heat exchanger

Abstract

When brazing a heat exchanger comprising a flow path forming section made by stacking multiple flow path forming units extending in the direction of air flow, a pair of flow path forming sections spaced apart from each other in the width direction perpendicular to the direction of air flow, a plurality of heat exchange tubes connecting the pair of flow path forming sections, heat transfer fins positioned on both outer sides of the heat exchange tubes located at both ends of the stacking direction among the heat exchange tubes stacked in the stacking direction of the flow path forming units, the heat transfer fins located at both ends of the stacking direction among the heat transfer fins, and a pair of side plates covering the pair of flow path forming sections from both sides of the stacking direction of the flow path forming unit, there was a problem in that adhesion occurred at the contact surface between the stainless steel jig and the aluminum components constituting the heat exchanger, causing damage to the heat exchanger when the jig was removed. [Solution] The end of the side plate is shaped to fill the step formed on the end face of the flow path forming unit.

Description

Technical Field

[0004] , , , , , , , , , ,

[0005] , , , , ,

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

Background Art

[0002] Among heat exchangers, for example, a heat exchanger used as a car heater is made of a predetermined one of main aluminum components such as a heat exchange tube, fins, a header tank, an inlet pipe, and an outlet pipe. For example, the heat exchange tube and the header tank are made of an aluminum brazing sheet, and the above components are assembled into the form of a heat exchanger. After setting this assembly on a stainless steel jig, it is manufactured by brazing the contact portions of the respective components by a vacuum brazing method, an inert gas atmosphere brazing method, a furnace brazing method, or the like. However, in the case of the above conventional method, the brazing surface of the aluminum brazing sheet component may contact the stainless steel jig, and as a result, there is a problem that the component and the jig are brazed together.

[0003] Therefore, a method has been taken in which a carbon brazing prevention member is interposed at the contact portion between the aluminum component and the stainless steel jig (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, the carbon brazing prevention member has problems in that it is expensive and easily damaged. In addition, it is necessary to set the carbon brazing prevention member every time brazing is performed, which is also a problem in terms of workability as it takes time. [Means for solving the problem]

[0006] To solve these problems, the heat exchanger according to the present invention has the following configuration. A heat exchanger comprising: a flow path forming section formed by stacking a plurality of flow path forming units extending in the direction of air flow, a pair of flow path forming sections spaced apart from each other in the width direction which is perpendicular to the direction of air flow, a plurality of heat exchange tubes connecting the pair of flow path forming sections, heat transfer fins arranged between adjacent heat exchange tubes and on the outside of each of the heat exchange tubes located at both ends of the stacking direction among the plurality of heat exchange tubes stacked in the stacking direction of the flow path forming units, and a pair of side plates that cover the heat transfer fins located at both ends of the stacking direction and the pair of flow path forming sections from both sides of the stacking direction of the flow path forming unit, wherein the ends of the side plates have auxiliary parts that fill the steps formed on both sides of the pair of flow path forming sections in the stacking direction. [Effects of the Invention]

[0007] According to the present invention, which has these characteristics, there is no need to use a brazing prevention member, making it economical, highly efficient, and preventing brazing defects. [Brief explanation of the drawing]

[0008] [Figure 1] This is an overall perspective view of a heat exchanger according to an embodiment of the present invention. [Figure 2] This is an exploded perspective view of the channel formation section. [Figure 3] This is an exploded perspective view of the flow path forming unit as seen from the first component side. [Figure 4] This is an exploded perspective view of the flow path forming unit as seen from the second component side. [Figure 5] This is a side view of the uppermost channel forming unit as seen from the first member side. [Figure 6]Figure 5 is a top view of the flow channel forming unit. [Figure 7] This is the end of the side plate as seen from the right side. [Figure 8] Figure 7 is a top view of the end of the side plate. [Figure 9] This is the left side of the end of the side plate, as viewed from the front. [Figure 10] This is the end of the side plate as seen from above (Comparative Example 2). [Modes for carrying out the invention]

[0009] Embodiments of the present invention will be described below with reference to the drawings. Each drawing shows one embodiment of the present invention and is not intended to limit the invention. In the following description, the same reference numerals in different drawings indicate parts with the same function, and redundant explanations in each drawing will be omitted as appropriate. In addition, the dimensional relationships of each element in the drawings are for the purpose of facilitating understanding and are not intended to limit the actual dimensional ratios. Furthermore, in this specification, stainless steel jigs are not limited to those having a clamping function to hold each component in an assembled state, but also include those that support the assembly by placing it on top of other objects, etc., and have a function to maintain the assembled form. Also, the term "aluminum" includes aluminum alloys as well as pure aluminum.

