heat exchanger

Abstract

To provide a heat exchanger capable of preventing water retention in the header tank of the heat exchanger and the resulting corrosion of the metal. [Solution] The heat exchanger 1 comprises a header tank 3 and a plurality of tubes 2. The header tank 3 includes a halved first tank member 31 and a second tank member 32. The first tank member 31 has a pair of first sides 31S extending in the longitudinal direction, and the second tank member 32 has a pair of second sides 32S extending in the longitudinal direction and a bottom surface 32B. The first tank member 31 and the second tank member 32 are oriented such that at least a portion of the pair of first sides 31S overlaps inside at least a portion of the pair of second sides 32S. In the region exposed to the outside of the second sides 32S, a thin-walled portion 325 is provided in at least a portion including the tip portion 323, which is thinner than the bottom surface 32B.

Description

Technical Field

[0001] The present invention relates to a heat exchanger.

Background Art

[0002] Conventionally, in a vehicle air conditioner using a heat pump cycle, a plurality of heat exchangers are used in a refrigerant circuit. These plurality of heat exchangers include, for example, a heat exchanger disposed in an HVAC (Heating, Ventilating, and Air Conditioning) unit having an air flow passage through which cabin air flows, and a heat exchanger (outdoor heat exchanger) disposed outside the vehicle cabin. The outdoor heat exchanger has, for example, a plurality of tubes arranged in parallel and tanks connected to both ends (upper and lower ends) thereof, and some function as a radiator during cooling and as a heat absorber during heating.

[0003] The tanks of the outdoor heat exchanger are formed, for example, by facing a first tank member and a second tank member each formed in a substantially concave shape so as to close each other's openings to form a cylindrical tank. At this time, for example, the side surface of the first tank member that becomes the upper side during use may be assembled so as to enter the inside of the side surface of the second tank member that becomes the lower side during use (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0004] [[ID=…]]​​​​​​​​​​​​​​​​ Let us explain this in detail with reference to Figure 9. The upper part of Figure 9 is a cross-sectional view of a conventional heat exchanger, perpendicular to the cylindrical axis of the header tank 501. The lower part of Figure 9 is an enlarged view of the dashed circled area in the upper part of Figure 9. The header tanks 501 of the heat exchanger are provided at both ends in the direction of extension of the tube (not shown). When the heat exchanger is in use, one header tank 501 is positioned above and the other header tank (not shown) is positioned below. Figure 9 shows only the upper header tank 501 in its position when in use. In the upper header tank 501, when in use, the first tank member 511 is positioned above and the second tank member 512 is positioned below, and one end of the tube is connected to the second tank member 512. In this positional relationship, when the first tank member 511 is assembled by overlapping it such that the side surface 511S of the first tank member 511 is located inside the side surface 512S of the second tank member 512, a horizontal protrusion Hg is created on the outside of the side surface 511S of the first tank member 511 by the side surface 512S, and a step ST is formed between the surface of the protrusion Hg and the side surface 511S of the first tank member 511.

[0007] When the heat exchanger functions as a heat absorber, condensation can occur, and in the case of an outdoor heat exchanger, rainwater can enter from outside the vehicle, potentially causing moisture to adhere to the surface of the header tank 501. If this moisture is retained in the protruding Hg, it can cause metal corrosion.

[0008] If the heat exchanger is a radiator that functions solely as a heat sink, there is no condensation problem. Also, the amount of overhang Hg corresponds to the thickness (plate thickness) D3 of the side surface 512S of the second tank component 512. For example, heat exchangers used in HVAC units are smaller than outdoor heat exchangers, and the plate thickness of the components is relatively thin (plate thickness is, for example, less than 1 mm). In other words, when the plate thickness is thin, the amount of overhang Hg is also small, making it difficult for moisture to adhere, and even if moisture adheres temporarily, it is easily discharged.

[0009] Furthermore, a fillet F of brazing material is often formed at the corner of the step ST where the first tank member 511 and the second tank member 512 are brazed together. If the curvature of the fillet F is, for example, about 0.5 mm, and the plate thickness is around 0.5 mm, the overhang Hg will be minimal, and in this case as well, moisture can be discharged relatively easily.

