Heat exchanger and method for manufacturing heat exchanger

Abstract

To enable stable brazing of a heat exchanger.SOLUTION: A heat exchanger 10 includes an inner member 30 having an inner bottom part 40 and inner wall parts 42 erected in both side parts of the inner bottom part 40. The heat exchanger 10 includes an outer member 32 having an outer bottom part 52 and outer wall parts 54 erected in both end parts of the outer bottom part 52 and each having an end part disposed on the outer side of the inner wall part 42. The heat exchanger 10 includes a support member 34 having: an outer beam part 70 extending in a width direction W of a tank 20 along the outer bottom part 52; an inner beam part 72 extending in the width direction W along the inner bottom part 40; and a pair of coupling parts 74 each coupling an end part of the outer beam part 70 to an end part of the inner beam part 72. In the support member 34, rigidity of an outer opposing portion 74B opposing to the outer wall part 54 is higher than that of an inner opposing portion 74A opposing to the inner wall part 42, and rigidity of a central part 81 in a length direction of the outer beam part 70 is lower than that of the outer opposing portion 74B.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a heat exchanger and a method for manufacturing the heat exchanger.

Background Art

[0002] Patent Document 1 discloses a heat exchanger. The tank body of the heat exchanger is formed by a tube plate having a U-shaped cross section and a tank plate having a U-shaped cross section.

[0003] The claw portion formed on the tube plate is bent and locked in the locking hole of the tank plate. Thereby, the tube plate and the tank plate are coupled to form a tank body.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the heat exchanger described in Patent Document 1, since the claw portion of the tube plate is plastically deformed to form the tank body, the gap between the connection portions of the tube plate and the tank plate changes depending on the bent state of the claw portion. When the gap between the connection portions of the tube plate and the tank plate changes, there is a risk that the brazing property of the tank body deteriorates.

[0006] The present invention has been made in view of the above problems, and an object thereof is to enable stable brazing of the heat exchanger.

Means for Solving the Problems

[0007] According to an aspect of the present invention, a heat exchanger is a heat exchanger including a hollow tank, the heat exchanger having an inner bottom portion extending in the longitudinal direction of the tank, and inner wall portions erected on both side portions of the inner bottom portion, the inner bottom portion and the inner wall portions forming an inner member having a substantially U-shaped cross section; an outer bottom portion extending in the longitudinal direction while facing the inner bottom portion; and outer wall portions erected on both side portions of the outer bottom portion and having ends disposed outside the inner wall portions, the outer bottom portion and the outer wall portions forming an outer member having a substantially U-shaped cross section and covering the outer periphery of the inner member to form the tank; a plurality of tubes connected to either the inner bottom portion or the outer bottom portion; an outer beam portion extending in the width direction of the tank along the outer bottom portion; an inner beam portion extending in the width direction along the inner bottom portion; and a pair of connecting portions connecting the ends of the outer beam portion and the ends of the inner beam portion, the heat exchanger being formed in an annular shape and including a support member disposed inside the inner member and the outer member, the support member having higher rigidity at an outer facing portion facing the outer wall portion than at an inner facing portion facing the inner wall portion, and having lower rigidity at a central portion in the longitudinal direction of the outer beam portion than at the outer facing portion.

Effects of the Invention

[0008] In the above aspect, the tank is formed by an inner member, an outer member, and a support member disposed inside the inner member and the outer member. The ends of the outer wall portions of the outer member are disposed outside the inner wall portions of the inner member. An inner facing portion of the support member is disposed inside the inner wall portion, and the joining state between the inner wall portion of the inner member and the outer wall portion of the outer member is maintained.

[0009] Therefore, compared with the case where the claw portions of the tube plate are plastically deformed to couple the tube plate and the tank plate to form the tank, the heat exchanger formed by the inner member and the outer member can suppress changes in the gaps that may occur between the outer member and the inner member. As a result, the heat exchanger can stably perform brazing of the inner member and the outer member.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

MODE FOR CARRYING OUT THE INVENTION

[0011] Hereinafter, with reference to the drawings, a heat exchanger 10 according to an embodiment of the present invention will be described.

[0012] First, with reference to FIG. 1, the overall configuration of the heat exchanger 10 will be described. FIG. 1 is a front view of the heat exchanger 10 according to the present embodiment.

[0013] The heat exchanger 10 is mounted on a vehicle (not shown). The heat exchanger 10 is, for example, an outdoor heat exchanger in a refrigeration cycle of an air conditioner (not shown). The heat exchanger 10 performs heat exchange between a refrigerant circulating in the refrigeration cycle and outside air. The heat exchanger 10 functions as a condenser when the air conditioner performs a cooling operation, and functions as an evaporator when the air conditioner performs a heating operation.