[0010] Figures 1 to 9 show a first embodiment of the present invention. In this embodiment, directions are indicated based on the front-to-back direction, left-to-right direction (width direction), and up-to-down direction (vertical direction), as shown by the solid arrows in Figure 1.

[0011] The heat exchanger 1 of the present invention is used, for example, in a vehicle air conditioning system that is installed for each of several seats in the passenger compartment of a vehicle and blows air as a second fluid with adjusted temperature and humidity toward the occupant seated in the seat. This vehicle air conditioning system includes an air conditioning unit in which components such as a compressor, heat exchanger 1, and expansion valve are integrally formed. The air conditioning unit is located, for example, under the seat, in the ceiling of the passenger compartment, in the door trim, or under the armrest in the center of the width direction of the passenger compartment. Air supplied from the air conditioning unit into the passenger compartment is blown out from outlets provided in the seat backs and cushions, under the seats, in the ceiling of the passenger compartment, or in the B-pillars of the vehicle.

[0012] The heat exchanger 1 is used in an air conditioning unit as a condenser for condensing the refrigerant, which is the first fluid discharged from the compressor, and as an evaporator for evaporating the refrigerant, which has been depressurized by an expansion valve after flowing out of the condenser.

[0013] As shown in Figure 1, the heat exchanger 1 comprises a pair of flow path forming sections 10 spaced apart from each other in the width direction, which is perpendicular to the front-to-back direction, which is the direction of air flow (indicated by white arrows in Figure 1); a plurality of heat exchange tubes 20 connecting the pair of flow path forming sections 10; heat transfer fins 30 positioned between the heat exchange tubes 20 and on the outside of the heat exchange tubes 20 located at both ends in the stacking direction of the flow path forming unit 11; and a pair of side plates 40 covering the heat transfer fins 30 located at both ends in the stacking direction and the pair of flow path forming sections 10 from both sides in the stacking direction of the flow path forming unit 11.

[0014] Each of the pair of flow path forming sections 10 has a plurality of refrigerant flow chambers 10a, which serve as first fluid flow chambers through which the refrigerant flows. Each of the pair of flow path forming sections 10 has a plurality of rows of refrigerant flow chambers 10a, each arranged in the direction of air flow, arranged in a plurality of rows in the vertical direction. In the present invention, it is preferable that each of the flow path forming sections 10 constituting the pair of flow path forming sections 10 is constructed by assembling a plurality of bent plate materials to form a plurality of refrigerant flow chambers 10a. In Figure 1, each of the pair of flow path forming sections 10 has 12 rows arranged in the vertical direction, each row having two refrigerant flow chambers 10a arranged in the front-to-back direction, forming a total of 24 refrigerant flow chambers 10a.

[0015] Specifically, as shown in FIG. 2, each of the pair of flow path forming portions 10 has a structure in which a plurality of flow path forming units 11 in which a plurality of refrigerant flow chambers 10a are arranged linearly in the front-rear direction are stacked in the vertical direction. The flow path forming unit 11 is provided so as to extend in the front-rear direction (the air flow direction) and is composed of members for the flow path forming unit. The members for the flow path forming unit include a first member 12 located on the outer side in the width direction and a second member 13 located on the inner side in the width direction, and a space extending in the front-rear direction is formed by assembling the first member 12 and the second member 13 to each other. Further, each of the pair of flow path forming portions 10 has a pair of closing members 14 that close one end portion and the other end portion in the front-rear direction in a plurality of flow path forming units 11 stacked in the vertical direction, and a plurality of partition members 15 that partition the refrigerant flow chambers 10a adjacent to each other in the front-rear direction in each of the plurality of stacked flow path forming units 11.