[0010] In contrast, as shown in Figure 9, in the case of large heat exchangers such as outdoor heat exchangers, the plate thickness is relatively thick (for example, thickness D3 is 1 mm or more) because the device needs to maintain a certain strength. In such cases, the amount of overhang Hg also increases, making it easier for moisture to adhere. Furthermore, if moisture adheres to the overhang Hg, some of it will be discharged by, for example, vehicle vibration, but small amounts of moisture (water droplets) that adhere to corners of steps ST, in particular, become difficult to drain. Even if a fillet F of brazing material is formed, the large overhang Hg (thickness D3) makes drainage difficult, and there is a risk of water retention. Thus, even if only a small amount of water is retained, the metal becomes more susceptible to corrosion, leading to problems such as leaks from the heat exchanger.

[0011] This invention has been made in view of the above problems and provides a heat exchanger capable of preventing water retention in the header tank of the heat exchanger and the resulting corrosion of the metal. [Means for solving the problem]

[0012] The present invention relates to a heat exchanger having a header tank and a plurality of tubes, wherein the header tank each includes a halved first tank member and a second tank member, the first tank member has a pair of first sides extending in the longitudinal direction, the second tank member has a pair of second sides extending in the longitudinal direction and a bottom surface, the first tank member and the second tank member are facing each other such that at least a portion of the pair of first sides overlaps the inside of at least a portion of the pair of second sides, and in the region exposed to the outside of the second sides, at least a portion including the tip located opposite the bottom surface is provided with a thin-walled portion having a plate thickness thinner than the bottom surface. [Effects of the Invention]

[0013] According to the present invention, it is possible to provide a heat exchanger that can prevent water retention in the header tank of the heat exchanger and the resulting corrosion of the metal. [Brief explanation of the drawing]

[0014] [Figure 1] This is an external perspective view of a heat exchanger according to an embodiment of the present invention. [Figure 2] This is a perspective view showing a header tank according to an embodiment of the present invention. [Figure 3] This is a cross-sectional view showing a header tank according to an embodiment of the present invention. [Figure 4] A perspective view showing another example of a header tank according to an embodiment of the present invention. [Figure 5] A perspective view showing another example of a header tank according to an embodiment of the present invention. [Figure 6] A perspective view showing another example of a header tank according to an embodiment of the present invention. [Figure 7] A perspective view showing another example of a header tank according to an embodiment of the present invention. [Figure 8] A perspective view showing another example of a header tank according to an embodiment of the present invention. [Figure 9] This is a cross-sectional view showing a portion of a conventional heat exchanger. [Modes for carrying out the invention]

[0015] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Figures 1 to 8 are examples of embodiments of the present invention, and in the figures, parts denoted by the same reference numerals indicate parts or components with the same function, and redundant explanations in each figure will be omitted as appropriate.

[0016] <Heat exchanger> FIG. 1 is a schematic perspective view showing an example of the heat exchanger 1 of the present embodiment. The heat exchanger 1 is used in the posture shown in FIG. 1. As shown in FIG. 1, the heat exchanger 1 includes a plurality of tubes 2 arranged in parallel and header tanks 3 and 4 connected to both ends of the plurality of tubes 2. Note that FIG. 1 is a schematic view, and the header tanks 3 and 4 have the configurations shown in FIGS. 2 and later in detail. The heat exchanger 1 performs heat exchange between, for example, a heat medium flowing through the tubes 2 via the header tanks 3 and 4 and a fluid (for example, air) passing between the plurality of tubes 2. In the present embodiment, as an example, the heat medium flows through the tubes 2, but a refrigerant may flow through them.

[0017] In the illustrated example, the tube 2 is a tubular body having a flat shape extending in one direction and along a direction (the direction of the arrow Z in the figure) intersecting the extending direction (the direction of the arrow X in the figure). The tubes 2 are arranged in parallel at a predetermined interval in a direction (the direction of the arrow Y in the figure) intersecting the extending direction, and the space between the plurality of tubes 2 becomes a passage path for the fluid to be heat-exchanged. The fluid to be heat-exchanged flows in the direction of the arrow Z in the figure and performs heat exchange with the heat medium flowing through the tubes 2 while passing between the plurality of tubes 2. In the space between the plurality of tubes 2, fins (for example, corrugated fins), generally not shown in the figure, are provided to enhance the heat exchange efficiency.

