves form a semicircle, the diameter of which is 3.2 to 3.8 times the wall thickness of the blank copper tube.

[0017] The positive effects of the above technical solution compared with the existing technology are: The flat tube section of this invention is connected to the corresponding elliptical inlet and outlet of the radiator, and the round tube section is connected to the outlet of a conventional round liquid storage tank. It conforms to both elliptical and round interfaces. The outer surface of the elliptical joint is about 10% larger than the outer surface of the round pipe. After the elliptical interface is connected to the radiator body with an elliptical cross section, the heat dissipation effect is increased without increasing the size of the equipment. The end of the circular tube portion of the present invention is provided with a rolled edge, which replaces the joint, reducing costs and improving assembly efficiency. The flat joint manufacturing method of the present invention adopts a floating structure, which can flatten the joint part into an ellipse while ensuring the roundness of the main pipe and avoiding the concavity of the pipe body. The flat connector manufacturing method of the present invention adopts a split-type edge-rolling forming tooling. In the case of wear on the mandrel head, only the mandrel needs to be replaced, while the mandrel sleeve is retained, thereby reducing manufacturing costs. Attached Figure Description

[0018] Figure 1 This is a cross-sectional view of the structure of a flat connector according to the present invention; Figure 2 This is a cross-sectional view of the flat tube portion of a flat connector according to the present invention; Figure 3 This is a schematic diagram of the structure of a flat connector in a blank state according to the present invention; Figure 4 This is a schematic diagram of the structure of a flat connector after shaping, according to the present invention. Figure 5 This is a schematic diagram of the structure of a flat connector after the end is flat, according to the method for preparing a flat connector of the present invention; Figure 6 This is a schematic diagram of the structure of a flat connector after edge curling and shaping according to the present invention. Figure 7 This is a schematic diagram of the flattening tooling used in the preparation method of a flat connector according to the present invention; Figure 8 This is a schematic diagram of the upper mold device in the method for preparing a flat connector according to the present invention; Figure 9 This is a schematic diagram of the lower mold device in the method for preparing a flat connector according to the present invention; Figure 10 This is a schematic diagram of the split-type edge-rolling forming tooling for a method of preparing a flat connector according to the present invention; Figure 11 This invention relates to a method for preparing a flat connector. Figure 10 A magnified view of a portion of the image; In the attached diagram: 1. Main tube section; 11. First arc groove; 12. Second arc groove; 13. Third arc groove; 14. Core sleeve; 15. Core rod; 2. Flat tube section; 3. Round tube section; 4. Curled edge; 5. Upper mold device; 51. Second outer mold; 52. Second inner mold; 53. Second outer mold forming cavity; 54. Second inner mold forming cavity; 55. Second elastic component; 56. Second receiving cavity; 57. Second outer mold step; 58. Second inner mold step; 6. Lower mold device; 61. First outer mold; 62. First inner mold; 63. First outer mold forming cavity; 64. First inner mold forming cavity; 65. First elastic component; 66. First receiving cavity; 67. First outer mold step; 68. First inner mold step; 7. Guide component; 71. Guide pin; 72. Guide pin hole; 8. Positioning component; 81. Positioning hole; 91. Elastic element; 92. First mounting cavity. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the scope of the invention.

[0020] Figure 1 This is a cross-sectional view of the structure of a flat connector according to the present invention. Figure 2 This is a structural cross-sectional view of the flat tube portion of a flat connector according to the present invention, as shown below. Figures 1 to 2 As shown, a preferred embodiment of the flat connector is illustrated, comprising a flat tube portion 2, a main tube portion, and a round tube portion 3 connected in sequence. The main tube portion 1 is bent and has a circular cross-section with an outer diameter of D. The flat tube portion 2 has an elliptical cross-section with a major axis of a and a minor axis of b. The round tube portion 3 has a circular cross-section with a diameter of d, where a ≤ d.

[0021] Furthermore, as a preferred embodiment, the outer periphery of the end of the circular tube portion 3 has a rolled edge 4.

[0022] The flat tube section 2 of this invention is connected to the corresponding elliptical inlet and outlet of the radiator, and the round tube section 3 is connected to the outlet of a conventional round liquid storage tank. It conforms to both elliptical and round interfaces. The outer surface of the elliptical joint is about 10% larger than the outer surface of the round pipe. After the elliptical interface is connected to the radiator body with an elliptical cross section, the heat dissipation effect is increased without increasing the size of the equipment.

