Heat exchanger and method for manufacturing heat exchanger

Abstract

A heat exchanger (10) comprises an inner member (30) having an inner bottom part (40) and inner wall parts (42) that are erected on two side parts of the inner bottom part (40). The heat exchanger (10) comprises an outer member (32) having an outer bottom part (52) and outer wall parts (54) that are erected on two side parts of the outer bottom part (52), with end parts of the outer wall parts (54) being disposed outside of the inner wall parts (42). The heat exchanger (10) comprises a support member (34) having: an outer beam part (70) that extends along the outer bottom part (52) in the width direction (W) of a tank (20); an inner beam part (72) that extends along the inner bottom part (40) in the width direction W; and a pair of linking parts (74) that link end parts of the outer beam part (70) with end parts of the inner beam part (72). In the support member (34), outside facing portions (74B) which face the outer wall parts (54) have higher rigidity than inside facing portions (74A) which face the inner wall parts (42), and a longitudinal-direction center part (81) of the outer beam part (70) has lower rigidity than the outside facing portions (74B).

Description

Heat exchanger and method for manufacturing the same

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

[0002] JP2010-085025A discloses a heat exchanger, the tank body of which is formed by a tube plate having a U-shaped cross section and a tank plate having a U-shaped cross section.

[0003] The claws formed on the tube plate are bent and locked into the locking holes in the tank plate, thereby joining the tube plate and the tank plate to form the tank body.

[0004] However, in the heat exchanger described in JP2010-085025A, the claws of the tube plate are plastically deformed to form the tank body, so the gap at the connection between the tube plate and the tank plate changes depending on the bending state of the claws. If the gap at the connection between the tube plate and the tank plate changes, there is a risk that the brazing properties of the tank body will deteriorate.

[0005] The present invention has been made in consideration of the above problems, and has an object to enable stable brazing of heat exchangers.

[0006] According to one aspect of the present invention, a heat exchanger is a heat exchanger having a hollow tank, comprising: an inner member having an approximately U-shaped cross section, the inner member having an inner bottom extending in the length direction of the tank and inner wall portions erected on both sides of the inner bottom; an outer member having an approximately U-shaped cross section, the outer member having an outer bottom extending in the length direction while facing the inner bottom, and outer wall portions erected on both sides of the outer bottom and having ends disposed outside the inner wall portions, the outer member covering the outer periphery of the inner member to form the tank; and a heat exchanger for forming the tank, the heat exchanger including: an inner member having an inner bottom extending in the length direction of the tank and inner wall portions erected on both sides of the inner bottom, the outer member having an approximately U-shaped cross section, the outer member covering the outer periphery of the inner member to form the tank; a support member formed in a ring shape having a plurality of tubes connected to each other, 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 to the end of the inner beam portion, and disposed inside the inner member and the outer member, wherein the support member has a higher rigidity at an outer facing portion facing the outer wall portion than at an inner facing portion facing the inner wall portion, and a lower rigidity at a longitudinal center portion of the outer beam portion than at the outer facing portion.

[0007] In the above aspect, the tank is formed by an inner member, an outer member, and a support member arranged inside the inner member and the outer member. An end of the outer wall portion of the outer member is arranged outside the inner wall portion of the inner member. An inner facing portion of the support member is arranged inside the inner wall portion, so that the inner wall portion of the inner member and the outer wall portion of the outer member are maintained in a joined state.

[0008] Therefore, compared to a case where the claws of the tube plate are plastically deformed to join the tube plate and the tank plate to form a tank, a heat exchanger formed from an inner member and an outer member can suppress changes in the gap that may occur between the outer member and the inner member, thereby enabling stable brazing of the inner member and the outer member of the heat exchanger.