[0016] As shown in FIGS. 3 and 4, the first member 12 has a side surface portion 12a extending in the vertical direction, an upper surface portion 12b extending from the upper end of the side surface portion 12a to the inner side in the width direction, and a lower surface portion 12c extending from the lower end of the side surface portion 12a to the inner side in the width direction.

[0017] A partition member insertion hole 12a1 for inserting the partition member 15 is provided in the side surface portion 12a. Further, as shown in FIG. 2, a refrigerant inlet 12a2 for allowing the refrigerant to flow into the heat exchanger 1 and a refrigerant outlet 12a3 for allowing the refrigerant to flow out from the heat exchanger 1 are provided in a part of the side surface portions 12a in the plurality of flow path forming units 11.

[0018] As shown in Figures 3 and 4, the upper surface portion 12b is provided with four refrigerant flow holes 12b1 for each refrigerant flow chamber 10a, for connecting the refrigerant flow chamber 10a of the adjacent flow path forming unit 11 located above it. In addition, the inner end of the upper surface portion 12b in the width direction is provided with a claw engagement notch 12b2 into which the claw portion of the second member 13, described later, engages. Furthermore, the ends of the upper surface portion 12b on both the front and rear sides are provided with connecting portion engagement notches 12a4 into which the connecting portion of the closing member 14, described later, engages.

[0019] As shown in Figure 4, the lower surface portion 12c is provided with four refrigerant flow holes 12c1 for each refrigerant flow chamber 10a, for connecting the refrigerant flow chamber 10a of the adjacent flow path forming unit 11 below. In addition, the inner end of the lower surface portion 12c in the width direction is provided with a claw engagement notch 12c2 into which the claw portion of the second member 13, which will be described later, engages.

[0020] The second member 13 has a side portion 13a extending in the vertical direction, a plurality of upper engaging claw portions 13b extending outward in the width direction from the upper end of the side portion 13a, and a plurality of lower engaging claw portions 13c extending outward in the width direction from the lower end of the side portion 13a.

[0021] The side portion 13a is provided with a plurality of tube insertion holes 13a1 for inserting the heat exchange tube 20.

[0022] Furthermore, the second member 13 has a plurality of upper engaging claws 13b provided at predetermined intervals, which are arranged to engage with the upper surface of the upper surface 12b of the first member 12. Similarly, a plurality of lower engaging claws 13c are provided at predetermined intervals, which are arranged to engage with the lower surface of the lower surface 12c of the first member 12.

[0023] Furthermore, the upper engaging claw portion 13b fits between the lower engaging claw portions 13c of the adjacent flow path forming unit 11 above, and its upper surface is flat so as to make surface contact with the lower surface portion 12c of the first member 12 of the adjacent flow path forming unit 11 above. Also, the lower engaging claw portion 13c fits between the upper engaging claw portions 13b of the adjacent flow path forming unit 11 below, and its lower surface is flat so as to make surface contact with the upper surface portion 12b of the first member 12 of the adjacent flow path forming unit 11 below.

[0024] Between the vertically adjacent flow path forming units 11, three members are interposed: the lower surface portion 12c of the upper first member 12, the lower engaging claw portion 13c of the upper second member 13 or the upper engaging claw portion 13b of the lower second member 13, and the upper surface portion 12b of the lower first member 12.

[0025] In this way, by connecting a portion of adjacent refrigerant flow chambers 10a in each of the pair of flow path forming sections 10, it becomes possible to set up a refrigerant flow path without increasing the outward protrusion dimension.

[0026] Furthermore, the upper engaging claw portion 13b fits between the lower engaging claw portions 13c and the lower engaging claw portion 13c of the adjacent flow path forming unit 11 above, and the lower engaging claw portion 13c fits between the upper engaging claw portions 13b and the upper engaging claw portion 13b of the adjacent flow path forming unit 11 below.

[0027] This allows for the positioning of the stacked flow path forming units 11 when assembling the heat exchanger 1, thereby improving the assembly accuracy of the heat exchanger 1. Furthermore, since the number of interposed members between adjacent flow path forming units 11 in the vertical direction can be reduced, it becomes possible to miniaturize the size of the flow path forming units 11 in the stacking direction.