[0023] The end of the round tube portion 3 of the present invention is provided with a rolled edge 4, which replaces the joint, reducing costs and improving assembly efficiency.

[0024] Figure 3 This is a schematic diagram of the structure of a flat connector in a blank state according to the present invention. Figure 4 This is a schematic diagram of the structure of a flat connector after shaping, according to the present invention. Figure 5 This is a schematic diagram of the structure of a flat connector after the flat end is prepared according to the method of manufacturing a flat connector of the present invention. Figure 6 This is a schematic diagram of the structure of a flat connector after edge curling and shaping, according to the present invention. Figure 7 This is a schematic diagram of the flattening tooling used in the preparation method of a flat joint according to the present invention. Figure 8 This is a schematic diagram of the upper mold device in the method for preparing a flat connector according to the present invention. Figure 9 This is a schematic diagram of the lower mold device in the method for preparing a flat connector according to the present invention. Figure 10 This is a schematic diagram of the split-type crimping forming fixture used in the preparation method of a flat connector according to the present invention. Figure 11 This invention relates to a method for preparing a flat connector. Figure 10 A magnified view of a portion of the image, such as Figures 3 to 11 The diagram illustrates a preferred embodiment of a method for preparing a flat connector, used to prepare the aforementioned flat connector. The method includes: Step S1: Bending, select a blank copper tube with a diameter of (a+b) / 2, and use a bending machine to bend the blank copper tube into a bent tube; Step S2: Cleaning of semi-finished products, using cleaning agents to clean the bends; Step S3: Shaping, flare one end of the bend to form a round tube part 3, flatten the other end of the bend using a flattening tool, and flare it twice to form a flat tube part 2; Step S4: Flattening the ends, flatten the round tube part 3 and the flat tube part 2 formed after flaring, and form a semi-finished product; Step S5: Cleaning of semi-finished products; clean the semi-finished products using cleaning agents. Step S6: Edge rolling and shaping, the end of the round tube 3 is rolled and shaped outward; Step S7: Flattening and shaping, flattening and shaping the rolled edge 4 on the round tube part 3 to form the finished product; Step S8: Finished product cleaning. The finished product is cleaned using a cleaning agent.

[0025] Furthermore, as a preferred embodiment, the cleaning materials include: stainless steel balls, water, cleaning agent, and brightener.

[0026] Furthermore, as a preferred embodiment, the flattening fixture includes an upper die device 5 and a lower die device 6, wherein the upper die device 5 and the lower die device 6 cooperate to form a forming cavity, which is used to accommodate the bent tube.

[0027] Furthermore, as a preferred embodiment, the lower mold device 6 includes: a first inner mold 62 and a first outer mold 61. The first outer mold 61 is sleeved on the outer periphery of the first inner mold 62. The first outer mold 61 has a first outer mold forming cavity 63, and the first inner mold 62 has a first inner mold forming cavity 64. The first outer mold forming cavity 63 is connected to the first inner mold forming cavity 64. The bottom of the first outer mold 61 is provided with a first elastic component 65, and the first outer mold 61 floats longitudinally through the first elastic component 65.

[0028] Furthermore, in a preferred embodiment, the upper mold device 5 includes: a second inner mold 52 and a second outer mold 51. The second outer mold 51 is sleeved on the outer periphery of the second inner mold 52. The second outer mold 51 has a second outer mold forming cavity 53, and the second inner mold 52 has a second inner mold forming cavity 54. The second outer mold forming cavity 53 is connected to the second inner mold forming cavity 54. The top of the second outer mold 51 is provided with a second elastic component 55, and the second outer mold 51 floats longitudinally through the second elastic component 55.

[0029] Preferably, the first outer mold 61 floats through the first elastic component 65, the first inner mold 62 is fixed, the second outer mold 51 floats through the second elastic component 55, and the second inner mold 2 is fixed. This ensures the roundness of the main pipe 1 while flattening the joint part into an ellipse, thus preventing the pipe body from being recessed.

[0030] Furthermore, as a preferred embodiment, the first outer mold 61 has a first receiving cavity 66, the first inner mold 61 is located in the first receiving cavity 66, the inner wall of the first receiving cavity 66 has a first outer mold step 67, the outer wall of the first inner mold 62 has a first inner mold step 68, and the first outer mold step 67 and the first inner mold step 68 are mutually restrictive and engaged.

