Heat exchanger having laminated header, and manufacturing method for heat exchanger

Abstract

To prevent decrease in a yield due to an incorrect assembly procedure.SOLUTION: In a manufacturing method for a heat exchanger (13), a plurality of plates each having a cutout (C) and an opening (O), is prepared. In the manufacturing method, a refrigerant flow path (RP) is formed in overlapping openings by laminating a plurality of plates (92). In the manufacturing method, the refrigerant flow path is isolated from an outside space (OS) by fitting engagement members (93, 94) into an engagement space (ES) that communicates with the refrigerant flow path. The engagement space (ES) is created by the overlapping cutouts (C). In the manufacturing method, a laminate (90) including the plurality of plates (92) and the engagement members (93, 94) is brazed in a furnace. The positions or sizes of the cutouts (C) in the plates (92) are all different.SELECTED DRAWING: Figure 9

Description

[Technical field]

[0001] The present disclosure relates to a heat exchanger for use in a refrigeration system and a method for manufacturing the same, and more particularly to a heat exchanger having a stacked header and a method for manufacturing the same. [Background technology]

[0002] The heat exchanger disclosed in Patent Document 1 (JP 2021-025718 A) has a stacked header. The stacked header has a plurality of plates. Some of the plates are applied with brazing material. The stacked plates are fixed by furnace brazing to obtain the stacked header. Summary of the Invention [Problem to be solved by the invention]

[0003] In the manufacture of stacked headers, mistakes can occur when the plates are stacked in the wrong order, and if the plates are brazed in the furnace, the resulting stacked header will not function as a heat exchanger component. [Means for solving the problem]

[0004] A manufacturing method according to a first aspect manufactures a heat exchanger. In the manufacturing method, a plurality of plates are prepared. Each of the plurality of plates has a notch and an opening. In the manufacturing method, the plurality of plates are stacked to form a refrigerant flow path in the overlapping opening. In the manufacturing method, an engagement member is fitted into an engagement space that communicates with the refrigerant flow path, thereby isolating the refrigerant flow path from an external space. The engagement space is formed by the overlapping notches. In the manufacturing method, a stack including the plurality of plates and the engagement members is brazed in a furnace. The positions or sizes of the notches in the plates are all different.

[0005] According to this method, among the many possible stacking arrangements of the plates, only the stacking arrangement that allows the plates to be fitted with the engaging member is necessarily selected, thereby reducing the inconvenience of selecting an incorrect stacking arrangement in the manufacture of the heat exchanger header.

[0006] The manufacturing method according to the second aspect is the manufacturing method according to the first aspect, wherein the engaging member has a shape that fits the stepped shape formed by the plurality of plates.

[0007] According to this method, the shapes of the engagement space and the engagement member match, so that the engagement space is filled with the engagement member, and the failure to fit the engagement member can be detected in the form of refrigerant leakage.

[0008] A manufacturing method according to a third aspect is the manufacturing method according to the first or second aspect, in which at least a part of the plurality of plates is a clad material.

[0009] According to this method, a part of the plate is made of clad material, and therefore the brazing is performed in the furnace with stable quality.

[0010] A fourth aspect of the present invention relates to the manufacturing method of any one of the first to third aspects, in which the engaging member is a clad material. During furnace brazing, the engaging member air-tightly seals the coolant flow path from the outside space.

[0011] According to this method, the clad material is brazed to the plates, so that if the clad material is not properly attached, it can be detected as a refrigerant leak.

[0012] A manufacturing method according to a fifth aspect is the manufacturing method according to any one of the first aspect to the fourth aspect, in which the engaging member includes at least a first engaging member and a second engaging member.

[0013] According to this method, the first engaging member and the second engaging member are fitted into the stacked plates, which can effectively reduce incorrect stacking arrangement in manufacturing the heat exchanger header.

[0014] A manufacturing method according to a sixth aspect is the manufacturing method according to the fifth aspect, in which the second engagement member after being fitted interferes with a path of the first engagement member being fitted into the engagement space.

[0015] In this manner, the second engagement member is recessed into the plates, preventing the assembly worker from moving the first engagement member, thus reducing the risk of the stack being destroyed before it is furnace brazed.

[0016] A header according to a seventh aspect includes a plurality of plates, a refrigerant flow path, an engagement space, an engagement member, and a brazing material. Each of the plurality of plates has a notch and an opening. The refrigerant flow path is formed by overlapping openings formed by stacking the plurality of plates. The engagement space is formed by overlapping notches formed by stacking the plurality of plates. The engagement space communicates with the refrigerant flow path. The engagement member is configured to be fitted into the engagement space to isolate the refrigerant flow path from an external space. The brazing material secures the plurality of plates and the engagement members. The positions or sizes of the notches in the plates are all different.