[0014] Hereinafter, the longitudinal direction of the tank 20 is referred to as the length direction L, and the width direction of the tank 20 is referred to as the width direction W. The heat exchanger 10 includes a pair of tanks 20, a plurality of tubes 22, and a plurality of fins 24. The tank 20, the tube 22, and the fin 24 are formed of a metal such as aluminum and are joined to each other by brazing to be integrated.

[0015] The tubes 22 are arranged in parallel and stacked with a space therebetween. A flow path through which the refrigerant flows is formed inside the tube 22. The tubes 22 are arranged such that the heat exchange surface in contact with the fins 24 is horizontal.

[0016] The tanks 20 are arranged so as to be respectively connected to both end portions in the length direction of the tubes 22. The tanks 20 are respectively arranged so as to be connected to the plurality of tubes 22 from the length direction. The tank 20 temporarily stores the refrigerant.

[0017] The refrigerant that has circulated through the refrigeration cycle and has been used for air conditioning flows into one of the tanks 20. The refrigerant that has flowed into the tank 20 respectively flows through the plurality of tubes 22. The refrigerant exchanges heat with the outside air when flowing through the tubes 22.

[0018] The refrigerant that has flowed through the tubes 22 flows into the other tank 20. The refrigerant that has flowed into the tank 20 circulates through the refrigeration cycle again and is used for air conditioning.

[0019] The fins 24 are provided between adjacent tubes 22 and are stacked alternately with the tubes 22. The fins 24 are formed in a wavy shape along the length direction of the tubes 22 and are joined to two adjacent tubes 22. The outside air introduced by the running of the vehicle or an outdoor fan (not shown) passes around the plurality of tubes 22 and the fins 24. Therefore, the refrigerant flowing through the inside of the tubes 22 can exchange heat with the outside air through the surfaces of the tubes 22 and the fins 24. In this way, the fins 24 promote the heat exchange between the refrigerant and the outside air.

[0020] Next, with reference to FIGS. 2 to 4, the tank 20 will be described in detail. FIG. 2 is a perspective view showing the main part of the tank 20 of the heat exchanger 10. FIG. 3 is a sectional view taken along line III-III in FIG. 2. FIG. 4 is a view showing the section of FIG. 3. FIG. 5 is a view showing the end of the tank 20.

[0021] As shown in FIGS. 2 to 4, the tank 20 is formed in a hollow shape. The tank 20 includes an inner member 30, an outer member 32, and a support member 34 disposed inside the inner member 30 and the outer member 32. Further, a lid body 36 (see FIG. 5) is provided at the end of the tank 20.

[0022] (Inner member) The inner member 30 has a plate-shaped inner bottom portion 40 extending in the length direction L of the tank 20, and plate-shaped inner side wall portions 42 erected on both sides of the inner bottom portion 40 (see FIG. 3). Thereby, the inner member 30 is formed in a substantially U-shaped cross section.

[0023] On the inner bottom portion 40, rectangular first support holes 43, second support holes 44, third support holes 46, and fourth support holes 48 extending in the width direction W of the tank 20 are formed (see FIG. 2). The support holes 43, 44, 46, and 48 are arranged at equal intervals in the length direction L. An elliptical hole 50 is formed at the central portion of the inner bottom portion 40 in the length direction L. A connection portion (not shown) for refrigerant flow is connected to the elliptical hole 50. The elliptical hole 50 is disposed between the second support hole 44 and the third support hole 46.

[0024] (Outer member) The outer member 32 has a plate-shaped outer bottom portion 52 extending in the length direction L of the tank 20 in a state facing the inner bottom portion 40, and outer side wall portions 54 erected on both sides of the outer bottom portion 52 (see FIG. 3). Thereby, the outer member 32 is formed in a substantially U-shaped cross section.

[0025] The tip end portion of the outer side wall portion 54 is disposed outside the inner side wall portion 42 of the inner member 30. Thereby, the outer member 32 covers the outer periphery of the inner member 30 to form the tank 20 having a closed cross-sectional shape.

[0026] Inside the outer wall portion 54, a hole 56 into which a protrusion 84 of a support member 34 described later enters is formed. The hole 56 may be a hole penetrating the outer wall portion 54 or a bottomed hole in which a part of the inner surface of the outer wall portion 54 is recessed. However, the hole 56 is preferably a bottomed hole. The hole 56 of the present embodiment is configured as a bottomed hole in which a part of the inner surface of the outer wall portion 54 is recessed.

