Method for manufacturing refrigerant manifold and refrigerant manifold manufactured using same

Abstract

The present invention relates to a method for manufacturing a coolant manifold. According to an embodiment, a method for manufacturing a coolant manifold may be provided, the method comprising the steps of: casting and forming a manifold body having multiple coupling holes and a flow path connecting the multiple coupling holes; preparing an insert member; and press-fitting and fixing the insert member into at least one of the multiple coupling holes.

Description

Method for manufacturing a refrigerant manifold and a refrigerant manifold manufactured using the same

[0001] The present invention relates to a method for manufacturing a refrigerant manifold and a refrigerant manifold manufactured using the same.

[0002] A manifold, which is generally applied to a vehicle, is a multi-pipe that has a passageway, which acts as a pipe, formed inside, and a number of device connection ports, such as valves, formed outside.

[0003] Refrigerant manifolds installed in vehicles are manufactured in various forms depending on the specifications or type of vehicle.

[0004] Prior art related to a refrigerant manifold installed in a vehicle as described above is as follows.

[0005] First, as disclosed in Korean Patent Publication No. 10-0350945 and Korean Patent Publication No. 10-0620122, a technology has been proposed for a manifold in which a pair of plates processed to form a passage through which refrigerant can circulate are joined by brazing or the like (Patent Document 1).

[0006] In addition, as disclosed in Korean Patent Registration No. 10-1413488 and Korean Patent Publication No. 10-2022-0108391, a technology has been proposed in which a manifold includes a body formed to form a flow path and a cover joined to one surface of the body by brazing or the like (Patent Document 2).

[0007] Each of the above manifolds is formed with a number of device connections such as valves.

[0008] In this way, the refrigerant manifold equipped in a conventional vehicle is manufactured by joining a pair of plates processed to form a flow path as in patent document 1, or by joining a cover to a body in which a flow path is formed as in patent document 2.

[0009] Accordingly, the refrigerant manifolds installed in conventional vehicles have the disadvantage of frequently causing refrigerant to leak due to cracks or deformation at the joints of two parts during the process of circulating the refrigerant through the passages formed in each plate or body.

[0010] This is also the cause of major defects in the vehicle's performance.

[0011] Additionally, since the two parts are processed separately and then joined, there are also problems that make manufacturing cumbersome and inconvenient.

[0012] A method for manufacturing a refrigerant manifold according to one embodiment of the present invention is proposed to solve the above-mentioned problem, and instead of forming a manifold body by brazing two parts, forging and insert methods are applied, thereby reducing cost and fundamentally preventing refrigerant leakage.

[0013] Meanwhile, the technical tasks to be achieved in the present invention are not limited to the technical tasks mentioned above, and other technical tasks not mentioned can be clearly understood by a person having ordinary knowledge in the technical field to which the present invention belongs from the description below.

[0014] According to one embodiment, a method for manufacturing a refrigerant manifold may be provided, including: a step of casting a manifold body having a plurality of coupling members and a flow path connecting the plurality of coupling members; a step of preparing an insert member; and a step of press-fitting and fixing the insert member into at least one coupling member among the plurality of coupling members.

[0015] According to one embodiment, a method for manufacturing a refrigerant manifold may be provided, including the steps of preparing an insert member; and casting a manifold body having a plurality of coupling holes and a flow path connecting the plurality of coupling holes; wherein, in the step of casting the manifold body, the insert member is placed at a formation position of at least one coupling hole among the plurality of coupling holes, and then casting the manifold body.

[0016] In addition, the insert member may be formed by at least one of sand casting, gravity casting, pressure casting, sheet metal casting, continuous casting, die casting, precision casting, reaction casting, rapid cooling casting, direct extrusion, indirect extrusion, isostatic extrusion, continuous extrusion, direct and indirect combined extrusion, impact extrusion, equal-passage angle extrusion, lateral extrusion casting, constant-speed rolling, constant-speed rolling, caliber rolling, ring rolling, open forging, die forging, hammer forging, press forging, upset forging, dewaxing casting, strip casting, centrifugal casting, shell mold casting, moldless casting, 3D printing, powder sintering, and laser sintering, or a combination thereof.

