Method for connecting pipe member and plate, method for manufacturing heat exchanger, and device for connecting pipe member and plate

Abstract

This method for connecting a pipe member and a plate connects: a pipe member having a tip section (65), a base section (66), and a large-diameter section; and a plate having a through hole (32, 33, 42, 43). This method for connecting a pipe member and a plate comprises: a step for disposing the pipe member and the plate in a state in which the base section (66) is passed through the through-hole (32, 33, 42, 43) and the large-diameter section is caused to be adjacent to the peripheral edge of the through-hole (32, 33, 42, 43); and a step for fixing, to the plate, the base section (66) of the pipe member in which the base section (66) has been passed through the through-hole (32, 33, 42, 43) and the large-diameter section has been caused to be adjacent to the peripheral edge of the through-hole (32, 33, 42, 43), such fixing performed by crimping and expanding the base section with the entire periphery of the large-diameter section being supported.

Description

Method for connecting tube members and plates, method for manufacturing a heat exchanger, and device for connecting tube members and plates

[0001] The present disclosure relates to a method for connecting a tube member and a plate, a method for manufacturing a heat exchanger, and an apparatus for connecting a tube member and a plate.

[0002] One method for connecting the tubular member and the plate is to insert the base end of the tubular member into a through-hole formed in the plate and then crimp the base end to connect the tubular member and the plate.

[0003] For example, Patent Document 1 discloses a method for connecting a pipe member having a large diameter portion, such as a flange, to a plate. In this connection method, the pipe member is fitted into a so-called split mold having a semicircular groove in cross section, and the base end of the pipe member is crimped to connect the pipe member to the plate.

[0004] In more detail, in the connection method described in Patent Document 1, the flange of the pipe member is placed adjacent to the peripheral edge of the semicircular opening of the half-die, and the base end of the pipe member is passed through the through-hole of the plate so that the plate surface abuts against the flange of the pipe member. Then, with the flange of the pipe member adjacent to the peripheral edge of the opening of the half-die, a punch is pressed into the base end of the pipe member to crimp the base end of the pipe member. This causes the edge of the through-hole in the plate to be sandwiched between the deformed base end of the pipe member and the flange, connecting the pipe member and the plate.

[0005] Japanese Patent Application Publication No. 8-327280

[0006] In the connection method described in Patent Document 1, only a portion of the flange is supported by the half die when the punch is pressed in. As a result, the remaining portion of the flange is deformed excessively by the punch pressing force. As a result, this connection method does not allow the base end of the tubular member to be crimped evenly, resulting in large variations in the crimping of the base end. This results in an insufficient connection between the tubular member and the plate.

[0007] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a method for connecting a pipe member and a plate, a method for manufacturing a heat exchanger, and a device for connecting a pipe member and a plate, which can suppress variation in the crimping of the base end of the pipe member and obtain sufficient connection strength.

[0008] To achieve the above object, a method for connecting a tubular member and a plate according to the present disclosure connects a tubular member having a distal end, a proximal end, and a large-diameter portion disposed between the distal end and the proximal end and having a larger outer diameter than the proximal end, to a plate having a through hole having a diameter larger than the outer diameter of the proximal end and smaller than the outer diameter of the large-diameter portion. The method for connecting the tubular member and the plate includes the steps of: passing the proximal end through the through hole and further arranging the tubular member and the plate so that the large-diameter portion is adjacent to the periphery of the through hole; and fixing the proximal end of the tubular member, with the proximal end passed through the through hole and the large-diameter portion adjacent to the periphery of the through hole, to the plate by crimping and expanding the proximal end while supporting the entire periphery of the large-diameter portion.

[0009] According to the configuration of the present disclosure, the method of connecting the tubular member and the plate fixes the large-diameter portion to the plate by crimping the large-diameter portion while supporting the entire circumference of the large-diameter portion, thereby suppressing variations in crimping of the base end portion. This allows the method of connecting the tubular member and the plate to obtain sufficient connection strength.

[0010] 1 shows a perspective view of a plate heat exchanger manufactured using the method for connecting tube members and plates according to embodiment 1 of the present disclosure; 2 shows an exploded perspective view of a plate heat exchanger manufactured using the method for connecting tube members and plates according to embodiment 1 of the present disclosure; 3 shows a perspective view of a pipe joint included in a plate heat exchanger manufactured using the method for connecting tube members and plates according to embodiment 1 of the present disclosure; 4 shows a cross-sectional view of a pipe joint included in a plate heat exchanger manufactured using the method for connecting tube members and plates according to embodiment 1 of the present disclosure; 5 shows a perspective view of a reinforcing plate and a pipe joint included in a plate heat exchanger manufactured using the method for connecting tube members and plates according to embodiment 1 of the present disclosure; 6 shows an enlarged cross-sectional view of a reinforcing plate and a pipe joint included in a plate heat exchanger manufactured using the method for connecting tube members and plates according to embodiment 1 of the present disclosure; A front view of a connecting device between a pipe fitting and a reinforcing plate according to embodiment 1 of the present disclosure. A top view of a connecting device between a pipe fitting and a reinforcing plate according to embodiment 1 of the present disclosure when the connecting device is in an open state. A conceptual cross-sectional view of a connecting device when a plunger provided in the connecting device between a pipe fitting and a reinforcing plate according to embodiment 1 of the present disclosure abuts near an O-ring groove at the tip of the pipe fitting. A conceptual cross-sectional view of a connecting device when it is assumed that a plunger provided in the connecting device between a pipe fitting and a reinforcing plate according to embodiment 1 of the present disclosure abuts against the end of the tip of the pipe fitting. 1 is a front view of a connecting device between a pipe fitting and a reinforcing plate according to a second embodiment of the present disclosure, when the connecting device is in an open state; FIG. 2 is a front view of the connecting device between a pipe fitting and a reinforcing plate according to a second embodiment of the present disclosure, when the tip of the pipe fitting abuts against the plunger when the connecting device is in an open state; FIG. 3 is a front view of the connecting device between a pipe fitting and a reinforcing plate according to a second embodiment of the present disclosure, when the tip of the pipe fitting is further pushed in when the connecting device is in an open state;