[0031] Furthermore, in a preferred embodiment, the second outer mold 51 has a second receiving cavity 56, the second inner mold 52 is located in the second receiving cavity 56, the inner wall of the second receiving cavity 56 has a second outer mold step 57, the outer wall of the second inner mold 52 has a second inner mold step 58, and the second outer mold step 57 and the second inner mold step 58 are mutually restrictive and engaged.

[0032] Furthermore, as a preferred embodiment, at least two guide components 7 are provided between the first outer mold 61 and the second outer mold 51, each guide component 7 including a guide pin hole 72 and a guide pin 71 that cooperate with each other.

[0033] Furthermore, as a preferred embodiment, at least two positioning components 8 are provided between the first outer mold 61 and the second outer mold 51. Each positioning component 8 includes two positioning holes 81 and a steel ball. The two positioning holes 81 are respectively provided on the first outer mold 61 and the second outer mold 51.

[0034] Furthermore, in a preferred embodiment, the first outer mold forming cavity 63 and the second outer mold forming cavity 53 are symmetrically arranged, the first inner mold forming cavity 64 and the second inner mold forming cavity 54 are symmetrically arranged, and the first elastic component 65 and the second elastic component 55 are symmetrically arranged.

[0035] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention.

[0036] In addition to the above, the present invention also has the following embodiments: In further embodiments of the present invention, please continue to refer to Figures 3 to 11 As shown, the first elastic component 65 and the second elastic component 55 include: a plurality of elastic elements 91, the bottom of the first outer mold 61 has a plurality of first mounting cavities 92, the plurality of elastic elements 91 are respectively installed in the plurality of first mounting cavities 92, and the compression stroke L of each elastic element 91 is ≥ 1.5*(D-b) / 2.

[0037] In a further embodiment of the present invention, in step S3, the two flaring processes respectively include: a first flaring and a second flaring. The other end of the bend is flared for the first time to form an elliptical opening, and the elliptical opening is flared for the second time to form a flat tube portion 2 at the other end of the bend.

[0038] Preferably, the long diameter end is flared twice to avoid excessive internal stress caused by excessive flaring, which would lead to excessive rebound and inaccurate finished product dimensions.

[0039] In a further embodiment of the present invention, the major axis of the elliptical opening is aX, where X = 0.3mm~0.4mm.

[0040] In a further embodiment of the present invention, in step S6, the edge curling is performed using a split edge curling forming fixture, which includes a core sleeve 14 and a mandrel 15. The core sleeve 14 is sleeved on the outside of the mandrel 15. The inner circumference of the end of the core sleeve 14 has a first arc groove 11, the outer circumference of the mandrel 14 has a second arc groove 12, and the first outer mold forming cavity 63 has a third arc groove 13. The first arc groove 11, the second arc groove 12 and the third arc groove 13 are connected in sequence.

[0041] Preferably, the end of the circular tube portion 3 is sequentially passed through the first circular arc groove 11, the second circular arc groove 12, and the third circular arc groove 13 to form a rolled edge 4.

[0042] In a further embodiment of the present invention, the first circular arc groove 11 and the second circular arc groove 12 form a semicircle, the diameter of which is 3.2 to 3.8 times the wall thickness of the blank copper tube.

[0043] Preferably, the second arc groove 12 and the third arc groove 13 are symmetrically arranged.

[0044] The flat connector manufacturing method of the present invention adopts a split-type edge-rolling forming tooling. In the case of wear on the mandrel head, only the mandrel needs to be replaced, while the mandrel sleeve is retained, thereby reducing manufacturing costs.

[0045] The above description is merely a preferred embodiment of the present invention and does not limit the implementation and protection scope of the present invention. Those skilled in the art should realize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A method of making a flat joint, characterized in that, Used in the manufacture of flat connectors; The flat connector includes a flat tube section, a main tube section, and a round tube section connected in sequence. The main tube section is curved and has a circular cross-section with an outer diameter of D. The flat tube section has an elliptical cross-section, and the round tube section has a circular cross-section. The major axis of the flat tube section is a, the minor axis is b, and the diameter of the circular tube section is d, wherein a ≤ d; The outer periphery of the end of the circular tube has a rolled edge; The preparation method includes: Step S1: Bending, select a blank copper tube with a diameter of (a+b) / 2, and use a bending machine to bend the blank copper tube into a bent tube; Step S2: Cleaning of semi-finished products, using cleaning agents to clean the bent pipe; Step S3: Shaping, flaring one end of the bent pipe to form the round pipe section, and flattening the other end of the bent pipe using a flattening tool, and flaring it twice to form the flat pipe section; Step S4: Flattening the ends, flattening the round tube portion and the flat tube portion formed after flaring, and forming a semi-finished product; Step S5: Cleaning of semi-finished products, using the cleaning agent to clean the semi-finished products; Step S6: Edge rolling and shaping, the end of the round tube is rolled and shaped outwards; Step S7: Flattening and shaping, flattening and shaping the rolled edge on the round tube to form the finished product; Step S8: Finished product cleaning, the finished product is cleaned using the cleaning agent.