[0017] According to this configuration, the use of the engaging member can reduce errors in the stacking arrangement, and therefore the header yield is high, and the header manufacturing cost can be reduced.

[0018] A heat exchanger according to an eighth aspect includes the header according to the seventh aspect.

[0019] According to this configuration, the yield of the heat exchanger is high, and therefore the manufacturing cost of the heat exchanger can be reduced.

[0020] A refrigeration device according to a ninth aspect includes the heat exchanger according to the eighth aspect.

[0021] According to this configuration, the yield of the refrigeration devices is high, and therefore the manufacturing cost of the refrigeration devices can be reduced. [Brief description of the drawings]

[0022] [Figure 1] FIG. 1 is a schematic diagram of a refrigeration device 100. [Diagram 2] FIG. 2 is a schematic diagram of the heat source heat exchanger 13. As shown in FIG. [Diagram 3] FIG. 3 is a perspective view of the heat source heat exchanger 13. As shown in FIG. [Figure 4] FIG. 4 is an overall perspective view of the first header 51. As shown in FIG. [Diagram 5] FIG. 5 is an overall perspective view of the second header 52. As shown in FIG. [Figure 6] FIG. 6 is a perspective view of the end portion of the second header 52. As shown in FIG. [Figure 7] FIG. 7 is a diagram showing a first step of the manufacturing method for the second header 52, and shows prepared plates 921 to 927. [Figure 8] FIG. 8 is a diagram showing a second step of the manufacturing method, illustrating a plurality of plates 921 to 927 to be stacked. [Figure 9] FIG. 9 is a diagram showing a third step of the manufacturing method, illustrating a first engagement member 93 and a second engagement member 94 that are fitted into the engagement space ES. [Figure 10] FIG. 10 is a diagram showing a fourth step of the manufacturing method, illustrating the crimping claw 91a before crimping. [Figure 11] FIG. 11 is a diagram showing a third step of the manufacturing method according to the modified example. [Figure 12] FIG. 11 is a diagram showing a fourth step of the manufacturing method according to the modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] <Embodiment> (1) Overall structure 1 is a schematic diagram of a refrigeration device 100. The refrigeration device 100 may be an air conditioner, a freezer, a refrigerator, a water heater, a floor heating device, or the like. The refrigeration device 100 has a heat source unit 10, a utilization unit 20, and a refrigerant communication pipe group 30. These constitute a refrigerant circuit that circulates the refrigerant. Furthermore, the refrigeration device 100 has a communication line 39.

[0024] (2) Detailed configuration (2-1) Heat source unit 10 The heat source unit 10 is for obtaining cold or heat from a heat source. The heat source unit 10 includes a heat source casing 105, a compressor 11, a four-way switching valve 12, a heat source heat exchanger 13, a heat source fan 14, a heat source expansion valve 15, an accumulator 16, a liquid shutoff valve 17, a gas shutoff valve 18, and a heat source control unit 19.

[0025] The compressor 11 draws in low-pressure gas refrigerant through a suction pipe 11a, compresses it, and produces high-pressure gas refrigerant, which is then discharged from a discharge pipe 11b.

[0026] The four-way switching valve 12 forms the connections shown by the solid lines in the case of cold heat utilization operation, and forms the connections shown by the dashed lines in the case of hot heat utilization operation.

[0027] The heat source heat exchanger 13 functions as a condenser in cold heat utilization operation. At this time, the heat source heat exchanger 13 receives high-pressure gas refrigerant from the gas side pipe 61 and discharges high-pressure liquid refrigerant from the liquid side pipe 71. On the other hand, the heat source heat exchanger 13 functions as an evaporator in hot heat utilization operation. At this time, the heat source heat exchanger 13 receives low-pressure gas-liquid two-phase refrigerant from the liquid side pipe 71 and discharges low-pressure gas refrigerant from the gas side pipe 61. The detailed structure of the heat source heat exchanger 13 will be described later.

[0028] The heat source fan 14 promotes heat exchange in the heat source heat exchanger 13 by generating an air flow that passes through the heat source heat exchanger 13 .

[0029] The heat source expansion valve reduces the pressure of the high-pressure liquid refrigerant to produce a low-pressure gas-liquid two-phase refrigerant.