[0009] FIG. 1 is a front view of a heat exchanger according to an embodiment of the present invention. FIG. 2 is a perspective view showing a main portion of a tank of the heat exchanger. FIG. 3 is a cross-sectional view taken along III-III in FIG. 2. FIG. 4 is a view showing the cross section of FIG. 3. FIG. 5 is a view showing an end of the tank. FIG. 6 is a front view showing a support member before assembly. FIG. 7 is an explanatory diagram showing a manufacturing process for a heat exchanger according to the present invention. FIG. 8 is an explanatory diagram showing a manufacturing process following FIG. 7. FIG. 9 is an explanatory diagram showing a manufacturing process following FIG. 8. FIG. 10 is an explanatory diagram showing a manufacturing process following FIG. 9.

[0010] Hereinafter, a heat exchanger 10 according to an embodiment of the present invention will be described with reference to the drawings.

[0011] First, the overall configuration of a heat exchanger 10 will be described with reference to Fig. 1. Fig. 1 is a front view of the heat exchanger 10 according to this embodiment.

[0012] The heat exchanger 10 is mounted on a vehicle (not shown). The heat exchanger 10 is, for example, an outdoor heat exchanger in the refrigeration cycle of an air conditioner (not shown). The heat exchanger 10 exchanges heat between the refrigerant circulating through the refrigeration cycle and outside air. The heat exchanger 10 functions as a condenser when the air conditioner is operating in cooling mode, and as an evaporator when the air conditioner is operating in heating mode.

[0013] Hereinafter, the longitudinal direction of the tank 20 will be referred to as the length direction L, and the width direction of the tank 20 will be 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 tanks 20, the tubes 22, and the fins 24 are formed of a metal such as aluminum, and are joined together by brazing to form an integrated unit.

[0014] The tubes 22 are arranged in parallel and stacked at intervals. A flow path through which a refrigerant flows is formed inside the tubes 22. The tubes 22 are arranged so that the heat exchange surface that abuts against the fins 24 is horizontal.

[0015] The tanks 20 are arranged so as to be connected to both longitudinal ends of the tubes 22. The tanks 20 are arranged so as to be connected to the plurality of tubes 22 in the longitudinal direction. The tanks 20 temporarily store the refrigerant.

[0016] The refrigerant that has been circulated through the refrigeration cycle and used for air conditioning flows into one of the tanks 20. The refrigerant that has flowed into the tank 20 flows through each of the multiple tubes 22. As the refrigerant flows through the tubes 22, it exchanges heat with the outside air.

[0017] The refrigerant that has circulated through the tubes 22 flows into the other tank 20. The refrigerant that has flowed into the tank 20 is circulated again through the refrigeration cycle and used for air conditioning.

[0018] The fins 24 are provided between adjacent tubes 22 and are stacked alternately with the tubes 22. The fins 24 are formed in a wave shape along the length of the tubes 22 and are joined to two adjacent tubes 22. Outside air introduced by the vehicle running or an exterior fan (not shown) passes around the multiple tubes 22 and fins 24. Therefore, the refrigerant flowing inside the tubes 22 can exchange heat with the outside air via the surfaces of the tubes 22 and the fins 24. In this way, the fins 24 promote heat exchange between the refrigerant and the outside air.

[0019] Next, the tank 20 will be described in detail with reference to Figures 2 to 4. Figure 2 is a perspective view showing a main part of the tank 20 of the heat exchanger 10. Figure 3 is a cross-sectional view taken along III-III in Figure 2. Figure 4 is a view showing the cross section of Figure 3. Figure 5 is a view showing an end of the tank 20.

[0020] 2 to 4, the tank 20 is hollow and includes an inner member 30, an outer member 32, and a support member 34 (see FIG. 3) disposed inside the inner member 30 and the outer member 32. A lid 36 (see FIG. 5) is provided at one end of the tank 20.

[0021] (Inner member) The inner member 30 has a plate-shaped inner bottom 40 extending in the longitudinal direction L of the tank 20, and plate-shaped inner wall portions 42 provided upright on both sides of the inner bottom 40 (see FIG. 3 ). As a result, the inner member 30 is formed with a generally U-shaped cross section.