[0018] In the following description, the direction of the arrow X in FIG. 1 is referred to as the tube extending direction, the direction of the arrow Y as the header tank longitudinal direction (or simply the longitudinal direction), and the direction of the arrow Z as the header tank short-side direction (or simply the short-side direction). Also, in the following description, the posture of the heat exchanger 1 shown in FIG. 1 in the use state is taken as a reference. That is, the upper part of FIG. 1 is defined as "upper" and the lower part of FIG. 1 as "lower" for the description.

[0019] The header tanks 3 and 4 are provided at both ends in the tube extending direction (X direction). The header tank 3 is the upper header tank, and the header tank 4 is the lower header tank.

[0020] The upper header tank 3 is formed by connecting, for example, an upper first tank member 31 and an upper second tank member 32 to form a cylindrical shape, and by closing both ends in the longitudinal direction of the header tank (direction Y of the arrow in the figure) with caps 33, a space is formed inside through which a heat transfer medium flows.

[0021] The lower header tank 4 is formed by connecting, for example, a lower first tank member 41 and a lower second tank member 42 to form a cylindrical shape, and by closing both ends in the longitudinal direction of the header tank (direction Y indicated by arrow in the figure) with caps 43, a space is formed inside through which a heat transfer medium flows. The upper first tank member 31 and the lower first tank member 41 have similar configurations, and the upper second tank member 32 and the lower second tank member 42 have similar configurations.

[0022] In the example shown in Figure 1, the upper header tank 3 has an inlet 6 in the upper first tank member 31, and the upper second tank member 32 is connected to one end (upper) of the tube 2 in the direction of extension. The lower header tank 4 has an outlet 7 in the lower first tank member 41, and the lower second tank member 42 is connected to the other end (downward) of the tube 2 in the direction of extension.

[0023] In this configuration, the heat transfer medium flowing in from the inlet 6 flows through the upper header tank 3 to the tube 2, and the heat transfer medium flowing through the tube 2 flows through the lower header tank 4 and is discharged from the outlet 7.

[0024] In other words, in the orientation used, the upper header tank 3 and the lower header tank 4 are in a positional relationship that is symmetrical with respect to the center in the extending direction of the tube 2. Specifically, in the upper header tank 3, the upper first tank member 31 is the upper tank member and the upper second tank member 32 is the lower tank member. On the other hand, in the lower header tank 4, the lower first tank member 41 is the lower tank member and the lower second tank member 42 is the upper tank member.

[0025] Multiple tubes 2 are arranged longitudinally along the header tank, and a pair of side plates 5 are provided at both ends. The pair of side plates 5 define the distance between the upper header tank 3 and the lower header tank 4, and the multiple tubes 2 arranged inside them form a heat exchange core.

[0026] As an example, the heat exchanger 1 of this embodiment has the functions of both a heat radiator and a heat absorber (having a heat dissipation mode to the outside air and a heat absorption mode from the outside air). The heat exchanger 1 is suitable for use in, for example, the heat transfer medium circuit of a heat pump system, and by constructing the upper header tank 3, lower header tank 4 and tube 2 from metal materials, low-temperature sealing performance can be improved compared to, for example, when these are constructed from resin materials. Furthermore, the heat exchanger 1 of this embodiment is relatively large, such as an outdoor heat exchanger for a vehicle, and has a thick metal plate and high strength.

[0027] In this embodiment, in particular, good drainage becomes possible in the upper header tank 3, where conventional methods made it difficult to drain accumulated moisture. This configuration will be described below. In this embodiment, the upper header tank 3, which was difficult to drain in its operating position, will be mainly described, but the lower header tank 4 has the same configuration as the upper header tank 3 and is assembled by reversing its orientation. In this case, there is no problem with drainage for the lower header tank 4 in its operating position. Also, in the following description, for convenience, mainly describing the upper header tank 3, the upper header tank 3, the upper first tank member 31, and the upper second tank member 32 will simply be referred to as header tank 3, first tank member 31, and second tank member 32.

[0028] <First example> Figures 2 and 3 show the header tank 3 of the first example. Figure 2 is a perspective view showing the header tank 3 (first tank member 31 and second tank member 32), and the cap 33 is not shown. Figure 2(A) is a perspective view of the entire header tank 3, the upper part of Figure 2(B) is a magnified view of a part of Figure 2(A), and the lower part of Figure 2(B) is a further magnified view of the dashed circle in the upper part of Figure 2(B), showing only the second tank member 32. The upper part of Figure 3 is a cross-sectional view of line XX in the upper part of Figure 2(B), and the lower part of Figure 3 is a magnified view of the dashed circle in the upper part of Figure 3.