[0027] The hole 56 is disposed on the outer bottom portion 52 side rather than the overlapping portion that overlaps the inner wall portion 42 of the inner member 30. The hole 56 is configured to increase in depth from the outer bottom portion 52 side toward the tip side of the outer wall portion 54.

[0028] On the outer bottom portion 52, a plurality of tube attachment portions 60 extending in the width direction W are provided at intervals in the length direction L. Each tube attachment portion 60 has a ridge portion 62 protruding toward the inside of the tank 20 and a insertion hole 64 provided in the ridge portion 62. The end portion of the tube 22 described above is connected to each tube attachment portion 60 in a state of being inserted into the insertion hole 64.

[0029] In the present embodiment, the case where the tube 22 is connected to the outer bottom portion 52 is described as an example, but the heat exchanger 10 is not limited to this configuration. For example, in the case of the heat exchanger 10 in which the tube 22 is connected to the inner bottom portion 40, a plurality of tube attachment portions 60 extending in the width direction W are provided at intervals in the length direction L on the inner bottom portion 40.

[0030] (Support member) The support member 34 has a plate-shaped outer beam portion 70 extending in the width direction W of the tank 20 along the outer bottom portion 52, a plate-shaped inner beam portion 72 extending in the width direction W along the inner bottom portion 40, and a pair of plate-shaped connecting portions 74 connecting the end portion of the outer beam portion 70 and the end portion of the inner beam portion 72. Thereby, the support member 34 is formed in a rectangular annular shape having a rectangular communication hole 76 in the central portion.

[0031] At the central portion in the length direction of the inner beam portion 72, a rectangular support piece 80 protruding outward is formed. The support member 34 is positioned in the tank 20 in a state where the support piece 80 is inserted into the second support hole 44 or the third support hole 46 of the inner member 30.

[0032] The connecting portion 74 of the support member 34 has an inner opposing portion 74A facing the inner wall portion 42 of the inner member 30 and an outer opposing portion 74B facing the outer wall portion 54 of the outer member 32. The support member 34 has a higher rigidity in the outer opposing portion 74B facing the outer wall portion 54 than in the inner opposing portion 74A facing the inner wall portion 42.

[0033] As a configuration in which the rigidity of the outer opposing portion 74B is higher than that of the inner opposing portion 74A, for example, a configuration in which the cross-sectional area of the outer opposing portion 74B is larger than the cross-sectional area of the inner opposing portion 74A can be mentioned.

[0034] As a configuration in which the cross-sectional area of the outer opposing portion 74B is larger than the cross-sectional area of the inner opposing portion 74A, for example, a configuration in which the thickness dimension of the outer opposing portion 74B is larger than the thickness dimension of the inner opposing portion 74A can be mentioned. Also, as a configuration in which the cross-sectional area of the outer opposing portion 74B is larger than the cross-sectional area of the inner opposing portion 74A, for example, a configuration in which the width dimension of the outer opposing portion 74B is larger than the width dimension of the inner opposing portion 74A can be mentioned.

[0035] The support member 34 of the present embodiment has a constant thickness dimension throughout, and the width dimension of the outer opposing portion 74B is larger than the width dimension of the inner opposing portion 74A.

[0036] Also, the support member 34 has a lower rigidity in the central portion 81 in the length direction of the outer beam portion 70 than in the outer opposing portion 74B of the connecting portion 74.

[0037] As a configuration in which the rigidity of the central portion 81 in the length direction of the outer beam portion 70 is lower than that of the outer opposing portion 74B, for example, a configuration in which the cross-sectional area of the central portion 81 in the length direction of the outer beam portion 70 is smaller than the cross-sectional area of the outer opposing portion 74B can be mentioned.

[0038] As a configuration in which the cross-sectional area of the central portion 81 in the longitudinal direction of the outer beam portion 70 is smaller than the cross-sectional area of the outer facing portion 74B, for example, a configuration in which the thickness dimension of the central portion 81 in the longitudinal direction of the outer beam portion 70 is smaller than the thickness dimension of the outer facing portion 74B can be cited. Further, as a configuration in which the cross-sectional area of the central portion 81 in the longitudinal direction of the outer beam portion 70 is smaller than the cross-sectional area of the outer facing portion 74B, for example, a configuration in which the width dimension of the central portion 81 in the longitudinal direction of the outer beam portion 70 is smaller than the width dimension of the outer facing portion 74B can be cited.

[0039] The support member 34 of the present embodiment has a constant thickness dimension throughout the entire area, and the width dimension of the central portion 81 in the longitudinal direction of the outer beam portion 70 is smaller than the width dimension of the outer facing portion 74B.