[0022] The inner bottom 40 is formed with a first support hole 43, a second support hole 44, a third support hole 46, and a fourth support hole 48, each of which has a rectangular shape and extends in the width direction W of the tank 20 (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 in the center of the inner bottom 40 in the length direction L. A connector (not shown) for circulating the refrigerant is connected to the elliptical hole 50. The elliptical hole 50 is arranged between the second support hole 44 and the third support hole 46.

[0023] (Outer Member) The outer member 32 has a plate-shaped outer bottom 52 that extends in the longitudinal direction L of the tank 20 while facing the inner bottom 40, and outer wall portions 54 that are erected on both sides of the outer bottom 52 (see FIG. 3 ). As a result, the outer member 32 is formed with a generally U-shaped cross section.

[0024] The tip of the outer wall portion 54 is disposed outside the inner wall portion 42 of the inner member 30. As a result, the outer member 32 covers the outer periphery of the inner member 30 to form the tank 20 with a closed cross-sectional shape.

[0025] A hole 56 into which a protrusion 84 of the support member 34, which will be described later, fits is formed inside the outer wall portion 54. The hole 56 may be a hole that penetrates the outer wall portion 54, or a bottomed hole in which a portion of the inner surface of the outer wall portion 54 is recessed. However, the hole 56 is preferably a bottomed hole. In this embodiment, the hole 56 is configured as a bottomed hole in which a portion of the inner surface of the outer wall portion 54 is recessed.

[0026] The hole 56 is disposed closer to the outer bottom portion 52 than the overlapping portion that overlaps with the inner wall portion 42 of the inner member 30. The hole 56 is configured so that its depth increases from the outer bottom portion 52 toward the tip end of the outer wall portion 54.

[0027] A plurality of tube mounting portions 60 extending in the width direction W are provided on the outer bottom portion 52 at intervals in the length direction L. Each tube mounting portion 60 has a ridge portion 62 protruding toward the inside of the tank 20 and an insertion hole 64 provided in the ridge portion 62. The end of the aforementioned tube 22 is connected to each tube mounting portion 60 with the end inserted into the insertion hole 64.

[0028] In this embodiment, the case where the tubes 22 are connected to the outer bottom 52 is described as an example, but the heat exchanger 10 is not limited to this configuration. For example, in the case of a heat exchanger 10 in which the tubes 22 are connected to the inner bottom 40, a plurality of tube mounting portions 60 extending in the width direction W are provided at intervals in the length direction L on the inner bottom 40.

[0029] 4, 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 an end of the outer beam portion 70 to an end of the inner beam portion 72. As a result, the support member 34 is formed in a rectangular ring shape with a rectangular communication hole 76 in the center.

[0030] A rectangular support piece 80 that protrudes outward is formed in the center in the longitudinal direction of the inner beam portion 72. The support member 34 is positioned in the tank 20 with the support piece 80 inserted into the second support hole 44 or the third support hole 46 of the inner member 30.

[0031] The connecting portion 74 of the support member 34 has an inner facing portion 74A facing the inner wall portion 42 of the inner member 30 and an outer facing portion 74B facing the outer wall portion 54 of the outer member 32. The outer facing portion 74B of the support member 34 facing the outer wall portion 54 has higher rigidity than the inner facing portion 74A facing the inner wall portion 42.

[0032] An example of a configuration in which the outer facing portion 74B has higher rigidity than the inner facing portion 74A is a configuration in which the cross-sectional area of ​​the outer facing portion 74B is larger than the cross-sectional area of ​​the inner facing portion 74A.

[0033] An example of a configuration in which the cross-sectional area of ​​the outer facing portion 74B is larger than the cross-sectional area of ​​the inner facing portion 74A is a configuration in which the thickness dimension of the outer facing portion 74B is larger than the thickness dimension of the inner facing portion 74A. Also, an example of a configuration in which the cross-sectional area of ​​the outer facing portion 74B is larger than the cross-sectional area of ​​the inner facing portion 74A is a configuration in which the width dimension of the outer facing portion 74B is larger than the width dimension of the inner facing portion 74A.