[0029] Referring to Figures 2 and 3, the first tank member 31 and the second tank member 32 are each half-cut. In this example, the first tank member 31 is formed in a roughly concave shape in side view and has a bottom surface 31B and two opposing first sides 31S that extend in the longitudinal direction of the header tank. When in use, the first tank member 31 is positioned so that the bottom surface 31B faces upward and the concave opening opposite the bottom surface 31B faces downward.

[0030] In this example, the second tank member 32 is shaped in a substantially concave form when viewed from the side, and has a bottom surface 32B and two opposing second sides 32S that extend in the longitudinal direction of the header tank. When in use, the second tank member 32 is positioned so that the bottom surface 32B faces downward and the concave opening opposite the bottom surface 32B faces upward.

[0031] The second side surface 32S is a surface that faces the header tank at both ends in the short direction (direction Z in Figure 1) and includes at least a portion that overlaps with a part of the first side surface 31S, and the bottom surface 32B of the second tank member 32 is the surface to which the multiple tubes 2 are connected. The first side surface 31S is a surface that faces the header tank at both ends in the short direction and includes at least a portion that overlaps with a part of the second side surface 32S, and the bottom surface 31B of the first tank member 31 is the surface that faces the bottom surface 32B of the second tank member 32.

[0032] The header tank 3 of this embodiment has a shape that is symmetrical with respect to a cylindrical axis. That is, the opposing first sides 31S of the first tank member 31 are the same shape, and the opposing second sides 32S of the second tank member 32 are the same shape.

[0033] The first tank member 31 and the second tank member 32 are combined so as to close each other's openings. In this configuration, the first tank member 31 and the second tank member 32 are positioned such that at least a portion of the first side surface 31S of the first tank member 31 overlaps with at least a portion of the second side surface 32S of the second tank member 32, thereby forming a cylindrical header tank 3.

[0034] More specifically, as shown in Figure 3, the first side surface 31S of the first tank member 31 is connected to both ends of the bottom surface 31B in the short direction of the header tank and is provided to rise up from the bottom surface 31B. The side of the first side surface 31S connected to the bottom surface 31B is called the base end 312, and the opposite side (opposite the bottom surface 31B) is called the tip end 313. In this embodiment, for the sake of explanation, the first side surface 31S is divided into the upper part 31Su and the lower part 31Sd. The lower part 31Sd is the portion of the first side surface 31S that includes the tip end 313. As an example, the lower part 31Sd is approximately half the height of the first side surface 31S including the tip end 313 (in the direction of tube extension, the up and down direction in Figure 3).

[0035] The second side surface 32S of the second tank member 32 is connected to both ends of the header tank in the short direction of the bottom surface 32B and is provided to rise up from the bottom surface 32B. In this embodiment, the side of the second side surface 32S connected to the bottom surface 32B is designated as the base end 322, and the opposite side (opposite to the bottom surface 32B) is designated as the tip end 323, thereby dividing the second side surface 32S into the upper second side surface 32Su and the lower second side surface 32Sd. The upper second side surface 32Su is the portion of the second side surface 32S that includes the tip end 323. As an example, the upper second side surface 32Su is approximately half the height of the second side surface 32S including the tip end 323. In this example, the header tank 3 is assembled by brazing a pair of lower first side surfaces 31Sd to overlap the inside of a pair of second side surfaces 32S.

[0036] In this embodiment, a thin-walled portion 325, which is thinner than the bottom surface 32B, is provided on at least a portion of the second side surface 32S, including the tip portion 323. The thin-walled portion 325 is shown by hatching in the lower part of Figure 3. More specifically, the thin-walled portion 325 is provided on at least a portion of the second side surface 32S that is exposed to the outside without being covered by the cap 33, including the tip portion 323. The at least portion including the tip portion 323 is, for example, the upper part of the second side surface 32Su. However, it is not limited to this, and the thin-walled portion 325 may be provided on only a further portion of the upper part of the second side surface 32Su including the tip portion 323, or it may be provided from the upper part of the second side surface 32Su to the lower part of the second side surface 32Sd, or it may be provided on the entire height direction (upright direction) of the second side surface 32S.