[0028] Each of the pair of closing members 14 is a plate-shaped member extending in the vertical direction, and has a closing portion 14a that closes the opening at the front or rear end of the flow path forming unit 11, and a connecting portion 14b provided between vertically adjacent closing portions 14a. The closing members 14 that close both ends of the flow path forming unit 11 in the front-rear direction are inserted into connecting portion engagement notches 12a4 formed on the side surfaces 12a of the first member 12 at both ends of the flow path forming unit 11 in the front-rear direction.

[0029] Each of the multiple partition members 15 is a plate-shaped member extending in the vertical direction, and has a partition portion 15a that separates adjacent refrigerant flow chambers 10a in the front-to-back direction, and a connecting portion 15b provided between adjacent partition portions 15a in the vertical direction. The partition members 15 separate adjacent refrigerant flow chambers 10a in the front-to-back direction, regardless of whether they communicate with each other, by inserting the partition portion 15a into the partition member insertion hole 12a1 of the first member 12 when the multiple flow path forming units 11 are stacked in the vertical direction. A communication hole 15c is provided in the partition portion 15a between adjacent refrigerant flow chambers 10a in the front-to-back direction that communicate with each other, as shown in Figure 2.

[0030] Multiple heat exchange tubes 20 are made of flattened tubular members, and are extruded tubes or plate-shaped members bent to form refrigerant flow paths. Each of the multiple heat exchange tubes 20 extends in the width direction, and the longitudinal direction of the cross-section is oriented in the front-to-back direction. In addition, multiple heat exchange tubes 20 are arranged in the front-to-back direction in a pair of flow path forming units 11 that face each other in the width direction. In this embodiment, two heat exchange tubes 20 are connected in the front-to-back direction to a pair of flow path forming units 11 that face each other in the width direction.

[0031] The heat transfer fins 30 are made of corrugated metal, such as metal plates bent into a wave shape. The heat transfer fins 30 are connected so that their apex is in contact with the heat exchange tube 20.

[0032] Each of the pair of side plates 40 is a plate-shaped member that extends in the width direction from one flow path forming section 10 to the other flow path forming section 10 and has approximately the same dimensions as the front-to-back dimensions of the heat transfer fins 30.

[0033] The heat exchanger 1 is created by brazing together all its components, including a pair of flow path forming sections 10 (first member 12, second member 13, a pair of closing members 14, and a plurality of partition members 15), a plurality of heat exchange tubes 20, a plurality of heat transfer fins 30, and a pair of side plates 40, as a single unit (hereinafter referred to as the "assembly"). Alternatively, the inlet and outlet pads (not shown) may also be brazed together as a single unit.

[0034] In the heat exchanger 1 configured as described above, a refrigerant flow path is established by providing refrigerant flow holes 13b1 and 13c1 in a part of the upper engaging claw portion 13b and lower engaging claw portion 13c of the second member 13 of the flow path forming unit 11, and by providing a communication hole 15c in a part of the partition portion 15a in a pair of flow path forming sections 10.

[0035] Thus, according to the heat exchanger 1 of this embodiment, the heat exchanger 1 comprises a pair of flow path forming sections 10, each consisting of multiple rows of refrigerant flow chambers 10a arranged in the direction of air flow, spaced apart from one another in the width direction of the air flow path, and through which the refrigerant flows. The rows of refrigerant flow chambers 10a are arranged in the direction of air flow, and the rows of refrigerant flow chambers 10a are arranged in the vertical direction. The refrigerant flow path is formed by connecting parts of adjacent refrigerant flow chambers 10a in the flow path forming section 10 and setting the order in which the refrigerant flows through the multiple heat exchange tubes 20.

[0036] Next, the structure of the widthwise end of the side plate 40 according to the present invention will be described in detail using the side plate 40 used on the upper surface of the assembly as an example, but the same applies to the side plate 40 used on the lower surface.

[0037] The flow path forming unit 11, which is brazed to the side plate 40, is composed of the upper surface portion 12b of the first member 12 and the upper engaging claw portion 13b of the second member 13. As shown in Figures 5 and 6, a step d is formed on the upper surface. Note that Figure 6 shows, as an example, the flow path forming unit 11 located at the uppermost stage of the flow path forming section 10, so the upper surface portion 12b of the first member 12 does not have a refrigerant flow hole 12b1 formed therein.