[0034] The support member 34 of this embodiment has a constant thickness across the entire area, and the width of the outer facing portion 74B is greater than the width of the inner facing portion 74A.

[0035] Furthermore, the support member 34 has lower rigidity at the longitudinal center portion 81 of the outer beam portion 70 than at the outer facing portion 74B of the connecting portion 74.

[0036] An example of a configuration in which the longitudinal central portion 81 of the outer beam portion 70 has lower rigidity than the outer facing portion 74B is a configuration in which the cross-sectional area of ​​the longitudinal central portion 81 of the outer beam portion 70 is smaller than the cross-sectional area of ​​the outer facing portion 74B.

[0037] An example of a configuration in which the cross-sectional area of ​​the longitudinal central portion 81 of the outer beam portion 70 is smaller than the cross-sectional area of ​​the outer facing portion 74B is a configuration in which the thickness dimension of the longitudinal central portion 81 of the outer beam portion 70 is smaller than the thickness dimension of the outer facing portion 74B. Furthermore, an example of a configuration in which the cross-sectional area of ​​the longitudinal central portion 81 of the outer beam portion 70 is smaller than the cross-sectional area of ​​the outer facing portion 74B is a configuration in which the width dimension of the longitudinal central portion 81 of the outer beam portion 70 is smaller than the width dimension of the outer facing portion 74B.

[0038] The support member 34 of this embodiment has a constant thickness over the entire area, and the width of the longitudinal center portion 81 of the outer beam portion 70 is smaller than the width of the outer facing portion 74B.

[0039] A protrusion 84 that protrudes toward the outside of the tank 20 is provided on the outer facing portion 74B of the connecting portion 74 of the support member 34. The protrusion 84 fits into the 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.

[0040] The height of the protrusion 84 decreases from the inner beam portion 72 side toward the outer beam portion 70 side. This makes it easy to insert the support member 34 into the outer member 32, and when the protrusion 84 is inserted into the hole 56, the support member 34 is prevented from coming off the outer member 32. In addition, the end of the protrusion 84 forms a support surface 84A that supports the tip of the inner wall portion 42 of the inner member 30.

[0041] A gap 90 is formed between the longitudinal center portion 81 of the outer beam portion 70 of the support member 34 and the outer bottom portion 52 .

[0042] In the tank 20 of this embodiment, the outer beam portion 70 has a curved shape in which a longitudinal center portion 81 protrudes toward the inner beam portion 72. The aforementioned gap 90 is formed between the longitudinal center portion 81 of the curved outer beam portion 70 and the outer bottom portion 52 of the outer member 32, which is configured as a flat surface. The gap 90 is filled with a brazing material used for brazing.

[0043] In this embodiment, the gap 90 between the longitudinal center 81 of the outer beam portion 70 of the support member 34 and the outer bottom 52 is filled with brazing material, but this embodiment is not limited to this configuration. The gap 90 between the longitudinal center 81 of the outer beam portion 70 of the support member 34 and the outer bottom 52 may be a space that is not filled with brazing material.

[0044] 5, the lid 36 has a first region 94 disposed inside the inner member 30 and a second region 96 disposed inside the outer member 32. The second region 96 has a width dimension larger than that of the first region 94. A step 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 step 98.

[0045] A protrusion 100 is formed in the first region 94. The lid 36 is positioned on the tank 20 with the protrusion 100 inserted into the first support hole 43 or the fourth support hole 48 of the inner member 30 (see FIG. 1). When positioned on the tank 20, the lid 36 closes the end opening of the tank 20.

[0046] (Method of Manufacturing Heat Exchanger) Next, a method of manufacturing the heat exchanger 10 will be described with reference to FIGS. 6 to 9. FIG.

