Header, heat exchanger, air conditioner, method for manufacturing header, and method for manufacturing heat exchanger

Abstract

A header (1) comprises: a pipe member that has at least one cutout (18, 19) extending in the circumferential direction, and an internal space (14) through which a refrigerant flows; and a partition member (30) that has a plate (31) partitioning the internal space (14), and at least one protrusion (32, 33) that has a thickness smaller than the thickness of the plate (31) and protrudes from the plate (31), the number of protrusion (32, 33) being the same as the number of the cutout (18, 19) and being fitted into the corresponding cutout (18, 19).

Description

Header, heat exchanger, air conditioner, header manufacturing method and heat exchanger manufacturing method

[0001] The present disclosure relates to a header, a heat exchanger, an air conditioner, a method for manufacturing a header, and a method for manufacturing a heat exchanger.

[0002] Some headers have partition members fitted into the ends of the pipe members to close the ends of the pipe members.

[0003] For example, Patent Document 1 discloses a header comprising a pipe member having a bottom with a C-shaped cross section with the opening facing upward and a top plate portion with a C-shaped cross section with the opening facing downward that covers the bottom, and a plate-shaped partition member having a protrusion that can be fitted into a cutout formed across the bottom and top plate portion of the pipe member.

[0004] Japanese Patent Application Laid-Open No. 2005-233570

[0005] In the header described in Patent Document 1, the entire thickness of the partition member is uniform, and as a result, the thickness of the protrusion and the main body of the partition member are the same. This can result in a large tolerance for the thickness of the protrusion in this header. In this case, the clearance between the protrusion and the cutout into which the protrusion fits becomes large, which can cause poor brazing between the protrusion and the inner wall of the cutout. This poor brazing can result in refrigerant leakage between the protrusion and the cutout.

[0006] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a header, a heat exchanger, an air conditioner, a method for manufacturing a header, and a method for manufacturing a heat exchanger that can be assembled with high precision and that suppress the occurrence of brazing defects.

[0007] To achieve the above object, the present disclosure provides a header including a pipe member and a partition member. The pipe member has at least one circumferentially extending notch through which a refrigerant flows in an interior space. The partition member also has a plate portion that separates the interior space, and at least one protruding portion that has a thickness smaller than that of the plate portion, protrudes from the plate portion, and is provided in the same number as the notches and is fitted into a corresponding notch.

[0008] According to the configuration of the present disclosure, the partition member has a thickness smaller than that of the plate portion, protrudes from the plate portion, and has at least one protrusion that is provided in the same number as the notches and fits into the corresponding notches. This allows the header to have a small tolerance for the protrusion and a small clearance between the protrusion and the notch. As a result, the header can be assembled with high precision, and the occurrence of brazing defects can be reduced.

[0009] a perspective view of a heat exchanger including a header according to the first embodiment of the present disclosure; a perspective view showing a cross section when a heat exchanger including a header according to the first embodiment of the present disclosure is cut along the II-II cutting line shown in FIG. 1; a perspective view of a header according to the first embodiment of the present disclosure; a cross-sectional view taken along the IV-IV cutting line shown in FIG. 3; a cross-sectional view taken along the V-V cutting line shown in FIG. 4; a cross-sectional view taken along the VI-VI cutting line shown in FIG. 4; a perspective view of a partition plate included in the header according to the first embodiment of the present disclosure; a flowchart of a method for manufacturing a header according to the first embodiment of the present disclosure; a perspective view of a main body having straight claws prepared in the method for manufacturing a header according to the first embodiment of the present disclosure; a conceptual diagram of a punch and a die used in a forming step of a partition plate included in the method for manufacturing a header according to the first embodiment of the present disclosure; a cross-sectional view of a partition plate brazed to a side wall portion in a brazing step included in the header according to the first embodiment of the present disclosure; a perspective view of a partition plate included in a header according to the second embodiment of the present disclosure;

[0010] A header, a heat exchanger, an air conditioner, a header manufacturing method, and a heat exchanger manufacturing method according to embodiments of the present disclosure will be described in detail below with reference to the drawings. Note that identical or equivalent parts in the drawings are designated by the same reference numerals. In the Cartesian coordinate system XYZ shown in the drawings, the extension direction of the heat transfer tubes of the heat exchanger is the up-down direction, and the extension direction of the header is the left-right direction. The left-right direction is the X-axis, the front-rear direction is the Y-axis, and the direction perpendicular to the X-axis and Y-axis is the Z-axis. This coordinate system will be referenced as appropriate below.

[0011] (Embodiment 1) The header according to embodiment 1 is a header in which the internal space of a tubular member is partitioned by a partition plate. In this header, the partition plate is attached to the tubular member by fitting a protrusion on the partition plate into a notch formed in the side wall of the tubular member. To improve assembly accuracy, the protrusion is made thinner than the main body of the partition plate. First, the configuration of a heat exchanger in which the header is incorporated will be described with reference to Figures 1 and 2.

[0012] In the first embodiment, the configuration of the heat exchanger will be described using as an example a case where the heat exchanger is used in an outdoor unit of an air conditioner and the air conditioner is in cooling operation.

[0013] Fig. 1 is a perspective view of a heat exchanger 100 including a header 1 according to embodiment 1. Fig. 2 is a perspective view showing a cross section of the heat exchanger 100 taken along line II-II in Fig. 1 .

[0014] For ease of understanding, Fig. 1 only shows some of the heat transfer tubes 4 and fins 5 of the heat exchanger 100. Also, Fig. 1 omits details of the headers 1 and 2. Furthermore, for ease of understanding, Fig. 2 omits illustration of the fins 5.