[0038] The present invention is characterized by providing an auxiliary part on the side plate 40 for filling this step d. Specifically, a normally thick portion 40a and an increased thickness portion 40b are provided at the widthwise end of the side plate 40 at a predetermined distance apart.

[0039] As shown in Figures 7 to 9, the widthwise end of the side plate 40 is formed such that the lower surface of the normally thickened portion 40a is in surface contact with the upper engaging claw portion 13b of the second member 13 of the uppermost flow channel forming unit 11, and the lower surface of the increased thickness portion 40b is in surface contact with the upper surface portion 12b of the first member 12 of the uppermost flow channel forming unit 11. In other words, the recess of the step d formed on the upper surface of the flow channel forming unit 11 is filled by the upper engaging claw portion 13b of the second member 13 and the upper surface portion 12b of the first member 12, so that the lower surface of the widthwise end of the side plate 40 and the upper surface of the flow channel forming unit 11 are in surface contact, and the upper surface of the end of the side plate 40 is formed to be flat.

[0040] Furthermore, it is preferable that the length of the thickened portion 40b in the width direction be the same as the width of the flow path forming unit 11, but it is sufficient if it is long enough for the jig to make surface contact with it.

[0041] The thickened portion 40b can be formed, for example, by preparing a wide, flat side plate in advance, cutting out the portion corresponding to the normal thickness, and then bending the remaining portion. In this case, by making the thickness of the side plate 40 equal to the step d, the step d can be filled with the side plate alone without requiring any additional members.

[0042] Therefore, the lower end surface of the side plate 40 is in surface contact with the upper engaging claw portion 13b of the second member 13 of the flow path forming unit 11 located at the top and the upper surface portion 12b of the first member 12. This makes it possible to apply even stress to the assembly from the upper surface of the side plate 40 using a stainless steel jig during brazing, thereby ensuring tight and secure fastening and suppressing the occurrence of brazing defects. Furthermore, since the upper surface of the side plate 40 is not brazed, it is possible to prevent unwanted adhesion of brazing material between the stainless steel jig and the aluminum components constituting the heat exchanger.

[0043] Furthermore, the upper engaging claw portion 13b fits between the thickened portions 40b of the side plate 40, and the thickened portions 40b fit between the upper engaging claw portions 13b of the adjacent lower flow path forming unit 11. This allows for the positioning of the side plate 40 and the flow path forming section 10 when assembling the heat exchanger 1, thereby improving the assembly accuracy of the heat exchanger 1. Furthermore, it is preferable that the side plate 40 be manufactured such that, when the side plate 40 is placed in the assembly, the upper surface of the fin located at the very top is in surface contact with the lower surface of the side plate 40.

[0044] (Comparative Example 1) The configuration was the same as in the example, except that a flat side plate without the thickened portion 40b was used instead of the side plate 40 used in the example, and brazing was attempted by pressing a stainless steel jig against it. Because the uppermost channel forming unit 11 has a recess caused by the step d, if a flat side plate without the thickened portion 40b is used, there is no surface contact between the upper surface portion 12b of the first member 12 and the side plate, and therefore a space exists. As a result, the assembly could not be sufficiently tightly fixed, and the brazing could not be performed properly.

[0045] (Comparative Example 2) To eliminate the space that was a problem in Comparative Example 1, the conditions were the same as in Comparative Example 1, except that a side plate was used in which a notch 40c was formed in the portion where the upper engaging claw portion 13b of the second member of the flow path forming unit 11 engages with the lower surface of the side plate, as shown in Figure 10. Since a notch 40c is formed, the side plate and the upper surface 12b of the first member 12 are in surface contact. Furthermore, by matching the thickness of the side plate with the thickness of the upper engaging claw portion 13b of the second member of the flow path forming unit 11, the side plate and the upper surface of the flow path forming unit 11 are in surface contact without any gaps. In addition, the end of the side plate that comes into contact with the stainless steel jig can be made flat.