[0011] Hereinafter, a method for connecting a tube member and a plate, a method for manufacturing a heat exchanger, and an apparatus for connecting a tube member and a plate according to embodiments of the present disclosure will be described in detail with reference to the drawings. In the drawings, the same or equivalent parts are designated by the same reference numerals.

[0012] (Embodiment 1) A method for connecting a tube member and a plate according to embodiment 1 involves inserting the tip of a tube member into a through-hole in an outermost heat transfer plate of a plate heat exchanger to allow a refrigerant to flow in and out of the plate heat exchanger, and then crimping the inserted tube member to connect the tube member to a reinforcing plate. Below, the configuration of this connection method will be described using an example in which the outermost heat transfer plate is a reinforcing plate and the tube member is a pipe joint. First, with reference to Figures 1 to 6, the configuration of a plate heat exchanger assembled using a reinforcing plate and a pipe joint will be described, along with the configuration of the reinforcing plate and the pipe joint to be connected.

[0013] (Plate Heat Exchanger) Fig. 1 is a perspective view of a plate heat exchanger 1 manufactured using the method for connecting tube members and plates according to embodiment 1. Fig. 2 is an exploded perspective view of the plate heat exchanger 1. For ease of understanding, the upright walls 11 of the heat transfer plate 10 and the upright walls 21 of the heat transfer plate 20 are omitted from Fig. 1.

[0014] As shown in FIGS. 1 and 2 , the plate heat exchanger 1 includes a plurality of heat transfer plates 10 and 20 stacked alternately, and reinforcing plates 30 and 40 that reinforce the stacked heat transfer plates 10 and 20 .

[0015] The heat transfer plates 10 and 20 are components for exchanging heat between two types of fluids, a first fluid and a second fluid. Specifically, the heat transfer plate 10 is made of a metal with high thermal conductivity, such as stainless steel. As shown in FIG. 2 , the heat transfer plate 10 is formed in the shape of a rectangular plate with rounded corners. The heat transfer plate 10 has an outer periphery surrounded by an upright wall 11, forming a flow path space for the first fluid to flow through. An inner fin 12 is provided in the flow path space to facilitate heat transfer of the first fluid. Furthermore, a metal foil 13 made of pure copper or a copper alloy is disposed on the right side of the heat transfer plate 10 to bond it to the heat transfer plate 20 when stacked together with the heat transfer plate 20. The metal foil 13 covers the right side of the heat transfer plate 10 and functions as a brazing material during manufacturing.

[0016] In contrast, the heat transfer plate 20 is also made of the same material as the heat transfer plate 10 and is formed in the same rectangular shape as the heat transfer plate 10. The heat transfer plate 20 also has an outer periphery surrounded by an upright wall 21, thereby forming a flow path space for flowing a second fluid separate from the first fluid. Inner fins 22 are also provided in this flow path space of the heat transfer plate 20 to improve heat transfer efficiency. Furthermore, a metal foil 23 made of pure copper or a copper alloy is also arranged on the right surface of the heat transfer plate 20, covering the right surface of the heat transfer plate 20 and functioning as a brazing material during manufacturing.

[0017] The heat transfer plates 10 and 20 are stacked alternately with the plate surfaces of the above-described shape facing left and right, the upstanding wall 11 or 21 facing left, and the right surface covered with metal foil 13 or 23. Furthermore, inlet and outlet holes 14, 15 and communication holes 16, 17 are formed at the four corners of the heat transfer plate 10. Communication holes 24, 25 and inlet and outlet holes 26, 27 are formed at the four corners of the heat transfer plate 20, which are positioned to overlap the inlet and outlet holes 14, 15 and communication holes 16, 17 in the left and right directions. By stacking the heat transfer plates 10 and 20 alternately, the inlet and outlet holes 14, 15 of one heat transfer plate 10 are connected to the communication holes 24, 25 of the adjacent heat transfer plate 20 on the right, which has a peripheral wall portion protruding to the right. This allows the first fluid to flow in and out of the heat transfer plate 20 to the heat transfer plate 10 on its right side through the inlet and outlet holes 14, 15. The inlet and outlet holes 26, 27 of the heat transfer plate 20 also have a peripheral wall portion that protrudes to the right and connects to the communication holes 16, 17 of the adjacent heat transfer plate 10 on the right side. As a result, the inlet and outlet holes 26, 27 allow the second fluid to flow in and out between the heat transfer plate 10 and the heat transfer plate 20 located further to the right.

[0018] The heat transfer plates 10 and 20 have this configuration and are stacked alternately in the left-right direction, thereby allowing the first fluid and the second fluid to circulate and transferring the heat of the first fluid and the second fluid to the heat transfer plates 10 and 20. As a result, when the first fluid and the second fluid are flowed, the heat transfer plates 10 and 20 cause heat exchange between the first fluid and the second fluid.