2. The method for preparing the flat connector according to claim 1, characterized in that, The cleaning materials include: stainless steel balls, water, cleaning agent, and brightener.

3. The method for preparing the flat connector according to claim 1, characterized in that, The flattening fixture includes an upper die device and a lower die device, wherein the upper die device and the lower die device cooperate to form a forming cavity, and the forming cavity is used to accommodate the bent tube; The lower mold device includes: a first inner mold and a first outer mold, the first outer mold being sleeved on the outer periphery of the first inner mold, the first outer mold having a first outer mold forming cavity, the first inner mold having a first inner mold forming cavity, the first outer mold forming cavity being connected to the first inner mold forming cavity, and a first elastic component being provided at the bottom of the first outer mold, the first outer mold floating longitudinally through the first elastic component; The upper mold device includes: a second inner mold and a second outer mold, the second outer mold being sleeved on the outer periphery of the second inner mold, the second outer mold having a second outer mold forming cavity, the second inner mold having a second inner mold forming cavity, the second outer mold forming cavity being connected to the second inner mold forming cavity, and a second elastic component being provided on the top of the second outer mold, the second outer mold floating longitudinally through the second elastic component; The first outer mold has a first receiving cavity, the first inner mold is located in the first receiving cavity, the inner wall of the first receiving cavity has a first outer mold step, the outer wall of the first inner mold has a first inner mold step, and the first outer mold step and the first inner mold step are in a limiting fit. The second outer mold has a second receiving cavity, the second inner mold is located in the second receiving cavity, the inner wall of the second receiving cavity has a second outer mold step, the outer wall of the second inner mold has a second inner mold step, and the second outer mold step and the second inner mold step are mutually limiting and engaging.

4. The method for preparing the flat connector according to claim 3, characterized in that, There are at least two guide components between the first outer mold and the second outer mold, and each guide component includes a guide pin hole and a guide pin that cooperate with each other; At least two positioning components are provided between the first outer mold and the second outer mold. Each positioning component includes two positioning holes and a steel ball. The two positioning holes are respectively provided on the first outer mold and the second outer mold. The first outer mold forming cavity and the second outer mold forming cavity are symmetrically arranged, the first inner mold forming cavity and the second inner mold forming cavity are symmetrically arranged, and the first elastic component and the second elastic component are symmetrically arranged.

5. The method for preparing the flat connector according to claim 4, characterized in that, The first elastic component and the second elastic component include: a plurality of elastic elements, the bottom of the first outer mold having a plurality of first mounting cavities, the plurality of elastic elements being respectively installed in the plurality of first mounting cavities, and the compression stroke L of each elastic element being ≥1.5*(D-b) / 2.

6. The method for preparing the flat connector according to claim 1, characterized in that, In step S3, the two flaring processes include: a first flaring and a second flaring. The first flaring is performed on the other end of the bent pipe to form an elliptical opening, and the second flaring is performed on the elliptical opening to form a flattened pipe portion at the other end of the bent pipe. The major axis of the elliptical opening is aX, where X = 0.3mm~0.4mm.

7. The method for preparing the flat connector according to claim 1, characterized in that, In step S6, the edge curling is performed using a split edge curling forming fixture, which includes a core sleeve and a mandrel. The core sleeve is fitted onto the outside of the mandrel. The inner circumference of the end of the core sleeve has a first arc groove, the outer circumference of the mandrel has a second arc groove, and the first outer mold forming cavity has a third arc groove. The first arc groove, the second arc groove, and the third arc groove are connected in sequence. The first and second circular arc grooves form a semicircle, the diameter of which is 3.2 to 3.8 times the wall thickness of the blank copper tube.

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