[0046] A stainless steel jig was directly brought into contact with the assembly using this side plate, and the assembly was tightly fixed and brazed. Although the assembly was brazed sufficiently, there was a portion where the upper engaging claw portion 13b of the second member of the aluminum flow path forming unit 11 and the stainless steel jig came into direct contact. As a result, when removing the jig from the assembly, the assembly and the jig stuck together.

[0047] Furthermore, when brazing was performed with a carbon fiber jig interposed between the assembly and the stainless steel jig, no adhesion problems occurred. However, the use of the expensive and easily damaged carbon fiber jig was economically unfeasible, and the need to set it up each time resulted in a decrease in work efficiency.

[0048] In the above embodiment, the heat exchanger of the present invention was shown applied to an air conditioning system for a vehicle, but the invention is not limited to this. For example, the present invention can be applied to heat exchangers used in air conditioning systems for the interior of buildings, or in refrigerated display cases and refrigerator display cases.

[0049] Furthermore, although the above embodiment shows the application of the present invention to a heat exchanger that exchanges heat between a refrigerant and air, the present invention is not limited to this. For example, the present invention may be applied to a heat exchanger that exchanges heat between water or antifreeze and air.

[0050] Furthermore, although the above embodiment shows a pair of flow path forming sections 10 spaced apart from each other in the width direction, the invention is not limited to this configuration. The pair of flow path forming sections 10 may also be spaced apart from each other in the vertical direction.

[0051] Furthermore, in the above embodiment, the front-to-back direction, width direction, and vertical direction of the heat exchanger 1 were defined as the direction of air flow for heat exchange with the refrigerant moving from rear to front, but the embodiment is not limited to this. For example, it is also possible to position the heat exchanger 1 with the direction of air flow moving from bottom to top, and define the front-to-back direction, width direction, and vertical direction of the heat exchanger 1 accordingly.

[0052] Although embodiments of the present invention have been described in detail above with reference to the drawings, the configuration of the present invention is not limited to the embodiments described, and any design changes, etc., that do not depart from the spirit of the present invention are also included. [Explanation of Symbols]

[0053] 1: Heat exchanger, 10: Flow channel forming section, 10a: Refrigerant flow chamber, 11: Flow channel forming unit, 12: First member, 12a: Side portion, 12a1: Partition member insertion hole, 12a2: Refrigerant inlet, 12a3: Refrigerant outlet, 12a4: Connecting part engagement notch, 12b: Top surface, 12b1: Coolant flow hole, 12b2: Claw engagement notch, 12c: Bottom surface, 12c1: Coolant flow hole, 12c2: Claw engagement notch, 13: Second member, 13a: Side portion, 13a1: Tube insertion hole, 13b: Upper engaging claw portion, 13c: Lower engaging claw portion, 14: Closing member, 15: Partition member, 15c: Communication hole, 20: Heat exchange tube, 30: Heat transfer fin, 40: Side plate, 40a: Standard thickness section, 40b: Increased thickness section, 40c: Notch section

Claims

1. A flow channel forming section is formed by stacking multiple flow channel forming units that extend in the direction of air flow, and a pair of flow channel forming sections are provided spaced apart from each other in the width direction, which is perpendicular to the direction of air flow, A plurality of heat exchange tubes connecting the pair of flow path forming sections, Between adjacent heat exchange tubes, and among the multiple heat exchange tubes stacked in the stacking direction of the flow path forming unit, heat transfer fins are arranged on the outside of each of the heat exchange tubes located at both ends in the stacking direction, The heat transfer fins include the heat transfer fins located at both ends in the stacking direction, and a pair of side plates that cover the pair of flow path forming portions from both sides of the flow path forming unit in the stacking direction, A heat exchanger equipped with, The ends of the side plates have auxiliary portions that fill the steps formed on both sides of the pair of flow path forming portions in the stacking direction. A heat exchanger characterized by the following features.

2. The aforementioned channel forming unit is composed of multiple types of channel forming unit members, The aforementioned step is formed by assembling the multiple types of flow path forming unit members. The heat exchanger according to feature 1.

3. The auxiliary portion is formed by bending the side plate. A heat exchanger according to claim 1 or 2, characterized by the features described above.

Images