[0015] As shown in FIG. 1, the heat exchanger 100 includes two opposing headers 1, 2, and 3, a plurality of heat transfer tubes 4 through which the refrigerant distributed or collected by the headers 1, 2, and 3 flows, and a plurality of fins 5 that release heat from the heat transfer tubes 4 into the surrounding air.

[0016] Headers 1, 2, and 3 have an elongated cylindrical shape and extend in the left-right direction. Specifically, header 1 has an elongated square tube shape with a rectangular pipe cross section and an axis A1 extending in the left-right direction. In contrast, headers 2 and 3 have elongated cylindrical shapes with an oval pipe cross section and axes A2 and A3 extending in the left-right direction. Refrigerant pipes 6 and 7, which connect to external equipment and supply and discharge refrigerant, are connected to the right ends of headers 2 and 3.

[0017] Each of the headers 1, 2, and 3 has a flow path formed therein for the refrigerant to flow. To allow the refrigerant to flow along the path indicated by arrows A4-A6 in FIG. 2 , header 1 faces headers 2 and 3 while being spaced apart in the vertical direction. Headers 2 and 3 are also arranged adjacent to each other in the front-to-rear direction. Headers 2 and 1 are connected by a plurality of heat transfer tubes 4. Headers 1 and 3 are also connected by another plurality of heat transfer tubes 4. With this configuration, when a refrigerant is supplied from an external device, the refrigerant flows among headers 1, 2, and 3. For example, a refrigerant flows from header 2 to header 3 via header 1.

[0018] Each heat transfer tube 4 is formed of a highly heat conductive metal such as pure aluminum or an aluminum alloy to enhance heat transfer. To further enhance heat transfer, each heat transfer tube 4 has a flattened tube shape. Each heat transfer tube 4 is arranged with its tube axis oriented vertically. The upper and lower ends of each heat transfer tube 4 are inserted into the insertion openings of the header 1 located above and the header 2 or 3 located below. This connects the flow paths inside the heat transfer tube 4 to the flow paths inside the header 1 and the header 2 or 3. As a result, when a refrigerant is supplied to the heat transfer tube 4 from an external device, the refrigerant flows from the headers 2 and 1. The heat of the refrigerant is then transferred to the heat transfer tube 4.

[0019] A large number of heat transfer tubes 4 are provided in the heat exchanger 100 to improve heat exchange efficiency. The heat transfer tubes 4 are arranged at a constant pitch in the left-right direction. Fins 5 are provided between the heat transfer tubes 4 as shown in Fig. 1 to efficiently dissipate heat transferred to the heat transfer tubes 4 into the air.

[0020] The fins 5 are made of a metal with high thermal conductivity, just like the heat transfer tubes 4, to enhance heat dissipation. The fins 5 have a corrugated plate shape to enhance heat dissipation. The fins 5 are sandwiched between the heat transfer tubes 4 with the continuous corrugated portion facing up and down. This allows heat to be transferred from the heat transfer tubes 4 to the fins 5, where it exchanges heat with the air in the gaps formed by the corrugations of the fins 5 themselves.

[0021] In the heat exchanger 100 having such a configuration, a plurality of partition plates are provided in the internal space of the header 1 to regulate the flow of the refrigerant. In the heat exchanger 100, the thickness of the protrusions of the partition plates is thinner than the main body of the partition plate, i.e., the plate portion, to increase the positional accuracy of the partition plates. Next, the configuration of the header 1 will be described in detail with reference to Figures 3 to 7.

[0022] Fig. 3 is a perspective view of the header 1. Fig. 4 is a cross-sectional view taken along the IV-IV cutting line shown in Fig. 3. Fig. 5 is a cross-sectional view taken along the VV cutting line shown in Fig. 4. Fig. 6 is a cross-sectional view taken along the VI-VI cutting line shown in Fig. 4. Fig. 7 is a perspective view of a partition plate 30 provided in the header 1.

[0023] For ease of understanding, FIGS. 3 to 6 show the header 1 without components of the heat exchanger 100, such as the heat transfer tubes 4, attached thereto.

[0024] As shown in Figure 3, the header 1 comprises a long, box-shaped main body 10 with an open top surface, a top plate 20 that covers the top surface of the main body 10, and a plurality of partition plates 30 that divide the internal space 14 of the main body 10.

[0025] The main body 10 is formed from a metal plate containing an aluminum material such as pure aluminum or an aluminum alloy to facilitate brazing to the heat transfer tube 4. The metal plate is press-formed to form the main body 10 into a U-shape with angular corners in the cross-sectional view shown in Figures 5 and 6. Furthermore, the opening of the U-shape of the main body 10 faces upward in the cross-sectional view.

[0026] 3, the main body 10 has a long, narrow, rectangular, flat bottom 11 with its length oriented in the left-right direction and its width oriented in the front-to-rear direction, and long, narrow, rectangular, flat side walls 12, 13 that rise upward from the front and rear ends of the bottom 11. As a result, the main body 10 is formed as a rectangular tube with open top, right side, and left side surfaces, i.e., in the shape of a gutter with a square cross section.

[0027] In the main body 10, the side walls 12 and 13 are perpendicular to the bottom 11, which has a horizontal plate surface, and the side walls 12 and 13 are parallel to each other. As a result, an internal space 14 for the refrigerant to flow is formed between the side walls 12 and 13. As shown in Figure 4, a corrugated plate 15 is disposed in the internal space 14. The corrugated plate 15 is formed into a shape in which a plurality of waves bending in the vertical direction are continuous in the horizontal direction. As a result, the corrugated plate 15 rectifies the flow of the refrigerant when it flows inside the internal space 14.