[0019] Meanwhile, the alternately stacked heat transfer plates 10 and 20, hereinafter referred to as a stack 50, are sandwiched between reinforcing plates 30 and 40 to reinforce the stack 50.

[0020] The reinforcing plates 30 and 40 are formed in the same rectangular plate shape as the heat transfer plates 10 and 20. The reinforcing plate 30 is disposed on the left side of the stack 50 with its plate surface facing left and right. Furthermore, a metal foil 31 made of brazing material is provided on the right side of the reinforcing plate 30, which functions as a joining material during manufacturing. While the reinforcing plate 30 and the metal foil 31 are shown as separate members in FIG. 2 for ease of understanding, they are actually molded integrally to form the clad material 35. The reinforcing plate 30 is firmly brazed to the stack 50 by melting the metal foil 31 during manufacturing.

[0021] In contrast, the reinforcing plate 40 is disposed on the right side of the laminate 50 with its plate surface facing left-right. A metal foil 41 formed from the same brazing material as the metal foil 31 is provided on the left side of the reinforcing plate 40. In FIG. 2 , for ease of understanding, the reinforcing plate 40 and the metal foil 41 are shown as separate members, but like the reinforcing plate 30 and the metal foil 31, they are molded integrally to form the clad material 45. The reinforcing plate 40 is also firmly brazed to the laminate 50 by melting the metal foil 41 during manufacturing.

[0022] The reinforcing plates 30 and 40 are arranged in this manner to sandwich and reinforce the stack 50 formed by the heat transfer plates 10 and 20. As a result, the reinforcing plates 30 and 40 suppress damage to the stack 50.

[0023] In order to circulate the first fluid and the second fluid through the stack 50 and perform heat exchange, the plate heat exchanger 1 further includes pipe joints 61-64 connected to the reinforcing plates 30 and 40. Next, the configuration of the pipe joints 61-64 will be described with reference to Figures 3 to 6.

[0024] (Pipe Joints) Fig. 3 is a perspective view of the pipe joints 61-64 provided in the plate heat exchanger 1. Fig. 4 is a cross-sectional view of the pipe joints 61-64. Fig. 5 is a perspective view of the reinforcing plate 30 and the pipe joint 62 provided in the plate heat exchanger 1. Fig. 6 is an enlarged cross-sectional view of the reinforcing plates 30, 40 and the pipe joints 61-64.

[0025] 3 to 5, when the pipe axis A1 of the pipe fittings 61-64 is oriented vertically and the bead portion 67 of the pipe fittings 61-64 is parallel to a horizontal plane, the vertical direction is the Z axis and the horizontal plane is the XY plane. The direction perpendicular to the Z axis and the X axis is the Y axis. This coordinate system will be referenced where appropriate in the following explanation.

[0026] As shown in Figures 3 and 4, the pipe fittings 61-64 have a tip portion 65 for connecting piping extending from an external device and through which the first fluid and the second fluid flow, a base portion 66 attached to the through holes of the reinforcing plates 30 and 40, and a bead portion 67 provided between the tip portion 65 and the base portion 66.

[0027] The tip portion 65 is the portion that is connected to the piping of an external device. The tip portion 65 is formed in the shape of a circular pipe so that it can be inserted into such a piping to connect. Although not shown in FIGS. 3 to 5, a groove extending in the circumferential direction is formed on the outer periphery of the tip portion 65 for attaching an O-ring (not shown). This configuration of the tip portion 65 improves the watertightness when connected to the piping of an external device.

[0028] In contrast, the base end 66 is a portion that is connected to the reinforcing plates 30, 40 in order to allow the first fluid and the second fluid that flow between the external devices to flow to the stack 50. As shown in FIG. 2 , the reinforcing plate 30 has through holes 32, 33 for connecting the pipe fittings 61, 62. The reinforcing plate 40 has through holes 42, 43 for connecting the pipe fittings 63, 64. The metal foils 31 and 41 also have through holes that correspond to the through holes 32, 33, 42, 43. The base end 66 is formed in the shape of a circular tube, as shown in FIGS. 3 and 4 , in order to be inserted into the through holes 32, 33, 42, or 43 and the corresponding through holes in the metal foils 31, 41.

[0029] The base end 66 has an outer diameter D1 shown in FIG. 4 that allows it to be inserted into the through holes 32, 33, 42, or 43 and the corresponding through holes of the metal foils 31, 41. When the pipe fittings 61-64 are connected to the reinforcing plates 30, 40, the base end 66 is crimped and mechanically joined. In addition to this mechanical joining, the pipe fittings 61-64 are brazed using a brazing ring 70 having a ring shape and formed from a brazing material, as shown in FIG. 5. To ensure the connection length required for such joining, the base end 66 has a length greater than the total thickness, which is the sum of the thickness T1 of the reinforcing plates 30, 40, the thickness T2 of the metal foils 31, 41, and the thickness T3 of the brazing ring 70, as shown in FIG. 6. This ensures the required connection length when the base end 66 is inserted into the through holes 32, 33, 42, or 43 and the corresponding through holes of the metal foils 31, 41. The base end 66 is inserted into the through hole 32, 33, 42 or 43 and the corresponding through hole of the metal foil 31, 41, and is then crimped and expanded to join the reinforcing plates 30, 40 and the metal foil 31, 41. As a result, the base end 66 sandwiches the clad materials 35, 45 formed by the reinforcing plates 30, 40 and the metal foil 31, 41, and the brazing ring 70 between the bead portion 67. When the base end 66 is crimped to expand the tube, it is advisable to crimp the base end 66 with a load that does not cause buckling of the tube or bending of the tube axis, in order to prevent damage to the base end 66.