[0047] Fig. 6 is a front view showing the support member 34 before assembly. Fig. 7 is an explanatory diagram showing the manufacturing process of the heat exchanger 10 of the present invention. Fig. 8 is an explanatory diagram showing the manufacturing process following Fig. 7. Fig. 9 is an explanatory diagram showing the manufacturing process following Fig. 8. Fig. 10 is an explanatory diagram showing the manufacturing process following Fig. 9.

[0048] For convenience of explanation, only the right side of the tank 20 is shown in FIGS. 7 to 10, but the tank 20 has a shape that is line-symmetrical with respect to the center line C.

[0049] Fig. 6 is a diagram showing a support member 34 used in manufacturing the heat exchanger 10. The support member 34 before manufacturing will be described, focusing on the differences from the support member 34 after manufacturing (see Fig. 4, for example).

[0050] Before assembly, the support member 34 has inner facing portions 74A of the connecting portions 74 that are inclined toward each other from the inner beam portion 72 toward the outer facing portions 74B. The outer facing portions 74B of the connecting portions 74 are inclined away from each other from the inner facing portions 74A toward the outer beam portion 70.

[0051] Furthermore, the outer beam portion 70 of the support member 34 is formed in an arc shape that protrudes toward the outer bottom portion 52 of the inserted outer member 32. As a result, the outer beam portion 70 of the support member 34 has an arc portion 70A that protrudes outward. The arc portion 70A has a longitudinal center portion 81 of the outer beam portion 70 that protrudes outward the furthest.

[0052] (Support Member Assembly Step) FIG. 7 is an explanatory diagram showing a support member assembly step 110 in which the support member 34 is assembled to the inner member 30. As shown in FIG.

[0053] In the support member assembling process 110, the worker 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. The worker also aligns the support piece 80 of another support member 34 with the third support hole 46 of the inner member 30, and 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 worker may fix the support member 34 to the inner member 30 by deforming the support piece 80, for example.

[0054] When the support member 34 is assembled to the inner member 30, the entire connecting portion 74 of the support member 34 moves away from the inner wall portion 42 of the inner member 30 as it moves from the inner beam portion 72 to the outer beam portion 70. Furthermore, the outer beam portion 70 of the support member 34 has a longitudinal center portion 81 where the arc portion 70A is formed, which protrudes outward.

[0055] The worker then aligns the protrusion 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 ). The worker then aligns the protrusion 100 of the other 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.

[0056] (Support Member Insertion Step) FIG. 8 is an explanatory diagram showing a support member insertion step 112 in which the support member 34 assembled to the inner member 30 is inserted into the outer member 32.

[0057] In the support member insertion step 112, the worker aligns the opening of the inner member 30 with 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 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.

[0058] The support member insertion step 112 can be performed, for example, by using a pressing tool that presses the abutted inner member 30 and outer member 32 toward each other. In the support member insertion step 112, the inner member 30 is positioned so that the tip end of the inner wall portion 42 is positioned inside the outer wall portion 54 of the outer member 32.

[0059] (Inner Member Inserting Step) FIG. 9 is an explanatory diagram showing an inner member inserting step 114 of inserting the inner member 30 into the outer member 32. As shown in FIG.

[0060] In the inner member insertion process 114, the worker uses, for example, a pressing tool to insert the inner member 30 to which the support member 34 is assembled into the outer member 32 so that the arc portion 70A of the outer beam portion 70 of the support member 34 abuts the outer bottom portion 52 of the outer member 32.

[0061] (Inner Member Assembly Step) FIG. 10 is an explanatory diagram showing an inner member assembly step 116 in which the inner member 30 is assembled to the outer member 32. As shown in FIG.

[0062] In the inner member assembling step 116, the worker uses, for example, a pressing tool to further press the inner member 30 and the outer member 32 in directions in which they approach each other.