[0028] Furthermore, to allow refrigerant to flow between the main body 10 and the heat transfer tubes 4, the bottom 11 is provided with a plurality of holes H11 arranged in the left-right direction for inserting the heat transfer tubes 4. These holes H11 are formed in two rows in the front-rear direction, i.e., the Y direction, as shown in FIG. 6 , to connect with the heat transfer tubes 4 connected to the headers 2 and 3. The total number of these holes H11 is the same as the number of heat transfer tubes 4 shown in FIGS. 1 and 2 . Although not shown, the upper ends of the heat transfer tubes 4 are inserted into each hole H11, and the heat transfer tubes 4 are brazed to the inner walls of each hole H11. This connects the internal space 14 of the main body 10 with the internal spaces of the heat transfer tubes 4, allowing refrigerant to flow therethrough.

[0029] The main body 10 has an opening at the top of the internal space 14. To close the opening, a top plate 20 is fitted between the upper ends of the side walls 12 and 13, as shown in FIG.

[0030] The top plate 20 is formed from a metal plate containing the same aluminum material as the main body 10 to facilitate brazing to the main body 10. As shown in FIG. 3 , the top plate 20 has a long, narrow rectangular, flat plate shape and is fitted between the upper ends of the side wall portions 12 and 13. This causes the front and rear ends of the top plate 20 to abut against the side wall portions 12 and 13. Furthermore, the top plate 20 is brazed to the side wall portions 12 and 13. As a result, the top plate 20 is fixed to the side wall portions 12 and 13.

[0031] Although not shown in Figures 3-6, the sidewalls 12 and 13 each have a protrusion at the vertically middle portion of their inner walls that protrudes horizontally toward the interior space 14 and extends left and right. The top panel 20 is positioned on these protrusions and is supported by them. Meanwhile, as shown in Figure 3, the upper end of the sidewall 12 has a plurality of claws 16 that extend toward the inside of the top panel 20, i.e., toward the rear, and are aligned left and right. The claws 16 are aligned at a constant pitch, with the exception of some of the claws 16. Similarly, the upper end of the sidewall 13 has a plurality of claws 17 that extend toward the inside of the top panel 20, i.e., toward the front, and are aligned left and right. The claws 17 are aligned at the same pitch as the claws 16. The lower ends of these claws 16, 17 abut against the upper surface of the top panel 20. Furthermore, these multiple claws 16, 17 are brazed to the top plate portion 20. As a result, the top plate portion 20 is sandwiched between the above-mentioned protrusions and the multiple claws 16, 17 and firmly fixed.

[0032] Meanwhile, the left and right ends of the internal space 14 of the main body 10 are open. Partition plates 30 are provided at the left and right ends and in the middle in the left-right direction of the main body 10 to close the left and right ends or to divide the internal space 14 and define the flow range of the refrigerant.

[0033] As shown in Figure 5, the partition plate 30 has a plate portion 31 that crosses the internal space 14 in the front-to-rear direction, i.e., the Y direction, to divide the internal space 14, and protrusions 32 and 33 that protrude from the front and rear ends of the plate portion 31 and engage with the side wall portions 12 and 13 of the main body portion 10.

[0034] The plate portion 31 is formed from a metal plate containing the same aluminum material as the main body 10 to facilitate brazing. The plate portion 31 is formed in a rectangular, flat shape with the same height H1 as the height W1 of the internal space 14 and the same width as the width W1 of the internal space 14. The plate portion 31 is fitted into the internal space 14 with its plate surface facing left-right, i.e., in the X direction. As a result, the plate portion 31 closes the left or right end of the internal space 14 or divides the internal space 14. As a result, the plate portion 31 defines the flow range of the refrigerant when it flows through the internal space 14.

[0035] In contrast, each of protrusions 32 and 33 has the shape of a small rectangular flat plate with its longitudinal direction facing up and down. Protrusion 32 has its plate surface facing left and right, i.e., in the X direction, and its upper end, i.e., the +Z end, is located on the +Z side of plate portion 31. In this state, protrusion 32 is located at the front end, i.e., the +Z side of the +Y end, of plate portion 31. As a result, protrusion 32 protrudes from plate portion 31 toward the +Y side, and also protrudes further toward the +Z side than plate portion 31.

[0036] Furthermore, the plate surface of protrusion 33 faces in the X direction, and the +Z end portion is positioned on the +Z side of plate portion 31. In this state, protrusion 33 is disposed at the rear end portion of plate portion 31, i.e., the +Z side portion of the -Y end portion. As a result, protrusion 33 protrudes from plate portion 31 to the -Y side, and also protrudes further from plate portion 31 to the +Z side.

[0037] As shown in Figures 4 and 5, the side wall 13 of the main body 10 has an elongated rectangular cutout 19 with its longitudinal direction oriented circumferentially, specifically in the Z direction, formed therein. Furthermore, as shown in Figure 5, the side wall 12 of the main body 10 also has a cutout 18 of the same shape formed therein. These cutouts 18, 19 are formed at positions symmetrical to the left and right with respect to the axis A1 of the main body 10 shown in Figure 3. Furthermore, the width W2 of the cutouts 18, 19 in the X direction shown in Figure 4 is either the same as or larger than the thickness of the protrusions 32, 33 of the partition plate 30 to an extent that the cutouts can be fitted into the protrusions 32, 33 and brazed.