[0030] The accumulator 16 separates the liquid component contained in the gas refrigerant and stores it in a container.

[0031] The liquid shutoff valve 17 and the gas shutoff valve 18 are closed when an installer shuts off the refrigerant circuit.

[0032] The heat source control unit 19 acquires output values ​​from various sensors and controls various actuators.

[0033] (2-2) Usage unit 20 The utilization unit 20 is for providing cold or hot heat to a user. The utilization unit 20 includes a utilization casing 205, a utilization heat exchanger 23, a utilization fan 24, and a utilization control unit 29.

[0034] The utilization heat exchanger 23 functions as an evaporator in the cold heat utilization operation, and functions as a condenser in the hot heat utilization operation.

[0035] The utilization fan 24 generates an air flow passing through the utilization heat exchanger 23, thereby promoting heat exchange in the utilization heat exchanger 23. In addition, when the refrigeration device 100 is an air conditioner, the utilization fan 24 delivers conditioned air to a user.

[0036] The usage control unit 29 acquires output values ​​from various sensors, controls various actuators, and communicates with the heat source control unit 19.

[0037] (2-3) Refrigerant connection pipe group 30 The refrigerant connection pipe group 30 includes a liquid connection pipe 31 and a gas connection pipe 32. The liquid connection pipe 31 connects the liquid stop valve 17 and the utilization heat exchanger 23. The gas connection pipe 32 connects the gas stop valve 18 and the utilization heat exchanger 23.

[0038] (2-4) Communication line 39 The communication line 39 connects the heat source control unit 19 and the usage control unit 29. The heat source control unit 19 and the usage control unit 29 transmit and receive commands, status, and data via the communication line 39.

[0039] (3) Detailed structure of heat source heat exchanger 13 2 is a schematic diagram showing the structure of the heat source heat exchanger 13. The heat source heat exchanger 13 has a first header 51, a second header 52, a heat exchange section 53, a gas side pipe 61, a liquid side pipe 71, and a return pipe 81.

[0040] (3-1) Heat exchange section 53 2, the heat exchange unit 53 has a plurality of refrigerant pipes 54 and a plurality of fins 55 attached to the refrigerant pipes 54. Each of the plurality of refrigerant pipes 54 connects the first gas chamber 51a and the second gas chamber 52a, or connects the first liquid chamber 51b and the second liquid chamber 52b.

[0041] 3 realistically illustrates the structure of the heat-source heat exchanger 13. The heat exchange section 53 forms a wall that stands vertically as a whole, and is L-shaped in plan view.

[0042] (3-2) 1st Header 51 The first header 51 shown in FIG. 2 is a stacked header having a plurality of stacked plates. The first header 51 has a first gas chamber 51a and a first liquid chamber 51b by means of cavities or the like provided in the plates. A plurality of first gas chambers 51a and a plurality of first liquid chambers 51b may be provided. A portion of the plate functions as a first partition wall 51c that separates the first gas chamber 51a and the first liquid chamber 51b. A gas side pipe 61 and a liquid side pipe 71 are connected to the first header 51. The gas side pipe 61 is connected to the first gas chamber 51a. The liquid side pipe 71 is connected to the first liquid chamber 51b.

[0043] As shown in Fig. 4, a gas side pipe 61 and a liquid side pipe 71 are connected to the first header 51. A cover 56 that covers the plate stack and forms a refrigerant flow path is provided around the gas side pipe 61. The cover 56 is held by crimping claws 59 of the plate stack. The liquid side pipe 71 is provided at the end of the first header 51 where the cover 56 is not present.

[0044] (3-3) 2nd Header 52 Returning to FIG. 2, the second header 52 is also a stacked header having a plurality of plates stacked in the same manner as the first header 51. The second header 52 has a second gas chamber 52a and a second liquid chamber 52b by a cavity or the like provided in the plate. A plurality of second gas chambers 52a and a plurality of second liquid chambers 52b may be provided. A part of the plate functions as a second partition wall 52c that separates the second gas chamber 52a and the second liquid chamber 52b. A return pipe 81 is connected to the second header 52. The second gas chamber 52a and the second liquid chamber 52b are connected to each other via the return pipe 81.

[0045] 5 shows the external appearance of the second header 52. The second header 52 has a plurality of stacked plates 92 and an outer wall member 91 surrounding them. The outer wall member 91 is provided with a plurality of crimping claws 91a. The plurality of crimping claws 91a restrain the plurality of plates 92 by being bent. The base portions of the plurality of folded-back pipes 81 are connected to the plate 92.