[0030] As described above, the bead portion 67 is a portion that sandwiches the clad material 35, 45 between the base end portion 66 and the bead portion 67 when the base end portion 66 is crimped and expanded. The bead portion 67 has a shape that protrudes outward from the base end portion 66. Specifically, the bead portion 67 has a shape in which the sidewall portion of the pipe of the pipe fittings 61-64 is bent outward once and then bent inward again. This causes the bead portion 67 to protrude outward in a convex shape. As a result, as shown in FIG. 4 , the bead portion 67 has a ring-shaped flange shape with an outer diameter D2 that is larger than the outer diameter D1 of the base end portion 66. As a result, the bead portion 67 abuts against the clad material 35, 45 and determines the position of the base end portion 66 when the base end portion 66 is inserted into the through hole 32, 33, 42, or 43 and the corresponding through hole of the metal foil 31, 41. That is, the bead portion 67 determines the insertion length of the base end portion 66 into the clad materials 35, 45. The annular surface of the bead portion 67 is perpendicular to the tube axis A1 of the base end portion 66 and is flat. This allows the base end portion 66 to be perpendicular to the clad materials 35, 45 when the base end portion 66 is inserted into the through hole 32, 33, 42, or 43 and the corresponding through hole of the metal foil 31, 41. Furthermore, the bead portion 67 allows for close contact with the brazing ring 70. The clad materials 35, 45 and the brazing ring 70 are sandwiched between the bead portion 67 and the crimped base end portion 66, and the clad materials 35, 45 and the brazing ring 70 are brazed together with the brazing material that forms the brazing ring 70.

[0031] The pipe joints 61-64 having such a configuration are made of metal, such as stainless steel, to ensure strength, and are formed by bending a plate of such material, for example, a plate having a thickness of 0.5 to 1.5 mm.

[0032] As described above, the proximal end 66 of the pipe fittings 61-64 is crimped and expanded to mechanically join the pipe fittings 61-64 themselves to the clad materials 35, 45. Furthermore, the pipe fittings 61-64 are brazed to the clad materials 35, 45 with the bead portion 67 in close contact with the brazing ring 70.

[0033] However, when the base end 66 of the pipe fittings 61-64 is crimped using a half die, as in the connection method described in Patent Document 1, the bead portion 67 may be locally deformed in the circumferential direction. Specifically, during crimping, only a portion of the bead portion 67 is supported by the half die, which can result in the other portions of the bead portion 67 being deformed more than the other portions. In this case, it is difficult to maintain a constant gap G between the clad material 35, 45 and the bead portion 67 in the circumferential direction. In other words, the gap G varies locally. As a result, the brazing ring 70 is not uniformly crushed by the crimping of the base end 66. This may result in insufficient brazing strength.

[0034] Therefore, in the manufacturing method of the plate heat exchanger 1, when connecting the pipe joints 61-64 to the clad materials 35, 45, i.e., the reinforcing plates 30, 40, the base end 66 is crimped while supporting the entire bead portion 67. Next, a manufacturing method of the plate heat exchanger 1 will be described with reference to Figures 7 and 8. A method of connecting the pipe joints 61-64 will also be described.

[0035] (Method of manufacturing a plate heat exchanger) Fig. 7 is a flowchart of a method of manufacturing a plate heat exchanger 1. Fig. 8 is a cross-sectional view of the pipe joints 61-64 and the reinforcing plates 30, 40 connected using a connecting device 8 in the step of connecting the pipe joints 61-64 and the reinforcing plates 30, 40 included in the method of manufacturing the plate heat exchanger 1.

[0036] First, prepare in advance the heat transfer plates 10, 20, metal foils 13, 23, reinforcing plates 30, 40, metal foils 31, 41, and pipe joints 61-64 of the above-mentioned shapes, sizes, and numbers. Also, assume that the metal foil 31 is integrally attached to the reinforcing plate 30, and the metal foil 41 is integrally attached to the reinforcing plate 40.

[0037] 7, a metal foil attachment process is performed (step S1). In this metal foil attachment process, a brazing ring 70 is attached to each of the pipe fittings 61-64. Specifically, first, one of the pipe fittings 61-64 is attached to the connecting fixture 8 shown in FIG.

[0038] Regarding the connector 8 used to attach the pipe fitting 61, as shown in FIG. 8 , the connector 8 has the shape of a rectangular prism block with its axis A2 oriented vertically. It has a cavity 81 inside that can accommodate any of the tip ends 65 of the pipe fittings 61-64. The cavity 81 has the shape of two cylinders with different inner diameters connected to each other. The cavity 81 also has a column axis, i.e., an axis, that is coaxial with the column axis A2 of the rectangular prism block. As a result, the axis of the cavity 81 extends vertically and further extends from the lower end to the upper end of the rectangular prism block, penetrating the block. As a result, the cavity 81 is connected to an opening 82 on its top surface. The opening 82 is shaped so that the portion adjacent to the bead portion 67 of the tip end 65 of the pipe fittings 61-64, i.e., the base portion of the tip end 65, can be fitted into the opening 82. Furthermore, the periphery of the opening 82 is flat because the top surface of the connecting device 8 is flat. As a result, the periphery of the opening 82 can uniformly support the brazing ring 70 all around. In order to accommodate the tip portions 65 of the pipe fittings 61-64 in the hollow portion 81, the connecting device 8 is composed of two blocks, a first block portion 83 and a second block portion 84, each having a shape divided into two by a plane passing through the above-mentioned axis of the hollow portion 81.