[0040] A protrusion 84 protruding outward from the tank 20 is provided on the outer facing portion 74B of the connecting portion 74 in the support member 34. The protrusion 84 enters a hole 56 formed in the outer wall portion 54. At this time, the inner facing portion 74A of the support member 34 is in close contact with the inner member 30.

[0041] The height of the protrusion 84 decreases as it goes from the inner beam portion 72 side toward the outer beam portion 70 side. Thereby, the support member 34 is easily inserted into the outer member 32, and in a state where the protrusion 84 is inserted into the hole 56, the support member 34 is suppressed from detaching from the outer member 32. Further, the end portion of the protrusion 84 constitutes a support surface 84A that supports the tip of the inner wall portion 42 of the inner member 30.

[0042] A gap 90 is formed between the central portion 81 in the longitudinal direction of the outer beam portion 70 of the support member 34 and the outer bottom portion 52.

[0043] In the tank 20 of the present embodiment, the outer beam portion 70 has a curved shape in which the central portion 81 in the longitudinal direction protrudes toward the inner beam portion 72 side. A gap 90 described above is formed between the central portion 81 in the longitudinal direction of the curved outer beam portion 70 and the outer bottom portion 52 of the outer member 32 composed of a flat surface. And this gap 90 is filled with a brazing material used when brazing.

[0044] In addition, in the present embodiment, a case where the gap 90 between the central portion 81 in the length direction of the outer beam portion 70 of the support member 34 and the outer bottom portion 52 is filled with brazing material will be described as an example. However, the present embodiment is not limited to this configuration. The gap 90 between the central portion 81 in the length direction of the outer beam portion 70 of the support member 34 and the outer bottom portion 52 may be a space not filled with brazing material.

[0045] (Cover) As shown in FIG. 5, the cover 36 has a first region 94 disposed inside the inner member 30 and a second region 96 disposed inside the outer member 32. The width dimension of the second region 96 is larger than that of the first region 94. A stepped portion 98 is formed between the first region 94 and the second region 96. The tip of the inner wall portion 42 of the inner member 30 abuts against the stepped portion 98.

[0046] A protruding piece 100 is formed in the first region 94. The cover 36 is positioned in the tank 20 with the protruding piece 100 inserted into the first support hole 43 or the fourth support hole 48 of the inner member 30 (see FIG. 1). The cover 36 closes the end opening of the tank 20 in a state where it is positioned in the tank 20.

[0047] (Method for manufacturing a heat exchanger) Next, with reference to FIGS. 6 to 9, a method for manufacturing the heat exchanger 10 will be described.

[0048] FIG. 6 is a front view showing the support member 34 before assembly. FIG. 7 is an explanatory view showing the manufacturing process of the heat exchanger 10 of the present invention. FIG. 8 is an explanatory view showing the manufacturing process following FIG. 7. FIG. 9 is an explanatory view showing the manufacturing process following FIG. 8. FIG. 10 is an explanatory view showing the manufacturing process following FIG. 9.

[0049] For convenience of explanation, only the right side of the tank 20 in the drawing is shown in FIGS. 7 to 10, but the tank 20 has a line-symmetric shape centered on the center line C.

[0050] FIG. 6 is a diagram showing the support member 34 used in the manufacture of the heat exchanger 10. With reference to FIG. 6, the differences between the support member 34 before manufacture and the support member 34 after manufacture (see, for example, FIG. 4) will be mainly described.

[0051] Before assembly, the inner opposing portions 74A of both connecting portions 74 of the support member 34 are inclined in a direction approaching each other as they extend from the inner beam portion 72 toward the outer opposing portion 74B. The outer opposing portions 74B of both connecting portions 74 are inclined in a direction away from each other as they extend from the inner opposing portion 74A toward the outer beam portion 70.

[0052] Further, the outer beam portion 70 of the support member 34 is formed in an arc shape protruding toward the outer bottom portion 52 of the inserted outer member 32. Accordingly, the outer beam portion 70 of the support member 34 has an arc portion 70A that protrudes outward in an arc shape. The arc portion 70A has the center portion 81 in the length direction of the outer beam portion 70 protruding most outward.

[0053] (Support member assembly step) FIG. 7 is an explanatory diagram showing a support member assembly step 110 of assembling the support member 34 to the inner member 30.

[0054] In the support member assembly step 110, the operator aligns the support piece 80 of the support member 34 with the second support hole 44 of the inner member 30, inserts the support member 34 into the inner member 30, and assembles the support member 34 to the inner member 30. Further, the operator aligns the support piece 80 of the other support member 34 with the third support hole 46 of the inner member 30, inserts the support member 34 into the inner member 30, and assembles the other support member 34 to the inner member 30. At this time, the operator may fix the support member 34 to the inner member 30 by deforming the support piece 80 or the like.