[0038] The above-mentioned protrusions 32, 33 are fitted into the cutouts 18, 19. As a result, the protrusions 32, 33 protrude from the plate portion 31 into the cutouts 18, 19, and then protrude outside the side wall portions 12, 13 through the cutouts 18, 19. The protrusions 32, 33 also protrude upward from the cutouts 18, 19 and further protrude above the side wall portions 12, 13. In this state, the protrusions 32, 33 are brazed to the inner walls of the cutouts 18, 19. As a result, the protrusions 32, 33 assemble the partition plate 30 to the side wall portions 12, 13 of the main body 10. The protrusions 32, 33 also assemble the partition plate 30 to the top plate portion 20. The protrusions 32 and 33 attach the partition plate 30 to the main body portion 10 and the top plate portion 20, thereby increasing the strength of the header 1.

[0039] As shown in FIG. 3 , the pitch of the claws 16 and 17 is smaller only at portions P1 and P2 where the notches 18 and 19 are located. Specifically, in each portion P1 where the pitch of the claws 16 is smaller, the spacing between the claws 16 is the same as the width W2 of the notch 18 in the X direction. As a result, in each portion P1, two claws 16 sandwich the notch 18 from both sides. These two claws 16 are adjacent to the upper end portion of a protrusion 32 that protrudes from the notch 18 above the upper end of the side wall portion 12. As a result, the upper end portion of the protrusion 32 is sandwiched between the two claws 16. As a result, the protrusion 32 is firmly held by these two claws 16.

[0040] Furthermore, even in portions P2 where the pitch of the claws 17 is small, the arrangement is the same as in portion P1, so that two claws 17 sandwich the cutout portion 19 from both sides. These two claws 17 are also adjacent to the upper end portion of the protrusion 33 that protrudes from the cutout portion 19 above the upper end of the side wall portion 13. As a result, these two claws 17 also sandwich the upper end portion of the protrusion 33. As a result, the protrusion 33 is firmly held by these two claws 17.

[0041] The protrusions 32, 33 having such a configuration may be formed to the same thickness as the main body of the partition member, i.e., the plate portion 31 of the partition plate 30, as in the header described in Patent Document 1.

[0042] However, in this case, the protrusions 32, 33 become relatively thick, which tends to increase the thickness tolerance. As a result, the clearance between the protrusions 32, 33 and the cutouts 18, 19 may become large. This may result in poor brazing of the protrusions 32, 33 to the inner walls of the cutouts 18, 19. This also increases the risk of refrigerant leakage between the protrusions 32, 33 and the inner walls of the cutouts 18, 19.

[0043] Therefore, in the header 1, the thickness of the protrusions 32, 33 is reduced to reduce the tolerance of the protrusions 32, 33.

[0044] Specifically, as shown in Fig. 7, the thickness T2 of the protrusions 32, 33 is smaller than the thickness T1 of the plate portion 31. For example, when the thickness T1 of the plate portion 31 is 3.0 mm, the thickness T2 of the protrusions 32, 33 is 2.8 mm. By having such a thickness T2, the protrusions 32, 33 reduce the tolerance, for example, from ±0.1 mm to 0.05 mm. As a result, the protrusions 32, 33 reduce the clearance with the cutouts 18, 19, suppressing poor brazing between the protrusions 32, 33 and the inner walls of the cutouts 18, 19.

[0045] Furthermore, the right side R surfaces of the protrusions 32 and 33, i.e., the +X surfaces, are in the same X position as the +X surface of the plate portion 31, and as a result, the +X surfaces of the protrusions 32 and 33 are flush with the +X surface of the plate portion 31. In contrast, the left side L surfaces of the protrusions 32 and 33, i.e., the -X surfaces, are located closer to the +X side than the -X surface of the plate portion 31, and as a result, steps 34 and 35 are formed between the -X surfaces of the protrusions 32 and 33 and the -X surface of the plate portion 31. This configuration is adopted to facilitate the manufacture of the protrusions 32 and 33, which have a thickness T2 that is smaller than the thickness T1 of the plate portion 31.

[0046] The protrusions 32, 33 having such thicknesses are formed, for example, by forging a metal plate having the same thickness as the thickness T1 of the plate portion 31. In other words, the protrusions 32, 33 are formed by crushing the metal plate. Next, with reference to Figures 8 to 11, a method for manufacturing the header 1 that includes a step of forming the protrusions 32, 33 having such thicknesses will be described.

[0047] Fig. 8 is a flowchart of the method for manufacturing the header 1. Fig. 9 is a perspective view of the main body 40 having straight claws 16, 17 prepared in the method for manufacturing the header 1. Fig. 10 is a conceptual diagram of a punch 55 and a die 56 used in the process for forming the partition plate 30 included in the method for manufacturing the header 1. Fig. 11 is a cross-sectional view of the partition plate 30 brazed to the side wall portion 12 in the brazing process included in the method for manufacturing the header 1.

[0048] First, as shown in FIG. 8, the main body 40, the top plate 20, and the partition plate 50 of uniform thickness are prepared, with the claws 16 and 17 not bent (step S1).

[0049] Specifically, a main body 40 is fabricated using the above-described material, with the claws 16, 17 not bent and extending straight in the direction in which the side walls 12, 13 stand, as shown in FIG. 9 . That is, a main body 40 is fabricated having the claws 16, 17 extending straight from the side walls 12, 13 in the +Z direction. A top plate 20 is also fabricated using the above-described material and with the above-described shape and size. Furthermore, a partition plate 50 is fabricated, with the entire surface having a uniform thickness, and the protrusions 52, 53 and the plate portion 51 shown in FIG. 10 have the same thickness. The shape and size of this partition plate 50 are the same as those of the above-described partition plate 30, except for the thickness. As described above, a main body 10 with unbent claws 16, 17, a top plate 20, and a partition plate 50 of uniform thickness are prepared.