[0039] The second block portion 84 is placed away from the first block portion 83 of the connecting device 8, and the tip portion 65 of the pipe fitting 61-64 to be attached is fitted into the hollow portion 81 of the first block portion 83. At this time, the pipe fitting 61-64 to be attached is oriented with the tip portion 65 facing downward and the base end 66 facing upward. The tip portion 65 in this orientation is then fitted into the hollow portion 81 of the first block portion 83. Next, the second block portion 84 is combined with the first block portion 83 to close the hollow portion 81 into which the tip portion 65 is fitted. This completes the attachment of one of the pipe fittings 61-64 to the connecting device 8. The bead portion 67 of the attached pipe fitting 61-64 is placed on the upper surface of the connecting device 8. In this state, the pipe fitting 61-64 is positioned with the base end 66 extending upward from the bead portion 67.

[0040] Next, a brazing ring 70 is passed through the upwardly extending base end 66 and placed on the bead portion 67. This brings the brazing ring 70 adjacent to the bead portion 67. By this operation, the brazing ring 70 is attached to one of the pipe fittings 61-64.

[0041] Returning to FIG. 7 , following the metal foil attachment step, the pipe fitting connection step (step S2) is performed. The base end 66 of the pipe fitting 61-64, to which the brazing ring 70 was attached in step S1, is passed through the through holes 32, 33, 42, and 43 of the reinforcing plate 30, 40 to which the pipe fitting 61-64 is to be attached. More specifically, the base end 66 is passed through the through holes 32, 33, 42, and 43 of the clad material 35, 45, in which the reinforcing plate 30, 40 and the metal foil 31, 41 are integrated. At this time, as shown in FIG. 8 , the clad material 35, 45 is oriented so that the side with the metal foil 31, 41 faces upward and the side with the reinforcing plate 30, 40 faces downward. Then, the side of the clad material 35, 45 with the reinforcing plate 30, 40 is abutted against the brazing ring 70.

[0042] As described above, the length of the base end 66 is longer than the total thickness of the clad materials 35, 45 and the brazing ring 70. Therefore, when the surfaces of the clad materials 35, 45 on which the reinforcing plates 30, 40 are located are brought into contact with the brazing ring 70, the upper end portion of the base end 66 protrudes above the clad materials 35, 45. A frustum-shaped punch 5, whose tip outer diameter is smaller than the inner diameter of the base end 66 and whose base outer diameter is larger than the outer diameter of the base end 66, is pressed into the tube interior space opening at the end surface of the upper end portion of the protruding base end 66 to crimp the base end 66. As a result, as shown in FIG. 6 , the inner diameter of the base end 66 increases upward, i.e., toward the +Z side, and the +Z end of the base end 66 becomes larger than the diameters of the through holes 32, 33, 42, and 43 in the clad materials 35, 45. In other words, the +Z end of the base end 66 is expanded. As a result, the pipe joints 61-64 are fixed to the reinforcing plates 30, 40.

[0043] When the base end 66 is crimped, the entire circumference of the bead portion 67 is supported by the upper surface of the connector 8, specifically the periphery of the opening 82. Therefore, when the pressing force of the punch 5 is transmitted to the bead portion 67, the bead portion 67 is compressed evenly all around. As a result, the bead portion 67 is less likely to deform locally. This makes the gap G between the reinforcing plates 30, 40 and the bead portion 67 the same size all around, and the brazing ring 70 is crushed to the same thickness all around.

[0044] Furthermore, since the entire periphery of the bead portion 67 is supported when the punch 5 is pressed in, the crimping of the base end portion 66 is less likely to vary over the entire periphery. As a result, the base end portion 66 is connected to the reinforcing plates 30, 40 with sufficient strength.

[0045] As explained above, in step S1, a brazing ring 70 is attached to one of the pipe fittings 61-64, and in step S2, the base end 66 of the pipe fitting 61-64 to which the brazing ring 70 is attached is crimped to connect the pipe fitting 61-64 to the reinforcing plates 30, 40. Steps S1 and S2 are repeated in this manner, so that the brazing ring 70 is attached and the pipe fittings 61-64 are connected to the reinforcing plates 30, 40 for all of the pipe fittings 61-64.

[0046] 7, a lamination process is performed (step S3). Specifically, the heat transfer plates 10, 20 and the metal foils 13, 23 are stacked in the above-described arrangement to assemble the laminate 50. The laminate 50 is then sandwiched between the reinforcing plate 30 to which the metal foil 31 and the pipe fittings 61, 62 are attached, and the reinforcing plate 40 to which the metal foil 41 and the pipe fittings 63, 64 are attached.

[0047] Following the stacking step, a pressing step is carried out (step S4). In this pressing step, the stack 50, which includes the reinforcing plates 30 and 40, is compressed by applying pressure in the stacking direction. This causes the heat transfer plates 10 and 20, the metal foils 13 and 23, and the reinforcing plates 30 and 40 that form the stack 50 to adhere to one another.

[0048] After compressing the laminate 50, a brazing process is performed (step S5). Specifically, the laminate 50 assembled with the reinforcing plates 30 and 40 is placed in a furnace and heated to a temperature at which the brazing material forming the metal foils 31 and 41 and the brazing ring 70 melts. This melts the metal foils 13 and 23 between the heat transfer plates 10 and 20 of the laminate 50, the brazing ring 70 attached to the pipe joint 62, and the metal foils 31 and 41. As a result, the molten brazing material of these components permeates the gaps between the components.