[0046] (4) Manufacturing method of the second header 52 6 shows one end of the completed second header 52 according to this embodiment. In this embodiment, seven aluminum plates 921-927 are stacked as the multiple plates 92. A first engagement member 93 and a second engagement member 94, which will be described later, are inserted into the end of the second header 52.

[0047] FIG. 7 is a diagram showing a first step of the manufacturing method of the second header 52. A plurality of plates 921-927 are prepared. A notch C and an opening O are formed in each of the plates 921-927. The positions or sizes of the notches C in the corresponding plates 921-927 are all different. The plates 921-922 are provided with a plurality of elongated openings O for connecting the plurality of refrigerant tubes 54. The plates 925-927 are provided with a circular opening O for connecting the return tube 81. The rectangular openings O formed in the plates 923-926 form a refrigerant flow path RP when the plurality of plates 921-927 are stacked. The refrigerant flow path RP is in communication with the notches C of the plates 925-926 via a joint flow path J.

[0048] 8 shows a second step of the manufacturing method. A plurality of plates 921-927 are stacked and inserted into the outer wall member 91. At least a portion of the plurality of plates 921-927 is a clad material. A clad material is a material in which a brazing material is disposed. The outer wall member 91 and the plates 924 and 926 are double-sided clad materials in which a brazing material 95 is disposed on both sides. The plates 921 and 927 are single-sided clad materials in which a brazing material 95 is disposed on only one side. The plates 922, 923, and 925 are bare materials in which no brazing material is disposed.

[0049] Clad materials are typically made by applying a rolled brazing filler metal to an aluminum substrate, although alternatively, the substrate may be pre-coated with hot liquid brazing filler metal and then cooled to obtain the clad material.

[0050] 9 shows a third step of the manufacturing method. In a laminate 90 including a plurality of plates 921-927 and an outer wall member 91, a plurality of overlapping notches C form an engagement space ES. A joining flow path J is exposed at the end of the second header 52 and communicates with the engagement space ES. First, a first engagement member 93 is fitted into the engagement space ES. Next, a second engagement member 94 is fitted into the engagement space ES. The first engagement member 93 and the second engagement member 94 have a shape that fits the step shape formed by the plurality of plates 921-927. The first engagement member 93 and the second engagement member 94 are clad materials.

[0051] 10 shows a fourth step of the manufacturing method. After being fitted into the engagement space ES, the second engagement member 94 interferes with the trajectory of the first engagement member 93 that is fitted into the engagement space ES. Therefore, when the second engagement member 94 is fitted, it is possible to prevent the first engagement member 93 from coming off.

[0052] By fitting the second engaging member 94, the joint flow passage J is not exposed at the end portion of the second header 52. This isolates the refrigerant flow passage RP from the outside space OS.

[0053] Thereafter, the plates 921-927 are restrained by bending the crimping claws 91a. Thereafter, the laminate 90 including the plurality of plates 921-927, the first engaging member 93, and the second engaging member 94 is brazed in a furnace. During the brazing in the furnace, the first engaging member 93 or the second engaging member 94, which is a clad material, air-tightly seals the refrigerant flow path RP from the outside space OS.

[0054] Thereafter, the completed second header 52 shown in Fig. 6 is obtained. In the second header 52, the multiple plates 921-927, the first engaging member 93, and the second engaging member 94 are fixed by the brazing material 95.

[0055] (5) Features (5-1) Of the many possible ways of stacking the multiple plates 921-927, only a stacking arrangement that allows the first engaging member 93 and the second engaging member 94 to be fitted is necessarily selected. This reduces the inconvenience of selecting an incorrect stacking arrangement in the manufacture of the second header 52 of the heat source heat exchanger 13.

[0056] Furthermore, since the header yield is high, the manufacturing costs of the header, the heat exchanger, and the refrigeration device can be reduced.

[0057] (5-2) The first engaging member 93 and the second engaging member 94 have a shape that fits the step shape formed by the multiple plates 921-927. Therefore, the engagement space ES is filled by the first engaging member 93 and the second engaging member 94. Therefore, if the first engaging member 93 or the second engaging member 94 is not fitted, it can be detected as a refrigerant leak.

[0058] (5-3) Some of the plates 921 to 927 are made of clad material, and therefore the brazing is performed in the furnace with stable quality.

[0059] (5-4) The first engaging member 93 or the second engaging member 94, which is a clad material, is brazed to the multiple plates 921 to 927. Therefore, if an engaging member is not fitted, it can be detected in the form of a refrigerant leak.