[0063] As a result, the arc portion 70A of the longitudinal center portion 81 of the outer beam portion 70 of the support member 34, which faces the outer bottom portion 52 of the outer member 32, is pressed against the outer bottom portion 52 of the outer member 32 earlier than both end portions of the outer beam portion 70. At this time, the arc portion 70A of the longitudinal center portion 81 of the outer beam portion 70, which is pressed against the outer bottom portion 52 of the outer member 32 earlier, has lower rigidity than the outer facing portion 74B of the connecting portion 74. For this reason, the arc portion 70A of the outer beam portion 70 is deformed, for example, into an arc shape that protrudes inward.

[0064] Furthermore, 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. Therefore, when the longitudinal central portion 81 of the outer beam portion 70 deforms so as to protrude inward, the outer facing portion 74B of the support member 34 displaces outward while tilting, and the inner facing portion 74A, which has lower rigidity than the outer facing portion 74B, displaces outward.

[0065] As a result, the inner wall portion 42 of the inner member 30 is pushed outward by the inner opposing portion 74A of the support member 34, and comes into close contact with the outer wall portion 54 of the outer member 32, so that the inner member 30 and the outer member 32 are maintained in their assembled positions.

[0066] Furthermore, when the inner facing portion 74A of the support member 34 is displaced outward, the protrusion 84 provided on the connecting portion 74 is inserted into the hole 56 formed in the outer member 32. This prevents the support member 34 from coming off the outer member 32.

[0067] An annular support member 34 is interposed between the inner member 30 and the outer member 32. Therefore, the amount of insertion of the inner member 30 into the outer member 32 is regulated 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.

[0068] As a result, the inner member 30 is assembled to the outer member 32 to form the tank 20 .

[0069] In this embodiment, the arc portion 70A is formed on the outer beam portion 70 of the support member 34, and the longitudinal center portion 81 of the outer beam portion 70 of the support member 34 is pressed against the outer bottom portion 52 before both end portions of the outer beam portion 70. However, this embodiment is not limited to this configuration.

[0070] For example, by forming an arc portion that protrudes inward on the outer bottom 52 of the outer member 32, the longitudinal center portion 81 of the outer beam portion 70 of the support member 34 can be pressed against the outer bottom 52 before both ends of the outer beam portion 70.

[0071] (Tube Assembly Process) In the tube assembly process, one end of the tubes 22 is inserted into the insertion holes 64 of each tube mounting portion 60 provided in 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 ). In this way, multiple 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 mounting portion 60 of another tank 20.

[0072] In a configuration in which the tubes 22 are connected to the inner bottom 40 of the inner member 30, one end of the tube 22 is inserted into the insertion hole 64 of each tube mounting part 60 provided on the inner bottom 40 of the tank 20. In this way, multiple tubes 22 are assembled to the inner bottom 40 of the inner member 30. The other end of the tube 22 is inserted into the insertion hole 64 of the tube mounting part 60 of another tank 20.

[0073] Then, fins 24 are set between the tubes 22 of the tank 20. In this way, the heat exchanger 10 is formed.

[0074] (Brazing Process) In the brazing process, the inner member 30, the outer member 32, the support member 34, the tubes 22, and the fins 24 are brazed to one another.

[0075] For example, the brazing method involves assembling the heat exchanger 10 using the inner member 30, outer member 32, support member 34, tubes 22, and fins 24 to which brazing material has already been applied, and then heating the heat exchanger 10 in a furnace to melt the brazing material and braze each component together.

[0076] For example, when a support member 34 having a brazing material applied to its surface is used, the gap 90 between the longitudinal center portion 81 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 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.

[0077] As a result, the heat exchanger 10 is formed by the integrated components.

[0078] In this embodiment, a 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 brazing filler metal is described as an example, but this embodiment is not limited to this configuration. In this 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 does not have to be filled with brazing filler metal. 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 brazing filler metal, the amount of brazing filler metal used can be reduced.

[0079] (Operations and Effects) According to the above embodiment, the following effects are achieved.