[0049] After heating for a certain period of time, the stack 50 to which the reinforcing plates 30 and 40 are attached is cooled. This solidifies the brazing material. As a result, the pipe joints 61-64 are joined to the reinforcing plates 30 and 40. This completes the plate heat exchanger 1.

[0050] As described above, in the manufacturing method of the plate-type heat exchanger 1, in the pipe joint connecting step, the base end 66 is crimped while the peripheral edge of the opening 82 of the connecting device 8 supports the entire circumference of the bead portion 67. Therefore, the brazing ring 70 is crushed to the same thickness all around. This makes the bead portion 67 less likely to deform locally. As a result, the brazing rate is improved in the bead portion 67 of the pipe joints 61-64. As a result, the brazing strength between the reinforcing plates 30, 40 and the bead portion 67 is increased.

[0051] Furthermore, in the manufacturing method of the plate heat exchanger 1, the base end 66 is crimped while the peripheral edge of the opening 82 supports the entire periphery of the bead portion 67, so the amount of crimping of the base end 66 is less likely to vary over the entire periphery. As a result, the connection strength between the reinforcing plates 30, 40 and the bead portion 67 is high.

[0052] In the manufacturing method of the plate-type heat exchanger 1 described above, the second block portion 84 is placed away from the first block portion 83 of the connecting device 8, and then the second block portion 84 is assembled to the first block portion 83. The connecting device 8 may include a mechanism, such as a rail or a linear guide device, for sliding the second block portion 84 relative to the first block portion 83, and such a sliding mechanism may be used to place the second block portion 84 away from the first block portion 83 or to assemble the second block portion 84 to the first block portion 83. In this case, the sliding mechanism may slide the first block portion 83 or the second block portion 84 in a direction perpendicular to the assembly surface, such as the mating surface, when assembling the second block portion 84 to the first block portion 83.

[0053] (Connecting Device for Pipe Joints and Reinforcing Plates) In the manufacturing method for the plate-type heat exchanger 1 described above, a connecting device 8 is used, the second block portion 84 is placed away from the first block portion 83, the tip portion 65 of the pipe joints 61-64 to be attached is fitted into the hollow portion 81 of the first block portion 83, and then the second block portion 84 is assembled to the first block portion 83. In addition to such a connecting device 8, a connecting device that automatically opens and closes the first block portion 83 and the second block portion 84 may also be used. Next, a connecting device 9A for such pipe joints 61-64 and reinforcing plates 30, 40 will be described with reference to Figures 9 to 13.

[0054] 9 and 10 are a front view and a top view of a connection device 9A for pipe fittings 61-64 and reinforcing plates 30, 40 according to embodiment 1. Fig. 11 is a front view of the connection device 9A in an open state. For ease of understanding, Figs. 9-11 show the connection device 9A with the pipe fittings 61-64 housed therein.

[0055] As shown in Figure 9, the connection device 9A is provided in a hollow portion 91 within the device and includes a columnar member 95 that is movable up and down when inserted into the tip portions 65 of the pipe fittings 61-64, and a first block portion 93 and a second block portion 94 that change between an open state and a closed state in conjunction with the columnar member 95 and accommodate the tip portions 65 of the pipe fittings 61-64 in the closed state.

[0056] The first block portion 93 and the second block portion 94 are combined to form a hollow portion 91 and an opening portion 92 that connects to the hollow portion 91. The columnar member 95 is provided within the hollow portion 91. The pipe fittings 61-64 are inserted into the opening portion 92, and the columnar member 95 is inserted into the tip end portion 65 of the pipe fittings 61-64 to hold the tip end portion 65. The columnar member 95 is formed in a cylindrical shape as shown in FIG. 9 so that it can be inserted into the tip end portion 65. The outer diameter D3 of the columnar member 95 is smaller than the inner diameter D4 of the tip end portion 65 of the pipe fittings 61-64 shown in FIG. 4, to a degree that allows the columnar member 95 to be inserted into the tip end portion 65. As shown in FIG. 9, the corners of the columnar end of the columnar member 95 are rounded, resulting in a narrow column end. The columnar member 95 has a column axis A3 that faces up and down, and its column end with the rounded corners faces upward. This allows the tip portions 65 of the pipe joints 61-64 to be placed over the columnar member 95 from above, and the columnar member 95 to be inserted into the tip portions 65. The columnar member 95 holds the tip portions 65 by being inserted into the tip portions 65.

[0057] The first block portion 93 and the second block portion 94 are joined at a plane that passes through the column axis A3 and extends in the front-to-rear direction, i.e., at their mating surfaces, to form a rectangular column shape. The first block portion 93 and the second block portion 94 each have a semicircular recess in cross section facing the mating surfaces. The first block portion 93 and the second block portion 94 are joined at their mating surfaces to form a cavity 91 having the same shape as the cavity 81 of the connecting device 8 described above, and an opening 92 having the same diameter and at the same position as the opening 82 of the connecting device 8 described above. Like the cavity 81, the cavity 91 is also coaxial with the column axis A3.

[0058] 9 and 10 are provided at the lower ends of the first block portion 93 and the second block portion 94, facing each other across their mating surfaces. The oscillation shafts 96 and 97 are parallel to the mating surfaces and perpendicular to the column axis A3. The oscillation shafts 96 and 97 support the first block portion 93 and the second block portion 94 so that they can oscillate. The first block portion 93 and the second block portion 94 are positioned on a base 98 and placed on the base 98.