[0050] 8, the heat transfer tubes 4 and fins 5 made of the above-described materials and having the above-described shapes and sizes are also fabricated to manufacture the heat exchanger 100. In this way, the components of the heat exchanger 100 are also prepared.

[0051] Next, the partition plate 50 is processed to form the partition plate 30 having the protruding portions 32 and 33 thinner than the plate portion 31, as shown in FIG. 8 (step S2).

[0052] Specifically, as shown in FIG. 10 , the partition plate 50 is placed on a die 56 having a flat upper surface, and then the protrusions 52 or 53 of the partition plate 50 are forged with a punch 55. More specifically, the punch 55 is pressed against the protrusions 52 or 53, applying a compressive force to the protrusions 52 or 53 and crushing them. This results in the formation of the protrusions 52 or 53, with the surface facing the die 56 remaining flat and only the portions of the surface opposite the die 56 where the punch 55 is pressed being recessed. As a result, the protrusions 52 or 53 become thinner than the plate portion 51. As a result, the partition plate 30 is formed, having protrusions 32, 33 that are thinner than the plate portion 31 described above.

[0053] It is preferable to adjust the thickness of the protrusions 32, 33 by adjusting the compressive force applied by the punch 55. Furthermore, instead of preparing the partition plate 50 in which the protrusions 52, 53 and the plate portion 51 have the same thickness in step S1, and instead of forming the partition plate 30 in which the protrusions 32, 33 are thinner than the plate portion 31 in step S2, the partition plate 30 may be formed in advance and then the partition plate 30 may be prepared.

[0054] Returning to FIG. 8 , the partition plate 30 is then assembled to the main body 40 and the top plate 20 (step S3). Although not shown, the top plate 20 and the partition plate 30 are attached to the main body 40 in the above-described arrangement. Next, the claws 16 and 17 extending straight from the side wall portions 12 and 13 of the main body 40 are bent to abut the claws 16 and 17 against the surface of the top plate 20. This forms a bent main body 10 with the claws 16 and 17, and secures the top plate 20 to the main body 10. Furthermore, by bending the claws 16 and 17 on both sides of the cutouts 18 and 19, the protrusions 32 and 33 of the partition plate 30 are held by the claws 16 and 17. As a result, the partition plate 30 is assembled to the main body 40 and the top plate 20.

[0055] In step S3, the heat transfer tubes 4 and fins 5 are also assembled to the main body 10 in order to manufacture the heat exchanger 100.

[0056] Next, the top plate 20 and the partition plate 30 are brazed to the main body 10 (step S4). For example, brazing is performed using a brazing method. Specifically, molten brazing filler metal is infiltrated into the joints between the main body 10 and the top plate 20 and the joints between the main body 10 and the partition plate 30, and the brazing filler metal is solidified to join the top plate 20 and the partition plate 30 to the main body 10.

[0057] In this case, the tolerance of the thickness T2 of the protrusions 32, 33 is smaller than the tolerance of the thickness T1 of the plate portion 31. This is because the protrusions 32, 33 are thinned by forging, i.e., by crushing, in step S2 described above. Furthermore, the tolerance of the thickness T2 resulting from the crushing process is small. As a result, the clearance between the cutout 18 and the protrusion 32 shown in FIG. 11 is small. Furthermore, although not shown in FIG. 11, the clearance between the cutout 19 and the protrusion 33 is also small. As a result, fillets are easily formed by brazing the inner walls of the cutouts 18, 19 to the protrusions 32, 33, and the joint strength between the inner walls of the cutouts 18, 19 and the protrusions 32, 33 is high. Furthermore, poor joints are less likely to occur when brazing the inner walls of the cutouts 18, 19 to the protrusions 32, 33.

[0058] As shown in FIG. 11 , the end of the protrusion 32 extends outward beyond the side wall 12, thereby protruding outward beyond the side wall 12. This facilitates the formation of a fillet between the end of the protrusion 32 and the side wall 12 in step S4. Although not shown in FIG. 11 , the end of the protrusion 33 also protrudes outward beyond the side wall 13. This facilitates the formation of a fillet between the end of the protrusion 33 and the side wall 13 in step S4. Furthermore, as shown in FIGS. 5 and 6 , the upper end portions of the protrusions 32 and 33 also protrude above the upper surfaces of the side wall 12 and 13. This facilitates the formation of a fillet at the upper end portions of the protrusions 32 and 33 in step S4. By forming such a fillet in step S4, the bonding strength between the protrusions 32 and 33 and the side wall 12 and 13 can be increased. Furthermore, the bonding strength between the protrusions 32 and 33 and the top plate 20 can be increased.

[0059] In step S4, in order to manufacture the heat exchanger 100, the heat transfer tubes 4 and the fins 5 assembled to the main body 10 in step S3 are brazed to the main body 10.

[0060] The header 1 is thus completed. The completed header 1 has small clearances between the cutouts 18, 19 and the protrusions 32, 33, resulting in high assembly precision. Also, refrigerant leakage from such clearances is suppressed. The completed header 1 and heat exchanger 100 may be incorporated into an outdoor unit to manufacture an air conditioner.