[0017] According to one embodiment, a refrigerant manifold may be provided, comprising: a manifold body having a plurality of coupling members and a flow path connecting the plurality of coupling members; and an insert member disposed and inserted into an inner surface of at least one coupling member among the plurality of coupling members.

[0018] In addition, a refrigerant manifold may be provided in which the manifold body is formed by casting, and the insert member is placed by being pressed into the inner circumferential surface of the joint of the manifold body formed by casting.

[0019] In addition, a refrigerant manifold may be provided in which the manifold body is formed by casting, and in the casting molding process of the manifold body, the insert member is pre-positioned at a formation position of at least one of the plurality of coupling holes, and then the casting molding is performed.

[0020] In addition, the insert member may be provided with a refrigerant manifold formed by at least one of sand casting, gravity casting, pressure casting, sheet metal casting, continuous casting, die casting, precision casting, reaction casting, rapid cooling casting, direct extrusion, indirect extrusion, isostatic extrusion, continuous extrusion, direct and indirect combined extrusion, impact extrusion, equal-passage angle extrusion, lateral extrusion casting, constant-speed rolling, constant-speed rolling, caliber rolling, ring rolling, open forging, die forging, hammer forging, press forging, upset forging, dewaxing casting, strip casting, centrifugal casting, shell mold casting, dieless casting, 3D printing, powder sintering, and laser sintering, or a combination thereof.

[0021] A method for manufacturing a refrigerant manifold according to one embodiment of the present invention has the effect of reducing costs and fundamentally preventing refrigerant leakage by applying forging and insert methods rather than brazing and welding two parts to form a manifold body.

[0022] Meanwhile, the effects that can be obtained from the present invention are not limited to the effects mentioned above, and other effects that are not mentioned can be clearly understood by a person having ordinary skill in the technical field to which the present invention belongs from the description below.

[0023] Figures 1 and 2 are perspective views showing a refrigerant manifold manufactured using a conventional manufacturing method.

[0024] Figure 3 is a flowchart illustrating a method for manufacturing a refrigerant manifold according to one embodiment of the present invention.

[0025] FIG. 4 is a perspective view showing a housing of a refrigerant manifold according to one embodiment of the present invention.

[0026] Figure 5 is a cross-sectional view taken along line A-A' of Figure 4.

[0027] Figures 6 and 7 are exemplary views showing the process of joining a housing and an insert member of a refrigerant manifold according to one embodiment of the present invention.

[0028] FIG. 8 is a perspective view showing a refrigerant manifold manufactured using a method for manufacturing a refrigerant manifold according to one embodiment of the present invention.

[0029] Figure 9 is a flowchart showing a method for manufacturing a refrigerant manifold according to another embodiment of the present invention.

[0030] Hereinafter, embodiments of the present invention will be described in more detail with reference to the attached drawings. The embodiments of the present invention may be modified in various ways, and the scope of the present invention should not be construed as being limited to the embodiments described below. These embodiments are provided to more fully explain the present invention to those of ordinary skill in the art. Accordingly, the shapes of elements in the drawings have been exaggerated for clarity.

[0031] In order to clearly solve the problem to be solved by the present invention, the composition of the invention is described in detail with reference to the attached drawings based on a preferred embodiment of the present invention, and when assigning reference numbers to components in the drawings, the same reference numbers are assigned to the same components even if they are in different drawings, and it is made clear in advance that components in other drawings may be cited when necessary when describing the drawings.

[0032] Figures 1 and 2 are perspective views showing a refrigerant manifold manufactured using a conventional manufacturing method.