[0037] The thickness D1 of the bottom surface 32B refers to the thickness in the direction in which the tube extends. In this example, the lower part of the second side surface 32Sd has the same thickness D1 as the bottom surface 32B, and the thickness D1 of the lower part of the second side surface 32Sd and the thickness D2 of the thin-walled portion 325 are thicknesses in a direction intersecting the thickness D1 of the bottom surface 32B, and refer to the thickness in the short-side direction of the header tank.

[0038] The thin-walled portion 325 may be provided with a generally constant thickness D2 in the height direction of the second side surface 32S, or it may have a varying thickness. In the latter case, the thickness D2 of the thin-walled portion 325 refers to the maximum thickness or the average thickness in the height direction. Furthermore, if the thickness D2 varies in the height direction, the thickness D2 at the tip portion 323 is the thinnest, and it becomes thicker as it approaches the lower part of the second side surface 32Sd.

[0039] For example, as shown in Figure 3, if a thin-walled portion 325 is provided on the upper part 32Su of the second side surface, the thickness of the lower part 32Sd of the second side surface 32S is D1, and the thickness of the thin-walled portion 325 is D2. In other words, the thin-walled portion 325 can be said to be a part that is thinner than the lower part 32Sd of the second side surface.

[0040] Figures 2 and 3 show an example of a thin-walled section 325 (325a). In this example, the thin-walled section 325 (325a) is formed by cutting off the upper part of the second side surface 32Su, which is originally a roughly rectangular parallelepiped shape that is long in the longitudinal direction of the header tank, along the diagonal of the surface shown in Figure 3, in the longitudinal direction of the header tank. In other words, the outer surface Sf of the thin-walled section 325a (upper part of the second side surface 32Su) is an inclined surface 325S with the tip 323 as the apex, and the plate thickness increases from the tip 323 towards the lower end of the upper part of the second side surface 32Su (the plate thickness decreases as you move from the bottom surface 32B side towards the first tank member 31 side). The thickness D2 of the thin-walled section 325a decreases towards the tip 323 (it is not a constant value), but at any point it is thinner than the thickness D1 of the bottom surface 32B. Strictly speaking, the lower end of the thin-walled section 325a and the upper end of the lower part of the second side surface 32Sd coincide.

[0041] The first tank member 31 of the header tank 3 is the upper tank member when in use, and the second tank member 32 is the lower tank member when in use. In this embodiment, a pair of lower first side surfaces 31Sd of the first tank member 31 are brazed to the inside of a pair of upper second side surfaces 32Su of the second tank member 32, overlapping each other to form a cylindrical header tank 3. In this embodiment, even with this structure in which the upper second side surface 32Su overlaps the outside of the first side surface 31S, a thin-walled portion 325 is provided in at least a part of the upper second side surface 32Su to prevent a horizontal protrusion Hg (see Figure 9) from occurring on the outside of the first side surface 31S.

[0042] In this example, the outer surface Sf of the thin-walled portion 325a is an inclined surface 325S, and its lower end is continuous with the lower part of the second side surface 32Sd. Furthermore, as shown in Figure 2, the thin-walled portion 325a is provided over the entire length of at least one pair of upper parts of the second side surface 32Su that are exposed from the caps 33 at both ends of the header tank 3, in the longitudinal direction of the header tank.

[0043] With this configuration, no horizontal protrusion Hg is formed in the second tank member 32, and moisture adhering to the thin-walled portion 325a is discharged downwards along the inclined surface 325S. Furthermore, there are no steps ST (see Figure 9) where minute water droplets may remain. Therefore, corrosion of the second tank member 32 (and the first tank member 31 in contact with it) due to water retention can be suppressed.

[0044] Furthermore, a thin-walled portion 325a may or may not be provided on the upper part 32Su of the second side surface of the portion covered by the cap 33.

[0045] Furthermore, as shown in Figure 2, one or more claws (crimping claws) 326 are provided on the upper part 32Su of the second side surface of the second tank member 32. The claws 326 temporarily fix the second tank member 32 to the first tank member 31 before brazing, and engage with ribs 316 etc. provided on the first tank member 31 by bending them inward in the short direction of the header tank. In the example shown in Figure 2, the thin-walled portion 325a includes these claws 326 (see Figure 2(B) below).