[0061] The main body 10 and top plate 20 are examples of tubular members as defined in the present disclosure. The partition plate 30 is an example of a partition member as defined in the present disclosure. The side walls 12 and 13 are examples of first and second side walls as defined in the present disclosure. The cutouts 18 and 19 are examples of first and second cutouts as defined in the present disclosure. The protrusions 32 and 33 are examples of first and second protrusions as defined in the present disclosure. Furthermore, the flat right side R surface of the partition plate 30, which has no step between the protrusions 32 and 33 and the plate portion 31, is an example of a first surface as defined in the present disclosure. The left side L surface of the partition plate 30, which has a step between the protrusions 32 and 33 and the plate portion 31, is an example of a second surface as defined in the present disclosure. The claws 16 and 17 are examples of first and second claws as defined in the present disclosure.

[0062] Furthermore, the partition plate 50 and the protrusions 52, 53 described in the manufacturing method of the header 1 are an example of the first member and first portion referred to in this disclosure.

[0063] As described above, in the header 1 according to the first embodiment, the partition plate 30 has a thickness smaller than that of the plate portion 31, protrudes from the plate portion 31, and has the same number of protrusions 32, 33 as the cutouts 18, 19, which are fitted into the corresponding cutouts 18, 19. Therefore, in the header 1, the tolerance of the protrusions 32, 33 can be reduced, thereby reducing the clearance between the protrusions 32, 33 and the cutouts 18, 19. As a result, the header 1 can be assembled with high precision, and the occurrence of brazing defects can be suppressed.

[0064] Furthermore, in the method for manufacturing the header 1, a compressive force is applied to the protruding portions 52, 53 of the partition plate 50, which has the protruding portions 52, 53 having the same thickness as the plate portion 31, to reduce the thickness, thereby forming the partition plate 30, which has the protruding portions 32, 33 having a thickness smaller than that of the plate portion 31. In the method for manufacturing the header 1, the protruding portions 32, 33 having a thickness smaller than that of the plate portion 31 can be formed by simple processing. Furthermore, this manufacturing method can reduce the tolerance of the protruding portions 32, 33, thereby improving the assembly precision of the header 1.

[0065] (Embodiment 2) In Embodiment 1, the partition plate 30 includes a plate portion 31 and protrusions 32 and 33. However, the partition plate 30 is not limited to this. The partition plate 30 may be a partition member including a plate portion 31 and at least one protrusion 32, 33 that has a thickness smaller than that of the plate portion 31, protrudes from the plate portion 31, is provided in the same number as the notches 18 and 19, and is fitted into the corresponding notches 18 and 19. Therefore, the partition plate 30 may include a configuration other than the plate portion 31 and the protrusions 32 and 33.

[0066] In the header 1 according to the second embodiment, the partition plate 60 includes thin portions 66 and 67 in addition to the plate portion 61 and the protrusions 62 and 63. The header 1 according to the second embodiment will be described below with reference to Figures 12 and 13. The description of the second embodiment will focus on the configuration that differs from the first embodiment.

[0067] Fig. 12 is a perspective view of a partition plate 60 provided in the header 1 according to embodiment 2. Fig. 13 is an enlarged view of a portion of the partition plate 60.

[0068] As shown in FIGS. 12 and 13, the partition plate 60 of the header 1 according to the second embodiment has thin portions 66 and 67 that are provided continuously with the base portions of the protrusions 62 and 63 .

[0069] Specifically, a protrusion 62 protrudes forward and upward from the upper end portion of the front F end of the plate portion 61. The thickness T2 of the protrusion 62 is smaller than the thickness T1 of the plate portion 61. A thin portion 66 is provided at the upper end portion of the front F end of the plate portion 61, continuing from the protrusion 62 and having the same thickness T2 as the protrusion 62. The thin portion 66 extends along the protrusion 62 and has a small rectangular shape with its longitudinal direction facing the up-down direction. The thin portion 66 also extends in the lateral direction from the front F end of the plate portion 61 toward the rear B. The length of the thin portion 66 in the lateral direction is preferably greater than the positional variation of the side wall portion 12 when the protrusion 62 is fitted into the cutout portion 18. This prevents interference between the thick plate portion 61 and the side wall portion 12. Furthermore, the thin portion 66 is recessed further than the surface of the left side L of the plate portion 61, resulting in a step 64 between the thin portion 66 and the surface of the left side L of the plate portion 61. Although not shown, the surface of the right side R of the thin portion 66 is located on the same plane as the surface of the right side R of the plate portion 61.

[0070] Furthermore, in the plate portion 61, a protrusion 63 protrudes rearward B and upward from the upper end portion of the rear B end, and the thickness of the protrusion 63 is the same as that of the protrusion 62. A thin portion 67 is provided at the upper end portion of the rear B end of the plate portion 61, continuing from the protrusion 63 and having the same thickness T2 as the protrusion 63. The shape of the thin portion 67 is bilaterally symmetrical to the thin portion 66 described above, and there is a step 65 between it and the surface on the left side L of the plate portion 61. For this reason, a detailed description of the shape will be omitted.

[0071] The thin portions 66, 67 having such shapes are formed simultaneously when forming the protruding portions 62, 63 thinner than the plate portion 61 using a punch having a larger tip than the punch 55 described in the first embodiment in step S2. That is, the thin portions 66, 67 are formed by simultaneously pressing a punch having a larger tip than the punch 55 against a first portion of the partition plate 60 that is to be machined into the protruding portions 62, 63 and a second portion that is to be machined into the thin portions 66, 67, and applying a compressive force to those portions. In this case as well, the tolerance of the protruding portions 62, 63 is reduced, and therefore the assembly precision of the header 1 according to the second embodiment is high.