[0033] First, referring to FIGS. 1 and 2, in a conventional refrigerant manifold manufacturing method, a housing top (1) is manufactured by forming a housing top by forging and then performing post-processing to create a flow path for refrigerant to flow through, and a housing bottom (2) is manufactured by forming a housing top (1) by pressing and then performing post-processing, and then the housing top (1) and the housing bottom (2) are joined by a brazing method to manufacture a final refrigerant manifold.

[0034] However, the forging mold and brazing method have very high process costs, so if a defect is found during a subsequent performance test, the manufactured finished product must be immediately discarded, resulting in a high cost loss.

[0035] FIG. 3 is a flowchart showing a method for manufacturing a refrigerant manifold according to one embodiment of the present invention, FIG. 4 is a perspective view showing a housing of a refrigerant manifold according to one embodiment of the present invention, FIG. 5 is a cross-sectional view taken along line A-A' of FIG. 4, FIGS. 6 and 7 are exemplary views showing a process of combining a housing and an insert member of a refrigerant manifold according to one embodiment of the present invention, and FIG. 8 is a perspective view showing a refrigerant manifold manufactured using a method for manufacturing a refrigerant manifold according to one embodiment of the present invention.

[0036] First, referring to FIG. 3, a method for manufacturing a refrigerant manifold according to one embodiment of the present invention may include a manifold body forming step (S10), an insert member forming step (S20), and a pressing step (S30).

[0037] Referring to FIGS. 4 and 5, in the manifold body forming step (S10), a manifold body (100) having a coupling member (110) and a flow path (120) can be formed through casting forming.

[0038] It is preferable that the manifold body (100) be formed of a metal material with high thermal conductivity and low specific gravity, such as aluminum, and it is preferable to apply a die casting casting method, in particular, as the casting method.

[0039] Here, die casting is a precision casting method that injects molten metal into a precisely machined steel mold that completely matches the required casting shape to obtain a product that is identical to the mold.

[0040] That is, a manifold body (100) of a desired material is manufactured by injecting molten metal (using a metal material with high thermal conductivity and low specific gravity, such as aluminum) into a mold that is precisely machined (reflecting a hollow core) to completely match the shape of the manifold body (100).

[0041] In addition, although not specifically shown, in casting molding, a core mold (not shown) can be used to form a plurality of coupling holes (110) formed on the outside of the manifold body (100) and a flow path (120) connecting each of the plurality of coupling holes (110).

[0042] That is, by using a core mold, a core (not shown) corresponding to the shape of a joint (110) and a flow path (120) is formed, and after the core is positioned inside the casting mold, molten metal is injected into the casting mold (not shown) to form a manifold body (100), and after cooling, the core is removed to manufacture a manifold body (100) having a joint (110) and a flow path (120).

[0043] Here, it is preferable that the core be composed of a metal different from the molten metal injected into the casting mold.

[0044] Meanwhile, the core can be removed (detached) from within the manifold body (100) using ultrasonic waves, etc.

[0045] In the insert member forming step (S20), an insert member (200) with a precision-machined inner and outer diameter can be manufactured by forming.

[0046] Here, in the insert member forming step (S20), the insert member (200) can be formed by at least one method among sand casting, gravity casting, pressure casting, sheet metal casting, continuous casting, die casting, precision casting, reaction casting, rapid cooling casting, direct extrusion, indirect extrusion, isostatic extrusion, continuous extrusion, direct and indirect combined extrusion, impact extrusion, equal-passage angle extrusion, lateral extrusion casting, constant-speed rolling, constant-speed rolling, caliber rolling, ring rolling, open forging, die forging, hammer forging, press forging, upset forging, dewaxing casting, strip casting, centrifugal casting, shell mold casting, moldless casting, 3D printing, powder sintering, and laser sintering, or a combination thereof.

[0047] The insert member (200) may be composed of the same material as the manifold body (100), but it is preferable that the insert member (200) be composed of a different material from the manifold body (100).

[0048] Accordingly, the sealing effect by the insert member (200) can be improved.