[0046] The thin-walled portion 325a is formed, for example, by metal ironing. In forming the second tank member 32, for example, a metal plate is trimmed to a desired shape, including the claws 326, formed into a concave shape, and the thin-walled portion 325a is formed by ironing. As shown in Figure 2, if the thin-walled portion 325a is formed over the entire upper part 32Su of the second side surface, including the claws 326, then the formation of the second tank member 32 becomes easier, even if it has a configuration with a thin-walled portion 325a.

[0047] Furthermore, in the examples shown in Figures 2 and 3, a space is provided between the claw 326 and the thin-walled portion 325 in order to bend the claw 326 toward the first tank member 31. Depending on the size of this space, the bottom may protrude horizontally Hg, potentially retaining water. Therefore, a configuration without a space may also be used. For example, the claw 326 and the surrounding thin-walled portion 325a may be made continuous in the longitudinal direction of the header tank, and only the height of the claw 326 may be made higher than the tip 323 of the thin-walled portion 325a (protruding in the X-axis direction). In this case, the cost will be higher, the weight will increase, and the difficulty of processing will be higher, but water retention in the space will be eliminated.

[0048] <Second example> Figure 4 is a perspective view of the header tank 3, showing a second example of this embodiment, with the cap 33 omitted from the illustration. The upper part of Figure 4 is an overall view of the header tank 3, and the lower part of Figure 4 is an enlarged view of the dashed circled portion in the upper part of Figure 4, showing only the second tank member 32.

[0049] The second example is similar to the first example shown in Figures 2 and 3, except that the shape of the claw 326 is different. In this example, the claw 326 does not have a thin-walled portion 325a. This increases the difficulty of manufacturing, but it can increase the strength of the claw 326 (fixing strength to the first tank member 31), for example.

[0050] In this case, the upper surface of the claw 326 will have a horizontal overhang Hg, but the area is small and the claw 326 is folded inward towards the first tank member 31, so the possibility of water retention is low.

[0051] <Third example> Figure 5 is a perspective view of a header tank 3 showing a third example of this embodiment, and the cap 33 is not shown. The upper part of Figure 5 is an overall view of the header tank 3, and the lower part of Figure 5 is an enlarged view of the dashed circled portion in the upper part of Figure 5, showing only the second tank member 32.

[0052] The thin-walled portion 325 (325b) may be provided in part (partially) along the longitudinal direction of the header tank on the upper part 32Su of the second side surface. When the thin-walled portion 325b is provided partially along the longitudinal direction of the header tank, multiple portions may be provided, and in that case, it is preferable to distribute them at predetermined intervals along the longitudinal direction of the header tank. In this case, the thin-walled portion 325 has a substantially triangular prism shape (substantially triangular in cross-section) with an inclined surface 325S, similar to the first example.

[0053] In this example, although horizontal protrusions Hg are present in the upper part 32Su of the second side surface other than the thin-walled portion 325b, even if moisture adheres to these protrusions, the moisture can be discharged over time (for example, due to vehicle vibration) via the thin-walled portion 325b.

[0054] Furthermore, in the case of a thin-walled section 325 having an inclined surface 325S, the tip 323 becomes sharp. As in the first example, if a configuration is made in which sharp tips 323 are continuous in the longitudinal direction of the header tank, there is a risk that scratches or damage may occur due to contact between components (parts) during assembly, resulting in defective products. There is also a possibility that workers may be injured by touching the tip 323, requiring extreme caution in handling. As a result, this may affect the workability and safety during the formation and assembly of the second tank member 32. On the other hand, as in the third example, if a thin-walled section 325b is provided only partially, the tip 323 of the thin-walled section 325b is covered by the upper second side surface 32Su where the adjacent thin-walled section 325b is not formed, making it difficult for other parts or workers to come into direct contact with it. Therefore, compared to the first example, it is possible to avoid deterioration in workability during the formation and assembly of the second tank member 32, and to improve drainage while ensuring safety.

[0055] In this example, the claw 326 does not have a thin-walled portion 326, but a thin-walled portion 325 may be provided on the claw 326 as in the first example.