[0072] Furthermore, during assembly of the header 1, due to processing accuracy, it is conceivable that the front F end and rear B end of the plate portion 61 of the partition plate 60 may interfere with the cutout portions 18, 19 of the main body portion 10. However, in the header 1 according to the second embodiment, the thin portions 66, 67 are provided, which prevents the front F end and rear B end of the plate portion 61 of the partition plate 60 from interfering with the cutout portions 18, 19 of the main body portion 10 during assembly of the header 1. As a result, the partition plate 60 and the cutout portions 18, 19 are assembled with high precision. This allows the partition plate 60 to be joined to the inner walls of the cutout portions 18, 19 with high strength.

[0073] As described above, in the header 1 according to the second embodiment, the partition plate 60 has thin portions 66, 67 that are continuous with the protruding portions 62, 63 and have the same thickness as the protruding portions 62, 63 at the portions of the plate portion 61 that are adjacent to the protruding portions 62, 63. This prevents the portions of the plate portion 61 that are adjacent to the protruding portions 62, 63 from interfering with the cutout portions 18, 19. As a result, the assembly precision of the header 1 according to the second embodiment is high.

[0074] The above describes the header 1, heat exchanger 100, air conditioner, manufacturing method of header 1, and manufacturing method of heat exchanger 100 according to the embodiments of the present disclosure, but the header 1, heat exchanger 100, air conditioner, manufacturing method of header 1, and manufacturing method of heat exchanger 100 are not limited to this.

[0075] For example, in the first and second embodiments, the cross-sectional shape of the header 1 is rectangular. As a result, the header 1 is a square tube. However, the tubular shape of the header 1 is not limited to this. The header 1 only needs to have at least one circumferentially extending notch 18, 19 and a tubular member through which the refrigerant flows in the internal space 14. Therefore, the tubular shape of the header 1 may be a cylinder in addition to a square tube. Furthermore, the tubular shape of the header 1 may be a tube with an oval cross section.

[0076] In addition, in the first and second embodiments, the main body 10 of the header 1 has the claws 16, 17. However, the header 1 is not limited to this. As it is clear that the header 1 only needs to have the above-described pipe member, the presence or absence of the claws 16, 17 is optional.

[0077] In the first and second embodiments, each of the partition plates 30 and 60 has two protrusions 32, 33, 62, and 63. However, the partition plates 30 and 60 are not limited to this. The partition plates 30 and 60 may be any partition member having a plate portion 31 and 61 that separates the internal space 14, and at least one protrusion 32, 33, 62, and 63 that has a thickness smaller than that of the plate portion 31 and 61, protrudes from the plate portion 31 and 61, and is provided in the same number as the cutout portions 18 and 19 and fits into the corresponding cutout portion 18 and 19. Therefore, the number of partition plates 30 and 60 does not have to be two. For example, if there are three cutout portions 18 and 19, the number of partition plates 30 and 60 may be three.

[0078] FIG. 14 is a perspective view of a modified example of the partition plate 60 provided in the header 1 according to the second embodiment.

[0079] As shown in FIG. 14 , the partition plate 60 may have a protrusion 68 protruding upward from the center and top surface of the plate portion 61 in the front-rear direction, in addition to the protrusions 62 and 63 provided at both ends of the plate portion 61 in the front-rear direction. In this case, a rectangular cutout extending in the front-rear direction, separate from the cutouts 18 and 19, may be formed in the top plate portion 20, and the protrusion 68 may fit into the cutout to hold the partition plate 60 to the top plate portion 20. Similarly to the protrusions 62 and 63, the thickness of the protrusion 68 may be a thickness T2 that is smaller than the thickness T1 of the plate portion 61. This is because such a configuration can reduce the thickness tolerance of the plate portion 61 and reduce the clearance with the cutout of the top plate portion 20.

[0080] In the first and second embodiments, the protrusions 32, 33, 62, and 63 are thinner than the plate portions 31 and 61 overall, and the thicknesses of the protrusions 32, 33, 62, and 63 are the same overall. However, the protrusions 32, 33, 62, and 63 are not limited to this. The protrusions 32, 33, 62, and 63 may have a thickness smaller than that of the plate portions 31 and 61, protrude from the plate portions 31 and 61, and be provided in the same number as the notches 18 and 19 so that they fit into the corresponding notches 18 and 19. Therefore, the protrusions 32, 33, 62, and 63 may not have the same thickness overall, and only portions of the protrusions 32, 33, 62, and 63 may have a different thickness. For example, when the protrusions 32, 33, 62, and 63 are fitted into the notches 18 and 19, the ends of the protrusions 32, 33, 62, and 63 that protrude upward or to the side of the side wall portions 12 and 13 may be the same as the thickness T2 of the plate portions 31 and 61. This is because even in this configuration, the protrusions 32, 33, 62, and 63 can be fitted into the cutouts 18 and 19.

[0081] In addition, in the first and second embodiments, the protrusions 32, 33, 62, and 63 extend along the same plane as the plate portions 31 and 61. However, the protrusions 32, 33, 62, and 63 are not limited to this. The protrusions 32, 33, 62, and 63 may extend in a direction inclined relative to the plate portions 31 and 61.