[0055] In a state where the support member 34 is assembled to the inner member 30, the entire connecting portion 74 of the support member 34 is separated from the inner wall portion 42 of the inner member 30 as it extends from the inner beam portion 72 toward the outer beam portion 70. Further, the outer beam portion 70 of the support member 34 has the center portion 81 in the length direction where the arc portion 70A is formed protruding outward.

[0056] Also, the operator aligns the protruding piece 100 of the lid body 36 with the first support hole 43 of the inner member 30, inserts the lid body 36 into the inner member 30, and assembles the lid body 36 to the inner member 30 (see FIG. 5). Also, the operator aligns the protruding piece 100 of another lid body 36 with the fourth support hole 48 of the inner member 30, inserts the lid body 36 into the inner member 30, and assembles the lid body 36 to the inner member 30.

[0057] (Support member insertion step) FIG. 8 is an explanatory diagram showing a support member insertion step 112 of inserting the support member 34 assembled to the inner member 30 into the outer member 32.

[0058] In the support member insertion step 112, the operator abuts the opening of the inner member 30 and the opening of the outer member 32, and inserts the support member 34 assembled to the inner member 30 into the outer member 32. At this time, the lid body 36 (see FIG. 5) assembled to the inner member 30 is inserted into the outer member 32 in the same manner as the support member 34.

[0059] The support member insertion step 112 can be performed, for example, by a pressing jig that presses the abutted inner member 30 and outer member 32 in a direction approaching each other. In the support member insertion step 112, the inner member 30 is arranged such that the tip of the inner wall portion 42 is located inside the outer wall portion 54 of the outer member 32.

[0060] (Inner member insertion step) FIG. 9 is an explanatory diagram showing an inner member insertion step 114 of inserting the inner member 30 into the outer member 32.

[0061] In the inner member insertion step 114, the operator inserts the inner member 30 to which the support member 34 is assembled into the outer member 32 using, for example, a pressing jig so that the arc portion 70A of the outer beam portion 70 of the support member 34 abuts against the outer bottom portion 52 of the outer member 32.

[0062] (Inner member assembly step) FIG. 10 is an explanatory diagram showing an inner member assembly step 116 of assembling the inner member 30 to the outer member 32.

[0063] In the inner member assembling step 116, an operator further presses the inner member 30 and the outer member 32 toward each other using, for example, a pressing jig.

[0064] Then, the arc portion 70A at the central portion 81 in the length direction of the outer beam portion 70 of the support member 34 facing the outer bottom portion 52 of the outer member 32 is pressed against the outer bottom portion 52 of the outer member 32 ahead of both end portions of the outer beam portion 70. At this time, the arc portion 70A at the central portion 81 in the length direction of the outer beam portion 70 pressed against the outer bottom portion 52 of the outer member 32 ahead is less rigid than the outer facing portion 74B of the connecting portion 74. For this reason, the arc portion 70A of the outer beam portion 70 deforms, for example, into an arc shape protruding inward.

[0065] Also, in the support member 34, the outer facing portion 74B facing the outer wall portion 54 of the outer member 32 has higher rigidity than the inner facing portion 74A facing the inner wall portion 42 of the inner member 30. For this reason, when the central portion 81 in the length direction of the outer beam portion 70 deforms so as to protrude inward, the outer facing portion 74B of the support member 34 is displaced outward while tilting, and the inner facing portion 74A having lower rigidity than the outer facing portion 74B is displaced outward.

[0066] As a result, the inner wall portion 42 of the inner member 30 is pushed outward by the inner facing portion 74A of the support member 34, comes into close contact with the outer wall portion 54 of the outer member 32, and the inner member 30 and the outer member 32 are in a state where the assembling position is held.

[0067] Also, the protrusion 84 provided on the connecting portion 74 when displacing the inner facing portion 74A of the support member 34 outward is inserted into the hole 56 formed in the outer member 32. Thereby, detachment of the support member 34 from the outer member 32 is suppressed.

[0068] An annular support member 34 is interposed between the inner member 30 and the outer member 32. Therefore, the insertion amount of the inner member 30 into the outer member 32 is restricted by the support member 34, and the cross-sectional area of the space formed between the inner member 30 and the outer member 32 is kept constant over the entire length.

[0069] As a result, the inner member 30 is assembled to the outer member 32, and the tank 20 is formed.

[0070] In this embodiment, an arc portion 70A is formed on the outer beam portion 70 of the support member 34, and the central portion 81 in the length direction of the outer beam portion 70 of the support member 34 is configured to be pressed against the outer bottom portion 52 ahead of both end portions of the outer beam portion 70. However, this embodiment is not limited to this configuration.