[0056] <Fourth example> Figure 6 shows a fourth example of this embodiment and is a front view of the second tank member 32. The upper part of Figure 6 is an overall view of the second tank member 32, and the lower part of Figure 6 is a partially enlarged view of the upper part of Figure 6. The formation position and shape of the thin-walled portion 325b are the same as in the third example shown in Figure 5, and the thin-walled portion 325b is partially formed in the longitudinal direction of the header tank. Furthermore, in the fourth example, at least a portion of the upper end edge 327 (the end edge that continues the tip portion 323 in the longitudinal direction) that extends in the longitudinal direction (the longitudinal direction of the header tank) of the upper part of the second side surface 32Su is provided with an end edge inclination portion 328 that slopes downward toward the thin-walled portion 325b. The end edge inclination portion 328 can be formed, for example, in trimming (cutting from a metal sheet) that forms the overall shape of the second tank member 32.

[0057] In the fourth example, multiple thin-walled sections 325b are provided at predetermined intervals, and multiple claws 326 are positioned, for example, midway between adjacent thin-walled sections 325b in the longitudinal direction of the header tank. The inclined edge section 328 is provided so as to descend toward the adjacent thin-walled section 325b, with the position of the claws 326 as its apex (highest position). The lowest part of the inclination of the inclined edge section 328 is continuous with the upper end of the thin-walled section 325b.

[0058] In the fourth example as well, a partial horizontal protrusion Hg occurs on the upper part 32Su of the second side surface other than the thin-walled portion 325. Even if moisture adheres to this protrusion Hg, the inclined edge portion 328 can guide the moisture to the thin-walled portion 325b, and the moisture can be discharged via the thin-walled portion 325b. In other words, reliable drainage becomes possible.

[0059] Furthermore, because the tip portion 323 is partially provided with a sharp, thin-walled portion 325b, it is safer and easier to handle compared to the first example. As a result, it is possible to improve drainage performance compared to the second example while avoiding deterioration in workability during the formation and assembly of the second tank member 32.

[0060] <Fifth example> Figure 7 is a diagram showing a fifth example of this embodiment, and is a cross-sectional view corresponding to the cross-sectional view in Figure 3. The second side surface 32S is configured in a stepped shape, and the thin-walled portion 325 (325c) may be the upper step of the stepped shape. In other words, in the example of Figure 7, the upper part 32Su of the second side surface may be configured in a stepped shape with a thickness D2, and the lower part 32Sd of the second side surface may be configured in a stepped shape with a thickness D1.

[0061] The thickness D2 of the thin-walled portion 325c (upper part of the second side surface 32Su) is, for example, 2 / 3 or less, preferably 1 / 2 or less, of the thickness D1 of the lower part of the second side surface 32Sd. Specifically, if the thickness D1 is, for example, 1.2 mm, the thickness D2 is, for example, 0.6 mm to 0.8 mm, preferably 0.5 mm to 0.7 mm. In this case, a horizontal overhang Hg is formed at the tip portion 323 (upper edge 327) of the thin-walled portion 325c. However, when the thickness D2 is thin, around 0.5 mm to 0.7 mm (for example, equivalent to the plate thickness of the heat exchanger of an HVAC unit), even if moisture adheres to the overhang Hg, it can be drained relatively easily due to its thinness. Furthermore, drainage is even easier when the radius of curvature of the fillet F of the brazing material is formed to be approximately the same as the thickness D2, as shown by the dashed line.

[0062] In the fifth example, since no sharp edges are formed in the thin-walled portion 325c, deterioration of workability during the formation and assembly of the second tank member 32 can be avoided, and drainage can be improved while ensuring safety. In this case, the thin-walled portion 325c may be provided over the entire length of the header tank of the upper part of the second side surface 32Su, as in the first example, or it may be provided only in part, as in the third example. Furthermore, the thin-walled portion 325c of the fifth example may be combined with the inclined edge portion 328 of the fourth example. This can further improve drainage.

[0063] <Sixth example> Figure 8 is a diagram showing a sixth example of this embodiment and is a cross-sectional view corresponding to the cross-sectional view in Figure 3. The thin-walled portion 325 (325d) may have an outer surface Sf that is curved 325R. Specifically, the inclined surface 325S of the first or third example may be composed of a curved surface 325R. Figure 7(A) is an example with an outwardly convex curved surface 325R, and Figure 7(B) is an example with an inwardly convex curved surface 325R. In the case of an outwardly convex curved surface 325R, even the maximum thickness D2 of the thin-walled portion 325 is considered to be thinner than the thickness D1 of the lower part 32Sd of the second side surface.

[0064] With this configuration, water retention is less likely to occur on the curved surface 325R in either case, and drainage can be improved. In this case as well, it may be provided on the entire upper part 32Su of the second side surface as in the first example, or on a part of it as in the second example.