[0049] Meanwhile, it is difficult to perfectly form pores on the surface of the manifold body (100) in the manifold body forming step (S10). Accordingly, a separate insert member (200) can be placed in the joint (110) through which refrigerant is introduced or discharged to prevent leakage due to pores.

[0050] Referring to FIGS. 6 and 7, in the press-fitting step (S30), an insert member (200) having a shape corresponding to at least one of the plurality of joints (110) of the manifold body (100) can be placed by press-fitting.

[0051] Here, as illustrated in FIG. 7, it is preferable that the insert member (200) is placed by being pressed into all of the plurality of joints (110), and the plurality of insert members (200) may have an outer diameter, an inner diameter, and a thickness corresponding to the shape of each of the plurality of joints (110).

[0052] That is, the inner diameter of at least one coupling member (110) or all of a plurality of coupling members (110) is reduced through the insert member (200), so that a leak can be prevented from occurring when the valve (300) is inserted thereafter.

[0053] Hereinafter, with reference to FIG. 9, a method for manufacturing a refrigerant manifold according to another embodiment of the present invention will be described.

[0054] Figure 9 is a flowchart showing a method for manufacturing a refrigerant manifold according to another embodiment of the present invention.

[0055] Referring to FIG. 9, a method for manufacturing a refrigerant manifold according to another embodiment of the present invention may include an insert member forming step (S110), an insert member arrangement step (S120), and a manifold body forming step (S130).

[0056] In the insert member forming step (S110), an insert member (200) with an inner diameter and an outer diameter precisely machined can be formed, similar to the insert member forming step (S20) of the method for manufacturing a refrigerant manifold of the above-described embodiment.

[0057] Here, in the insert member forming step (S110), the insert member can be formed by at least one method among sand casting, gravity casting, pressure casting, sheet metal casting, continuous casting, die casting, precision casting, reaction casting, rapid cooling casting, direct extrusion, indirect extrusion, isostatic extrusion, continuous extrusion, direct and indirect combined extrusion, impact extrusion, equal-passage angle extrusion, lateral extrusion casting, constant-speed rolling, constant-speed rolling, caliber rolling, ring rolling, open forging, die forging, hammer forging, press forging, upset forging, dewaxing casting, strip casting, centrifugal casting, shell mold casting, moldless casting, 3D printing, powder sintering, and laser sintering, or a combination thereof.

[0058] The insert member may be composed of the same material as the manifold body described later, but it is preferable that the insert member and the manifold body be composed of different materials.

[0059] Meanwhile, it is preferable that the insert member manufactured in the insert member forming step (S110) not melt at the melting temperature of the molten metal forming the manifold body. Accordingly, in the manifold body forming step (S130), when the molten metal is injected into the casting mold, the insert member should not be melted by the molten metal.

[0060] In the insert member arrangement step (S120), at least one insert member manufactured in the insert member molding step (S110) can be arranged in the casting mold before the manifold body molding step (S130).

[0061] That is, before the step of manufacturing the manifold body by die casting in the manifold body forming step (S130), an insert member can be inserted into a forced mold for manufacturing the manifold body and preprocessed so that the insert member is embedded in the formation position of the joint of the manifold body.

[0062] In the manifold body forming step (S130), the manifold body can be formed by injecting molten metal into a steel mold in which an insert member is embedded.

[0063] That is, in the manifold body forming step (S130), a manifold body having a joint and a flow path can be formed through casting forming.

[0064] As described above, it is preferable that the manifold body be formed of a metal material with high thermal conductivity and low specific gravity, such as aluminum, and it is preferable to apply a die casting casting method, in particular, as the casting method.

[0065] That is, a manifold body of the desired material can be manufactured by injecting molten metal (using a metal material with high thermal conductivity and low specific gravity, such as aluminum) into a mold that is precisely machined to match the shape of the manifold body (reflecting the hollow core).

[0066] In addition, although not specifically shown, in the casting molding as described above, a core mold (not shown) can be used to form a plurality of joints formed on the outside of the manifold body and a flow path connecting each of the plurality of joints.