[0059] The columnar member 95 is provided so as to be movable up and down in order to swing the first block portion 93 and the second block portion 94 in conjunction with each other. More specifically, the columnar member 95 is supported on a support base (not shown) that is movable up and down by a shaft portion 951 shown in Fig. 11. The detailed configuration of the columnar member 95 will be described later, but when the tip portions 65 of the pipe fittings 61-64 are placed on the columnar member 95 from above and inserted into the tip portions 65, the columnar member 95 moves in the insertion direction, i.e., from top to bottom.

[0060] The support base (not shown) described above has through holes through which the swing shafts 96, 97 pass and holds the swing shafts 96, 97. Furthermore, as described above, the first block portion 93 and the second block portion 94 are placed on the base 98. With this configuration, when the columnar member 95 moves up and down and, as a result, the support base moves up and down, the distance D5 from the swing shafts 96, 97 to the base 98 changes.

[0061] When the columnar member 95 moves downward and the support base moves to the lower position, the distance D5 from the swing shafts 96, 97 to the base 98 becomes the same as the distance D6 from the swing shaft 96 to the lower end surface of the first block portion 93 or the distance D6 from the swing shaft 97 to the lower end surface of the second block portion 94, as shown in Figure 9. This makes the lower end surfaces of the first block portion 93 and the second block portion 94 parallel to the upper surface of the base 98. As a result, the longitudinal directions of the first block portion 93 and the second block portion 94 are oriented in the vertical direction, and the first block portion 93 and the second block portion 94 are in a closed state where their mating surfaces meet.

[0062] On the other hand, when the columnar member 95 moves upward and the support base moves to the upper position, the distance D5 from the swing shaft 96 or 97 to the base 98 becomes larger than the distance D6, as shown in FIG. 11 . As a result, the lower end surfaces of the first block portion 93 and the second block portion 94 tilt with respect to the upper surface of the base 98. As a result of the swing shafts 96 and 97 being misaligned to the right and left within the first block portion 93 and the second block portion 94, the first block portion 93 tilts to the left and falls, and the second block portion 94 tilts to the right and falls. As a result, as shown in FIG. 11 , the first block portion 93 and the second block portion 94 are in an open state in which their upper sides are separated from each other.

[0063] In this way, the columnar member 95 moves up and down, thereby swinging the first block portion 93 and the second block portion 94. As a result, the columnar member 95 changes the state of the first block portion 93 and the second block portion 94 between the closed state and the open state described above.

[0064] In addition, when the tip end 65 of the pipe fitting 61-64 is placed over the columnar member 95 from above and inserted into the tip end 65, the columnar member 95 moves up and down in conjunction with the insertion, so as shown in Figures 9 and 11, the columnar member 95 has a plunger 953 on the side surface of the cylinder.

[0065] The plunger 953 is a component with a pin or ball at its tip, and the pin or ball is biased toward the tip by an internal spring. The tip of the plunger 953 protrudes from the side surface of the columnar member 95. When the first block portion 93 and the second block portion 94 are in the open state and the tip portions 65 of the pipe fittings 61-64 are placed over and inserted into the columnar member 95, the plunger 953 abuts against the inner wall of the tip portions 65. The plunger 953 in this state is shown in Figures 12 and 13.

[0066] Figure 12 is a conceptual cross-sectional view of the connection device 9A when the plunger 953 included in the connection device 9A abuts against the O-ring groove 68 in the tip portion 65 of the pipe joints 61-64. Figure 13 is a conceptual cross-sectional view of the connection device 9A when it is assumed that the plunger 953 included in the connection device 9A abuts against the end of the tip portion 65 of the pipe joints 61-64. Note that for ease of understanding, only a partial cross section of the connection device 9A is shown in Figures 12 and 13. Furthermore, hatching of the columnar member 95 and plunger 953 included in the connection device 9A has been omitted.

[0067] 12, when the tip portion 65 of the pipe fitting 61-64 is placed over and inserted into the columnar member 95, the plunger 953 presses the tip against the inner wall of the tip portion 65 by the biasing force of the spring. As a result, as the tip portion 65 of the pipe fitting 61-64 is inserted into the columnar member 95, the plunger 953 moves the columnar member 95 in conjunction with the tip portion 65. As a result, as the tip portion 65 is inserted into the columnar member 95, the plunger 953 moves the columnar member 95 downward in conjunction with the insertion.

[0068] The plunger 953 is disposed at a central position in the column axis A3 direction of the side surface of the columnar member 95. This central position is a position where the plunger 953 abuts against a portion of the inner wall of the tip portion 65 that faces the O-ring groove 68 when the tip portions 65 of the pipe fittings 61-64 are inserted over the columnar member 95 and the bead portions 67 of the pipe fittings 61-64 abut against the peripheral portions of the openings 92 of the first block portion 93 and the second block portion 94. This is because, at this position, even if there is an error in the abutment position of the plunger 953 when the bead portions 67 of the pipe fittings 61-64 abut against the peripheral portions of the openings 92 of the first block portion 93 and the second block portion 94, it is possible to abut the bead portions 67 against the peripheral portions of the openings 92 without any gaps. 13 , if the plunger 953 is positioned to abut against the end of the inner wall of the tip portion 65, i.e., the lower end, when the bead portion 67 abuts against the periphery of the opening 92 of the first block portion 93 and the second block portion 94, an error in the abutment position of the plunger 953 could prevent the bead portion 67 from abutting against the periphery of the opening 92 without a gap, which could result in a gap between the bead portion 67 and the periphery of the opening 92. Therefore, to prevent such a problem, the plunger 953 is positioned as described above.