[0071] For example, by forming an arc portion protruding inward on the outer bottom portion 52 of the outer member 32, the central portion 81 in the length direction of the outer beam portion 70 of the support member 34 may be configured to be pressed against the outer bottom portion 52 ahead of both end portions of the outer beam portion 70.

[0072] (Tube assembly process) In the tube assembly process, one end of the tube 22 is inserted into the insertion hole 64 of each tube attachment portion 60 provided on the outer bottom portion 52 of the tank 20 in which the inner member 30 is assembled to the outer member 32 (see FIGS. 1 and 3). As a result, a plurality of tubes 22 are assembled to the outer bottom portion 52 of the outer member 32. The other end of the tube 22 is inserted into the insertion hole 64 of the tube attachment portion 60 of another tank 20.

[0073] In the case of a configuration in which the tube 22 is connected to the inner bottom portion 40 of the inner member 30, one end of the tube 22 is inserted into the insertion hole 64 of each tube attachment portion 60 provided on the inner bottom portion 40 of the tank 20. As a result, a plurality of tubes 22 are assembled to the inner bottom portion 40 of the inner member 30. The other end of the tube 22 is inserted into the insertion hole 64 of the tube attachment portion 60 of another tank 20.

[0074] Then, fins 24 are set between the respective tubes 22 of the tank 20. Thereby, the heat exchanger 10 is formed.

[0075] (Brazing process) In the brazing process, the inner member 30, the outer member 32, the support member 34, the tube 22, and the fin 24 are brazed to each other.

[0076] As a method of brazing, for example, after assembling the heat exchanger 10 using the inner member 30, the outer member 32, the support member 34, the tube 22, and the fin 24 to which a brazing material has been previously attached, the heat exchanger 10 is heated in a furnace to melt the brazing material, thereby brazing the respective members.

[0077] For example, when using the support member 34 with a brazing material attached to its surface, the gap 90 between the central portion 81 in the length direction of the outer beam portion 70 of the support member 34 and the outer bottom portion 52 of the outer member 32 is filled with the brazing material, and the outer beam portion 70 of the support member 34 is fixed to the outer bottom portion 52 of the outer member 32.

[0078] Thereby, the heat exchanger 10 is formed by the integrated respective members.

[0079] In addition, in the present embodiment, the case where the gap 90 between the outer beam portion 70 of the support member 34 and the outer bottom portion 52 of the outer member 32 is filled with the brazing material is taken as an example for explanation, but the present embodiment is not limited to this configuration. In the present embodiment, the gap 90 formed between the outer beam portion 70 of the support member 34 and the outer bottom portion 52 of the outer member 32 may not be filled with the brazing material. In a configuration where the gap 90 between the outer beam portion 70 of the support member 34 and the outer bottom portion 52 of the outer member 32 is not filled with the brazing material, the amount of brazing material used can be reduced.

[0080] (Function and effect) According to the above embodiments, the following effects are achieved.

[0081] The heat exchanger 10 of the present embodiment is a heat exchanger 10 including a hollow tank 20. The heat exchanger 10 includes an inner member 30 that has an inner bottom 40 extending in the length direction L of the tank 20 and inner wall portions 42 erected on both side portions of the inner bottom 40 and is formed in a substantially U-shaped cross section. The heat exchanger 10 includes an outer bottom 52 extending in the length direction L in a state of facing the inner bottom 40, and outer wall portions 54 erected on both side portions of the outer bottom 52 and having ends disposed outside the inner wall portions 42, and includes an outer member 32 that is formed in a substantially U-shaped cross section and covers the outer periphery of the inner member 30 to form the tank 20. The heat exchanger 10 includes a plurality of tubes 22 connected to either the inner bottom 40 or the outer bottom 52. The heat exchanger 10 includes an outer beam portion 70 extending in the width direction W of the tank 20 along the outer bottom 52, an inner beam portion 72 extending in the width direction W along the inner bottom 40, and a pair of connecting portions 74 connecting the ends of the outer beam portion 70 and the ends of the inner beam portion 72, and includes a support member 34 formed in an annular shape and disposed inside the inner member 30 and the outer member 32. The support member 34 has higher rigidity at an outer facing portion 74B facing the outer wall portion 54 than at an inner facing portion 74A facing the inner wall portion 42, and has lower rigidity at a central portion 81 in the length direction of the outer beam portion 70 than at the outer facing portion 74B.