[0065] In the embodiments described above, a relatively large heat exchanger 1, such as an outdoor heat exchanger for a vehicle, with a thick metal plate (for example, a plate thickness of 1 mm or more) was used as an example. However, the size and plate thickness of the heat exchanger 1 are arbitrary, and the heat exchanger 1 may be small or made of a thin metal plate.

[0066] Furthermore, in the above embodiment, as an example, the case in which the upper first tank member 31 and the upper second tank member 32 are substantially concave in side (cross-sectional) view is illustrated, but the embodiment is not limited to this. For example, they may be substantially semi-elliptical or substantially semi-circular in side view. In that case as well, the second side surface 32S of the second tank member 32 is a surface that faces each other at both ends in the short direction of the header tank and includes at least a portion that overlaps with the first side surface 31S, and the bottom surface 32B of the second tank member 32 is a surface to which the multiple tubes 2 are connected.

[0067] Furthermore, the thin-walled portion 325 is provided on at least a part of the surface of the second tank member 32 (the upper part of the second side surface 32Su) in the longitudinal direction of the header tank, excluding the portion covered by the cap 33, but it may also be provided on the portion covered by the cap 33.

[0068] Furthermore, in this embodiment, the thin-walled portion 325 is provided in a configuration where it is located on a part of the second side surface 32S in the height direction (the upper part of the second side surface 32Su, including the tip portion 323). Since the strength of the thin-walled portion 325 is reduced, the strength of the second side surface 32S is ensured by providing it on a part or all of the upper part of the second side surface 32Su (for example, ensuring that the lower part of the second side surface 32Sd has a thickness D1 equivalent to that of the bottom surface 32B). However, if there is no problem with the strength of the second side surface 32S, the thin-walled portion 325 may be formed to reach the lower part of the second side surface 32sd (the entire height direction of the second side surface 32S).

[0069] It should be noted that the heat exchanger 1 of the present invention is not limited to the embodiments described above, and various modifications can be made without departing from the spirit of the present invention. [Explanation of Symbols]

[0070] 1 heat exchanger 2 tubes 3 Upper header tank 4. Lower header tank 5 Side Plates 6 Inlet 7 Outlet 31 Upper first tank member (first tank member) 31B Bottom 31S first side 31Sd First side lower part 31Su First side upper part 32 Upper second tank member (second tank member) 32B Bottom 32S second side 32Su second side upper part 32sd 2nd side lower part 33 caps 41 Lower first tank member 42 Lower second tank member 43 Cap 312 Proximal end 313 Tip 316 Rib 322 Proximal end 323 Tip 325 Thin-walled section 325R curved surface 325S Slope 326 Nails 327 Top edge 328 Edge inclined section

Claims

1. Header tank and A heat exchanger having multiple tubes, The header tank includes a first tank member and a second tank member, each being half-cut. The first tank member has a set of first sides extending in the longitudinal direction, The second tank member has a pair of second sides and a bottom surface that extend in the longitudinal direction. The first tank member and the second tank member are positioned facing each other such that at least a portion of the first side surface of the pair overlaps the inside of at least a portion of the second side surface of the pair. In the region of the second side surface that is exposed to the outside, a thin-walled portion is provided in at least a part of it, including the tip located on the opposite side of the bottom surface, where the thickness of the plate is thinner than that of the bottom surface. A heat exchanger characterized by the following features.

2. Having other header tanks, The header tank is a tank located above when in use. The aforementioned other header tank is a tank located at the bottom when in use. The aforementioned first tank member is the tank member that is on the upper side when in use. The aforementioned second tank member is the tank member that is on the lower side when in use. A heat exchanger as described in feature 1.

3. The thin-walled portion is provided on a part of the second side surface in the longitudinal direction. The heat exchanger according to feature 1.

4. At least a portion of the end edge extending in the longitudinal direction of the second side surface is provided with an end edge inclined portion that slopes downward toward the thin-walled portion. The heat exchanger according to feature 3.

5. The thin-walled portion has an inclined surface where the plate thickness decreases from the bottom side toward the first tank member side. The heat exchanger according to feature 1.

6. The second side surface is configured with a stepped shape, The thin-walled portion is the upper step of the stepped shape. The heat exchanger according to feature 1.

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