[0080] The heat exchanger 10 of this embodiment is a heat exchanger 10 including a hollow tank 20. The heat exchanger 10 includes an inner member 30 having an approximately U-shaped cross section, with an inner bottom 40 extending in the longitudinal direction L of the tank 20 and inner wall portions 42 erected on both sides of the inner bottom 40. The heat exchanger 10 also includes an outer member 32 having an approximately U-shaped cross section, with an outer bottom 52 extending in the longitudinal direction L while facing the inner bottom 40, and outer wall portions 54 erected on both sides of the outer bottom 52 and having ends disposed outside the inner wall portions 42, covering 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 a support member 34 that is formed in an annular shape and has 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 an end of the outer beam portion 70 to an end of the inner beam portion 72, and is disposed inside the inner member 30 and the outer member 32. The support member 34 has a 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 a longitudinal center portion 81 of the outer beam portion 70 is lower in rigidity than at the outer facing portion 74B.

[0081] In this configuration, the tank 20 of the heat exchanger 10 is formed by an inner member 30, an outer member 32, and a support member 34 arranged inside the inner member 30 and the outer member 32. In this tank 20, the end of the outer wall portion 54 of the outer member 32 is arranged outside the inner wall portion 42 of the inner member 30. Furthermore, an inner facing portion 74A of the support member 34 is arranged inside the inner wall portion 42. As a result, the inner wall portion 42 of the inner member 30 is prevented from collapsing inward by the inner facing portion 74A of the support member 34, so that the joined 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.

[0082] Therefore, compared to a case where the tank 20 is formed by joining the tube plate and the tank plate by plastically deforming the claw portions of the tube plate, the tank 20 of this embodiment can suppress changes in the gap that may occur between the outer member 32 and the inner member 30. As a result, the heat exchanger 10 of this embodiment can stably braze the inner member 30 and the outer member 32, making it possible to facilitate the brazing work.

[0083] In the heat exchanger 10 of this embodiment, the outer facing portion 74B of the support member 34 is provided with a protrusion 84 that protrudes toward the outside of the tank 20, and the protrusion 84 fits into a hole 56 formed in the outer wall portion 54 of the outer member 32.

[0084] In this configuration, the tank 20 of the heat exchanger 10 can prevent the support member 34 from coming off the outer member 32 .

[0085] In the heat exchanger 10 of this embodiment, a gap 90 is formed between the longitudinal center portion 81 of the outer beam portion 70 and the outer bottom portion 52, or the gap 90 is filled with brazing material.

[0086] In this configuration, in a structure in which a gap 90 is formed between the longitudinal center portion 81 of the outer beam portion 70 and the outer bottom portion 52, the flow resistance of the refrigerant inside the tank can be reduced because the refrigerant is allowed to flow into the gap 90. Furthermore, in a structure in which the gap 90 between the longitudinal center portion 81 of the outer beam portion 70 and the outer bottom portion 52 of the outer member 32 is filled with brazing material, the support member 34 acts as a reinforcing member, contributing to improving the strength of the tank.

[0087] The manufacturing method for the heat exchanger 10 of this embodiment is a method for manufacturing a heat exchanger 10 including a hollow tank 20. In the manufacturing method for the heat exchanger 10, the heat exchanger 10 includes an inner member 30 having a generally U-shaped cross section, the inner member 30 having an inner bottom 40 extending in the longitudinal direction L of the tank 20 and inner wall portions 42 erected on both sides of the inner bottom 40. The heat exchanger 10 also includes an outer member 32 having a generally U-shaped cross section, the outer member 32 covering the outer periphery of the inner member 30 to form the tank 20, the outer bottom 52 extending in the longitudinal direction L while facing the inner bottom 40, and outer wall portions 54 erected on both sides of the outer bottom 52 with their ends disposed outside the inner wall portions 42. The heat exchanger 10 includes a support member 34 that is annularly formed and 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 an end of the outer beam portion 70 to an end of the inner beam portion 72. The support member 34 is 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 that protrudes in an arc shape toward the other. The manufacturing method for 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 for the heat exchanger 10 also includes a step of inserting the inner member 30, to which the support member 34 has been assembled, into the outer member 32 so that the outer beam portion 70 of the support member 34 abuts against the outer member 32 (support member inserting step 112). The manufacturing method of the heat exchanger 10 includes a step of pressing the longitudinal center portion 81 of the outer beam portion 70, which faces the outer bottom portion 52 of the outer member 32, against the outer bottom portion 52 prior to both end portions of the outer beam portion 70 to deform the outer beam portion 70 (inner member insertion step 114), and assembling the inner member 30 to the outer member 32 while displacing the inner facing portion 74A of the support member 34, which faces the inner wall portion 42, outward (inner member assembling step 116).The manufacturing method of the heat exchanger 10 also 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 together (brazing step).