[0082] In this configuration, the tank 20 of the heat exchanger 10 is formed by the inner member 30, the outer member 32, and the support member 34 disposed inside the inner member 30 and the outer member 32. And in this tank 20, the ends of the outer wall portion 54 of the outer member 32 are disposed outside the inner wall portion 42 of the inner member 30. Further, an inner facing portion 74A of the support member 34 is disposed inside the inner wall portion 42. Thereby, the inner wall portion 42 of the inner member 30 is suppressed from falling inward by the inner facing portion 74A of the support member 34, so that the joining state between the inner wall portion 42 of the inner member 30 and the outer wall portion 54 of the outer member 32 is maintained.

[0083] Therefore, compared with the case where the claw portion of the tube plate is plastically deformed to join the tube plate and the tank plate to form the tank 20, the tank 20 of the present embodiment can suppress changes in the gap that can occur between the outer member 32 and the inner member 30. As a result, the heat exchanger 10 of the present embodiment can stably perform brazing of the inner member 30 and the outer member 32, facilitating the brazing operation.

[0084] In the heat exchanger 10 of the present embodiment, a protrusion 84 protruding toward the outside of the tank 20 is provided at the outer facing portion 74B of the support member 34, and the protrusion 84 enters a hole 56 formed in the outer wall portion 54 of the outer member 32.

[0085] In this configuration, the tank 20 of the heat exchanger 10 can be prevented from detaching from the outer member 32 of the support member 34.

[0086] In the heat exchanger 10 of the present embodiment, a gap 90 is formed between the central portion 81 in the length direction of the outer beam portion 70 and the outer bottom portion 52, or the gap 90 is filled with a brazing material.

[0087] In the structure in which the gap 90 is formed between the central portion 81 in the length direction of the outer beam portion 70 and the outer bottom portion 52 in this configuration, since the flow of the refrigerant into the gap 90 is allowed, the flow path resistance of the refrigerant in the tank can be reduced. Further, in the structure in which the gap 90 between the central portion 81 in the length direction of the outer beam portion 70 and the outer bottom portion 52 of the outer member 32 is filled with a brazing material, the support member 34 can act as a reinforcing member and contribute to the improvement of the tank strength.

[0088] The manufacturing method of the heat exchanger 10 according to this embodiment is a manufacturing method for manufacturing a heat exchanger 10 including a hollow tank 20. In the manufacturing method of the heat exchanger 10, the heat exchanger 10 includes an inner bottom portion 40 extending in the length direction L of the tank 20, and inner wall portions 42 erected on both side portions of the inner bottom portion 40, and includes an inner member 30 formed in a substantially U-shaped cross section. The heat exchanger 10 includes an outer bottom portion 52 extending in the length direction L in a state facing the inner bottom portion 40, and outer wall portions 54 erected on both side portions of the outer bottom portion 52 and having ends disposed outside the inner wall portions 42, and includes an outer member 32 formed in a substantially U-shaped cross section and covering the outer periphery of the inner member 30 to form the tank 20. The heat exchanger 10 includes an outer beam portion 70 extending in the width direction W of the tank 20 along the outer bottom portion 52, an inner beam portion 72 extending in the width direction W along the inner bottom portion 40, and a pair of connecting portions 74 connecting the ends of the outer beam portion 70 and the ends of the inner beam portion 72, and includes a support member 34 formed in an annular shape and disposed inside the inner member 30 and the outer member 32. One of the outer beam portion 70 of the support member 34 and the outer bottom portion 52 of the outer member 32 has an arc portion 70A protruding in an arc shape toward the other. The manufacturing method of the heat exchanger 10 includes a step of assembling the support member 34 to the inner member 30 (support member assembling step 110). The manufacturing method of the heat exchanger 10 includes a step of inserting the inner member 30, in which the support member 34 is assembled so that the outer beam portion 70 of the support member 34 abuts on the outer member 32, into the outer member 32 (support member inserting step 112). The manufacturing method of the heat exchanger 10 includes a step of deforming the outer beam portion 70 by pressing the central portion 81 in the length direction of the outer beam portion 70 facing the outer bottom portion 52 of the outer member 32 against the outer bottom portion 52 ahead of both end portions of the outer beam portion 70 (inner member inserting step 114), and a step of assembling the inner member 30 to the outer member 32 while displacing the inner opposing portion 74A of the support member 34 facing the inner wall portion 42 outward (inner member assembling step 116). The manufacturing method of the heat exchanger 10 includes a step of assembling a plurality of tubes 22 to either the outer bottom portion 52 or the inner bottom portion 40 (tube assembling step), and a step of brazing the inner member 30, the outer member 32, the support member 34, and the tubes 22 (brazing step).

[0089] In this configuration, similar to the heat exchanger 10 described above, it is possible to suppress changes in the gap that may occur between the outer member 32 and the inner member 30, and it becomes possible to stably perform brazing of the inner member 30 and the outer member 32.