[0060] (5-5) Two types of engaging members, a first engaging member 93 and a second engaging member 94, are used in manufacturing the second header 52, and both are fitted into the stacked multiple plates 921-927. Therefore, incorrect stacking arrangement in manufacturing the second header 52 of the heat source heat exchanger 13 can be more effectively reduced.

[0061] (5-6) By fitting the second engagement member 94 into the plurality of plates 921-927, an assembly worker cannot move the first engagement member 93. Therefore, the laminate 90 is less likely to be destroyed before being brazed in the furnace.

[0062] (6) Variations (6-1) Variation A In the embodiment described above, two types of engaging members, the first engaging member 93 and the second engaging member 94, are used to manufacture the second header 52 and are fitted into the engagement space ES. Alternatively, the second header 52 may be manufactured using only one engaging member.

[0063] 11 and 12 show a method for manufacturing the second head according to this modified example. Fig. 11 is a diagram corresponding to the third step described above. Fig. 12 is a diagram corresponding to the fourth step described above. As shown in these figures, it is also possible to manufacture the second header 52 using only one engaging member.

[0064] (6-2) Variation B In the embodiment described above, two types of engaging members, the first engaging member 93 and the second engaging member 94, are used to manufacture the second header 52 and are fitted into the engagement space ES. Alternatively, the second header 52 may be manufactured using three or more engaging members.

[0065] (6-3) Variation C In the above embodiment, the manufacturing method using the engagement member is used to manufacture only the second header 52. Alternatively, the first header 51 may be manufactured using the manufacturing method using the engagement member.

[0066] <Conclusion> Although the embodiments of the present disclosure have been described above, it will be understood that various changes in form and details can be made without departing from the spirit and scope of the present disclosure described in the claims. [Explanation of symbols]

[0067] 10: Heat source unit 13: Heat source heat exchanger (heat exchanger) 20: Unit of use 51: First header 52: Second header (Header) 53:Heat exchange section 54: Refrigerant pipe 55: Finn 81: Folding tube 90: Laminate 91: Exterior wall components 91a: Crimp claw 92: Plate 93: First engaging member (engaging member) 94: Second engaging member (engaging member) 95: Brazing material 100: Refrigeration equipment 921: Plate 922: Plate 923: Plate 924: Plate 925: Plate 926: Plate 927: Plate C: Notch ES: Engagement space J: Junction channel O: Opening OS: External space RP: Coolant flow path [Prior art documents] [Patent documents]

[0068] [Patent Document 1] Patent Publication No. 2021-025718

Claims

1. providing a plurality of plates (92) each having a notch (C) and an opening (O); By stacking the plurality of plates, a coolant flow path (RP) is formed in the overlapping openings; The refrigerant flow path is isolated from an outside space (OS) by fitting an engagement member (93, 94) into an engagement space (ES) formed by the overlapping notches (C) and communicating with the refrigerant flow path, brazing the stack (90) including the plurality of plates (92) and the engaging members (93, 94) in a furnace; A method for manufacturing a heat exchanger (13), comprising the steps of: The positions or sizes of the notches (C) in the plates (92) are all different. Manufacturing method.

2. The engaging member has a shape that matches a step shape formed by the plurality of plates (92). The method of claim 1 .

3. At least a portion of the plurality of plates (92) is a clad material. The method according to claim 2 .

4. The engaging members (93, 94) are clad materials, When the brazing is performed in the furnace, the engaging member air-tightly closes the refrigerant flow path from the external space. The method according to claim 3.

5. The engaging members include at least a first engaging member (93) and a second engaging member (94). The method according to any one of claims 1 to 4.

6. the second engagement member after being fitted interferes with a trajectory of the first engagement member fitted into the engagement space; The method according to claim 5 .

7. a plurality of plates (92) each having a notch (C) and an opening (O); A coolant flow path (RP) formed by stacking the plurality of plates and the overlapping openings; An engagement space (ES) formed by stacking the plurality of plates and the notches and communicating with the refrigerant flow path; an engagement member (93, 94) configured to be fitted into the engagement space (ES) to isolate the refrigerant flow path from an outside space (OS); a brazing material (95) that fixes the plurality of plates (92) and the engaging members (93, 94); Equipped with The positions or sizes of the notches (C) in the plates (92) are all different. Header (52).

8. A header (52) according to claim 7. A heat exchanger (13).

9. A heat exchanger (13) according to claim 8, A refrigeration device (100).

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