[0088] 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 is possible to stably braze the inner member 30 and the outer member 32.

[0089] In the manufacturing method of the heat exchanger 10 of this embodiment, the protrusions 84 provided on the connecting portions 74 are inserted into the holes 56 formed in the outer member 32 when the inner facing portions 74A of the support members 34 are displaced outward.

[0090] With this configuration, it is possible to prevent the support member 34 from coming off the outer member 32 in the manufactured tank 20 .

[0091] Although the embodiments of the present invention have been described above, the above embodiments merely illustrate some of the application examples of the present invention, and it is not intended that the technical scope of the present invention be limited to the specific configurations of the above embodiments.

[0092] This application claims priority based on Japanese Patent Application No. 2023-209128, filed with the Japan Patent Office on December 12, 2023, the entire contents of which are incorporated herein by reference.

Claims

1. A heat exchanger having a hollow tank, comprising: an inner member having an approximately U-shaped cross section, with an inner bottom extending in the length direction of the tank and inner wall portions erected on both sides of the inner bottom; an outer member having an approximately U-shaped cross section and covering the outer periphery of the inner member to form the tank, with an outer bottom extending in the length direction while facing the inner bottom, and outer wall portions erected on both sides of the outer bottom and with ends disposed outside the inner wall portion; and a support member disposed inside the inner member and the outer member, formed in an annular shape, with 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 an end of the outer beam portion and an end of the inner beam portion, a longitudinal center portion of the outer beam portion having a lower rigidity than an outer facing portion of the support member; 2. A heat exchanger as claimed in claim 1, wherein the outer facing portion is provided with a protrusion that protrudes outwards from the tank, the protrusion fitting into a hole formed in the outer wall portion.

3. A heat exchanger as claimed in claim 1 or 2, wherein a gap is formed between the longitudinal center of the outer beam portion and the outer bottom portion, or the gap is filled with brazing material.

4. A method of manufacturing a heat exchanger including a hollow tank, the heat exchanger comprising: an inner member having an inner bottom extending in the length direction of the tank and inner wall portions erected on both sides of the inner bottom, and having a generally U-shaped cross section; an outer member having an outer bottom extending in the length direction facing the inner bottom, and outer wall portions erected on both sides of the outer bottom and having ends disposed outside the inner wall portion, and having a generally U-shaped cross section covering the outer periphery of the inner member to form the tank; and a support member disposed inside the inner member and the outer member, the support member having 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 an end of the outer beam portion and an end of the inner beam portion ... a step of assembling the support member to the inner member; a step of inserting the inner member, with the support member assembled thereto, into the outer member so that the outer beam portion of the support member abuts against the outer member; a step of pressing a longitudinal center portion of the outer beam portion facing the outer bottom portion of the outer member against the outer bottom prior to both ends of the outer beam portion to deform the outer beam portion, and assembling the inner member to the outer member while displacing an inner facing portion of the support member facing the inner wall portion outward; a step of assembling a plurality of tubes to either the outer bottom portion or the inner bottom portion; and a step of brazing the inner member, the outer member, the support member, and the tubes together.

5. A method for manufacturing a heat exchanger as described in claim 4, comprising inserting a protrusion provided on the connecting portion into a hole formed in the outer member when displacing the inner opposing portion of the support member outward.

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