[0067] Meanwhile, in the insert member arrangement step (S120), the insert member is arranged in advance at the formation location of the joint within the casting mold, so that the insert member can be arranged in a state of being embedded on the inner circumferential surface of the joint of the manifold body manufactured in the manifold body forming step (S130).

[0068] Meanwhile, it is difficult to perfectly form pores on the surface of the manifold body during the manifold body molding step (S130). Accordingly, a separate insert member can be placed (embedded) in the joint through which refrigerant flows in or out to prevent leakage due to pores.

[0069] The detailed description above is illustrative of the present invention. Furthermore, the foregoing description illustrates preferred embodiments of the present invention, and the present invention can be used in various other combinations, modifications, and environments. In other words, changes or modifications may be made within the scope of the inventive concepts disclosed herein, the scope equivalent to the written disclosure, and / or the scope of technology or knowledge in the art. The written embodiments illustrate the best possible state for implementing the technical idea of ​​the present invention, and various modifications required for specific applications and uses of the present invention are also possible. Therefore, the detailed description of the invention above is not intended to limit the present invention to the disclosed embodiments. Furthermore, the appended claims should be construed to include other embodiments.

Claims

1. A step of casting a manifold body having a plurality of coupling members and a path connecting the plurality of coupling members; Step of preparing the insert absence; and A step of fixing the insert member by pressing it into at least one of the plurality of coupling members; comprising; Method for manufacturing a refrigerant manifold.

2. Step of preparing the insert member; and A step of casting a manifold body having a plurality of coupling members and a path connecting the plurality of coupling members; comprising: In the step of casting the above manifold body, after placing the insert member at the formation position of at least one of the plurality of joining holes, casting is performed. Method for manufacturing a refrigerant manifold.

3. In paragraph 1 or 2, The above insert absence is, A molded product formed by at least one of the following methods, or a combination thereof: sand casting, gravity casting, pressure casting, sheet metal casting, continuous casting, die casting, precision casting, reaction casting, rapid cooling casting, direct extrusion, indirect extrusion, isostatic pressing, continuous extrusion, direct and indirect combined extrusion, impact extrusion, equal-pass angle extrusion, lateral extrusion casting, spherical continuous rolling, spherical continuous rolling, caliber rolling, ring rolling, open forging, die forging, hammer forging, press forging, upset forging, dewaxing casting, strip casting, centrifugal casting, shell mold casting, dieless casting, 3D printing, powder sintering and laser sintering. Method for manufacturing a refrigerant manifold.

4. A manifold body having a plurality of coupling members and a path connecting the plurality of coupling members; and Including an insert member inserted and arranged on the inner surface of at least one of the above plurality of coupling members, Refrigerant manifold.

5. In paragraph 4, The above manifold body is formed by casting, The above insert member is placed and pressed into the inner surface of the joint of the manifold body formed by casting. Refrigerant manifold.

6. In paragraph 4, The above manifold body is formed by casting, In the casting molding process of the above manifold body, the insert member is pre-positioned at the formation position of at least one of the plurality of coupling holes, and then casting molding is performed. Refrigerant manifold.

7. In paragraph 5 or 6, The above insert absence is, A molded product formed by at least one of the following methods, or a combination thereof: sand casting, gravity casting, pressure casting, sheet metal casting, continuous casting, die casting, precision casting, reaction casting, rapid cooling casting, direct extrusion, indirect extrusion, isostatic pressing, continuous extrusion, direct and indirect combined extrusion, impact extrusion, equal-pass angle extrusion, lateral extrusion casting, spherical continuous rolling, spherical continuous rolling, caliber rolling, ring rolling, open forging, die forging, hammer forging, press forging, upset forging, dewaxing casting, strip casting, centrifugal casting, shell mold casting, dieless casting, 3D printing, powder sintering and laser sintering. Refrigerant manifold.

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