[0090] In the manufacturing method of the heat exchanger 10 of the present embodiment, when displacing the inner facing portion 74A of the support member 34 outward, the protrusion 84 provided at the connecting portion 74 is inserted into the hole 56 formed in the outer member 32.

[0091] In this configuration, in the manufactured tank 20, it becomes possible to suppress detachment of the support member 34 from the outer member 32.

[0092] As described above, the embodiments of the present invention have been described. However, the above embodiments merely show a part of the application examples of the present invention, and are not intended to limit the technical scope of the present invention to the specific configurations of the above embodiments.

Explanation of Reference Numerals

[0093] 10 Heat exchanger 20 Tank 22 Tube 30 Inner member 32 Outer member 34 Support member 40 Inner bottom 42 Inner wall portion 52 Outer bottom 54 Outer wall portion 56 Hole 60 Tube mounting portion 70 Outer beam portion 70A Arc portion 72 Inner beam portion 74 Connecting portion 74A Inner facing portion 74B Outer facing portion 81 Central portion in the length direction 84 Protrusion 90 Gap 110 Support member assembly step 112 Support member insertion step 114 Inner member insertion step 116 Inner member assembly process L length direction W width direction

Claims

1. A heat exchanger comprising a hollow tank, an inner member having an inner bottom portion extending in the longitudinal direction of the tank and inner wall portions erected on both sides of the inner bottom portion, and formed in a substantially U-shaped cross section, an outer member having an outer bottom portion extending in the longitudinal direction in a state facing the inner bottom portion and outer wall portions erected on both sides of the outer bottom portion, with ends disposed outside the inner wall portions, and formed in a substantially U-shaped cross section to cover the outer periphery of the inner member and form the tank, a plurality of tubes connected to either the inner bottom portion or the outer bottom portion, a support member formed in an annular shape and disposed inside the inner member and the outer member, the support member having an outer side beam portion extending in the width direction of the tank along the outer bottom portion, an inner side beam portion extending in the width direction along the inner bottom portion, and a pair of connecting portions connecting the ends of the outer side beam portion and the ends of the inner side beam portion, comprising, the support member having higher rigidity in an outer facing portion facing the outer wall portion than in an inner facing portion facing the inner wall portion, and lower rigidity in a central portion in the longitudinal direction of the outer side beam portion than in the outer facing portion, a heat exchanger.

2. The heat exchanger according to claim 1, wherein a protrusion protruding outward from the tank is provided in the outer facing portion, and the protrusion fits into a hole formed in the outer wall portion. a heat exchanger.

3. The heat exchanger according to claim 1 or claim 2, wherein a gap is formed between a central portion in the longitudinal direction of the outer side beam portion and the outer bottom portion, or the gap is filled with a brazing material. a heat exchanger.

4. A method for manufacturing a heat exchanger for manufacturing a heat exchanger comprising a hollow tank, wherein the heat exchanger has an inner member having an inner bottom portion extending in the longitudinal direction of the tank and inner wall portions erected on both sides of the inner bottom portion, and formed in a substantially U-shaped cross section, and an outer member having an outer bottom portion extending in the longitudinal direction in a state facing the inner bottom portion and outer wall portions erected on both sides of the outer bottom portion, with ends disposed outside the inner wall portions, and formed in a substantially U-shaped cross section to cover the outer periphery of the inner member and form the tank, An outer beam portion extending in the width direction of the tank along the outer bottom, an inner beam portion extending in the width direction along the inner bottom, and a pair of connecting portions connecting the end of the outer beam portion and the end of the inner beam portion, which are formed in an annular shape and are disposed inside the inner member and the outer member, a support member; comprising; One of the outer beam portion of the support member and the outer bottom of the outer member has an arc portion that protrudes in an arc shape toward the other; The step of assembling the support member to the inner member; The step of inserting the inner member, in which the support member is assembled so that the outer beam portion of the support member abuts against the outer member, into the outer member; The step of deforming the outer beam portion by pressing the central portion in the length direction of the outer beam portion facing the outer bottom of the outer member against the outer bottom ahead of both ends of the outer beam portion, and assembling the inner member to the outer member while displacing the inner facing portion of the support member facing the inner wall portion outward; The step of assembling a plurality of tubes to either the outer bottom or the inner bottom; The step of brazing the inner member, the outer member, the support member, and the tube; including; A method for manufacturing a heat exchanger.

5. A method for manufacturing a heat exchanger according to claim 4, when displacing the inner facing portion of the support member outward, inserting a protrusion provided on the connecting portion into a hole formed in the outer member; A method for manufacturing a heat exchanger.

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