[0082] The present disclosure allows various embodiments and modifications without departing from the broad spirit and scope of the present disclosure. Furthermore, the above-described embodiments are intended to explain the present disclosure and do not limit the scope of the present disclosure. That is, the scope of the present disclosure is defined by the claims, not the embodiments. Various modifications made within the scope of the claims and within the meaning of the disclosure equivalent thereto are considered to be within the scope of the present disclosure.

[0083] 1-3 header, 4 heat transfer tube, 5 fins, 6, 7 refrigerant tube, 10 main body, 11 bottom, 12, 13 side wall, 14 internal space, 15 corrugated sheet, 16, 17 claws, 18, 19 notch, 20 top plate, 30 partition plate, 31 plate portion, 32, 33 protrusion, 34, 35 step, 40 main body, 50 partition plate, 51 plate portion, 52, 53 protrusion, 55 punch, 56 die, 60 partition plate, 61 plate portion, 62, 63 protrusion, 64, 65 step, 66, 67 thin portion, 68 protrusion, 100 heat exchanger, A1-A3 axis, A4-A6 arrow, B rear, F front, H1 height, H11 hole, L Left side, P1, P2 part, R right side, W1, W2 width.

Claims

1. A header comprising: a pipe member having at least one circumferentially extending notch and through which a refrigerant flows in an internal space; a plate portion that separates the internal space; and a partition member having at least one protruding portion that has a thickness smaller than that of the plate portion, protruding from the plate portion, and that is provided in the same number as the notches and is fitted into a corresponding one of the notches.

2. The header according to claim 1, wherein the partition member further has a thin section at a portion of the plate section adjacent to the protrusion, the thin section being continuous with the protrusion and having the same thickness as the protrusion but smaller than the thickness of the plate section.

3. A header as claimed in claim 1 or 2, wherein the protrusion has a first surface that is flush with one of the plate surfaces of the plate portion, and a second surface that faces the opposite side to the first surface and has a step between it and the other plate surface of the plate portion.

4. The header according to any one of claims 1 to 3, wherein the protrusion is flat.

5. A header according to any one of claims 1 to 4, wherein the protrusion extends through the cutout to the outside of the tube member and is brazed to the inner wall of the cutout.

6. The pipe member has a bottom portion, a first side wall portion and a second side wall portion provided on both sides of the bottom portion, and a top plate portion fitted between the first side wall portion and the second side wall portion, and at least one of the cutout portions has a first cutout portion extending downward and in the circumferential direction from the upper end of the first side wall portion, and a second cutout portion provided at the end of extension of the first cutout portion and extending downward and in the circumferential direction from the upper end of the second side wall portion, and the plate portion is disposed between the first cutout portion and the second cutout portion, 6. The header of claim 1, wherein at least one of the protrusions includes a first protrusion extending from the plate portion into the first cutout portion and extending upward from the first cutout portion, and a second protrusion extending from the plate portion into the second cutout portion and extending upward from the second cutout portion, the first protrusion and the second protrusion sandwiching the top plate portion.

7. A header as described in claim 6, wherein the first side wall portion has a plurality of first claw portions arranged in the extension direction of the pipe member and pressing against the upper surface of the top plate portion, the second side wall portion has a plurality of second claw portions arranged in the extension direction of the pipe member and pressing against the upper surface of the top plate portion, the plurality of first claw portions sandwiching the first protrusion portion to hold the first protrusion portion, and the plurality of second claw portions sandwiching the second protrusion portion to hold the second protrusion portion.

8. A heat exchanger comprising: a header according to any one of claims 1 to 7; a heat transfer tube connected to the header and through which a refrigerant flows between the header and the heat transfer tube; and fins attached to the heat transfer tube.

9. An air conditioner comprising the heat exchanger according to claim 8.

10. A method for manufacturing a header comprising: a pipe member having at least one circumferentially extending cutout portion and through which a refrigerant flows in an internal space; and a partition member having a plate portion that separates the internal space, and at least one protrusion having a thickness smaller than that of the plate portion, protruding from the plate portion, and provided in the same number as the cutout portions and fitted into a corresponding one of the cutout portions, the method comprising the steps of: preparing a partition member comprising the plate portion and the protrusion having a thickness smaller than that of the plate portion by applying a compressive force to reduce the thickness of a first portion of a first member having the plate portion and a first portion having the same thickness as the plate portion, protruding from the plate portion, and provided in the same number as the cutout portions; and assembling the partition member to the pipe member by fitting the protrusion of the partition member into the cutout portion.

11. A method for manufacturing a header as described in claim 10, wherein in the step of preparing the partition member, the compressive force is applied to the first portion and a second portion of the plate portion adjacent to the first portion to reduce the thickness of the first portion and the second portion, thereby preparing the partition member which further has a thin portion adjacent to the protrusion and has the same thickness as the protrusion.

12. A method for manufacturing a header as described in claim 10 or 11, wherein in the step of preparing the partition member, one plate surface of the plate portion and a third surface of the first portion facing in the same direction as the one plate surface are supported by a flat die, and a fourth surface of the first portion facing the opposite side to the third surface is crushed by a punch with a flat tip, thereby preparing the partition member in which one plate surface of the plate portion and the first surface of the protruding portion are positioned flush with each other and in which a step is provided between the other plate surface of the plate portion and a second surface of the protruding portion facing the opposite side to the first surface.

13. A method for manufacturing a header according to any one of claims 10 to 12, wherein the first portion is flat and the protruding portion is flat.

14. A method for manufacturing a heat exchanger, comprising: a method for manufacturing a header according to any one of claims 10 to 13; a step of assembling a heat transfer tube having fins attached to the header; and a step of brazing the heat transfer tube to the header.

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