[0069] With this configuration, the plunger 953 moves the columnar member 95 up and down in conjunction with the insertion of the tip portions 65 of the pipe fittings 61-64. As a result, the plunger 953 changes the state of the first block portion 93 and the second block portion 94 between a closed state and an open state. More specifically, as the tip portions 65 of the pipe fittings 61-64 are inserted into the columnar member 95, the plunger 953 changes the state of the first block portion 93 and the second block portion 94 from an open state to a closed state. When the first block portion 93 and the second block portion 94 are in the closed state, the peripheral portions of the openings 92 of the first block portion 93 and the second block portion 94 support the bead portions 67 of the pipe fittings 61-64.

[0070] Returning to Figure 10, an annular recess 921 that surrounds the entire periphery of the opening 92 is adjacent to the periphery of the opening 92 of the first block portion 93 and the second block portion 94. The outer diameter of the recess 921 is larger than the outer diameter of the bead portion 67 of the pipe fittings 61-64. The depth of the recess 921 is equal to or greater than the thickness of the bead portion 67. As a result, the bead portion 67 can fit into the recess 921. The bottom of the recess 921 is flat, which allows the bead portion 67 to fit tightly.

[0071] As shown in FIG. 10 , when the first block portion 93 and the second block portion 94 are in a closed state, the bead portion 67 fits into the recess 921. As a result, the recess 921 supports the bead portion 67 over its entire circumference. More specifically, when the first block portion 93 and the second block portion 94 are in a closed state and the bead portion 67 is fitted into the recess 921, the bottom of the recess 921 on the periphery of the opening 92 comes into close contact with the bead portion 67 when the punch 5 described above is pressed into the base end portion 66 to connect the base end portion 66 of the pipe fitting 61-64 to the reinforcing plate 30, 40. The bead portion 67 is then supported over its entire circumference by the bottom of the recess 921. As a result, when the base end portion 66 is crimped with the punch 5, the bead portion 67 is compressed evenly over its entire circumference. As a result, the bead portion 67 is less likely to deform locally. As a result, the gap G between the reinforcing plates 30, 40 and the bead portion 67 becomes the same size all around, and the brazing ring 70 is crushed to the same thickness all around. As a result, the brazing rate is improved in the bead portion 67 of the pipe joints 61-64. This also increases the brazing strength between the reinforcing plates 30, 40 and the bead portion 67.

[0072] The above-mentioned pipe fittings 61-64 are an example of a pipe member as defined in the present disclosure. The bead portion 67 of the pipe fittings 61-64 is an example of a large-diameter portion as defined in the present disclosure. The reinforcing plate 30 or the clad material 35 is an example of a plate, an outermost heat transfer plate, or a heat transfer plate as defined in the present disclosure. The brazing ring 70 is an example of a ring member as defined in the present disclosure. The connecting fixture 8 and connecting device 9A between the pipe fittings 61-64 and the reinforcing plates 30, 40 are an example of a connecting device between a pipe member and a plate. The plate heat exchanger 1 is an example of a heat exchanger as defined in the present disclosure.

[0073] The first block portion 93 and the second block portion 94 are an example of a support mechanism as defined in the present disclosure. The rectangular prism-shaped block formed by combining the first block portion 93 and the second block portion 94 is an example of a main body as defined in the present disclosure. The upper position of the support base of the columnar member 95 is an example of a first position as defined in the present disclosure. The lower position of the support base of the columnar member 95 is an example of a second position as defined in the present disclosure.

[0074] As described above, in the connection device 9A, when performing the metal foil attachment step in the manufacturing method for the plate-type heat exchanger 1, the peripheral edges of the openings 92 provided in the first block portion 93 and the second block portion 94 support the bead portions 67 of the pipe fittings 61-64 over the entire circumference. Specifically, the recesses 921 on the peripheral edges of the openings 92 can fit into the bead portions 67, and when the bead portions 67 are fitted, the bottoms of the recesses 921 support the bead portions 67 over the entire circumference. Therefore, the connection device 9A can suppress variations in the crimping of the base ends 66 of the pipe fittings 61-64. As a result, the connection device 9A can connect the pipe fittings 61-64 to the reinforcing plates 30, 40 with sufficient connection strength.

[0075] Furthermore, in the connection device 9A, the bead portion 67 is less likely to deform locally, which results in an improved brazing rate at the bead portion 67 and an increased brazing strength between the reinforcing plates 30, 40 and the bead portion 67.

[0076] Furthermore, in the connection device 9A, the first block portion 93 and the second block portion 94 change their state from an open state to a closed state in conjunction with the insertion of the pipe joints 61-64 into the columnar member 95. This makes it easy to connect the pipe joints 61-64 to the reinforcing plates 30, 40.

[0077] (Embodiment 2) In Embodiment 1, the connection device 9A for the pipe fittings 61-64 and the reinforcing plates 30, 40 includes: (1) a columnar member 95 that is provided in a hollow portion 91 within the device and that can move up and down by being inserted into the tip portions 65 of the pipe fittings 61-64; and (2) a first block portion 93 and a second block portion 94 that change between an open state and a closed state in conjunction with the columnar member 95 and that accommodate the tip portions 65 of the pipe fittings 61-64 in the closed state. However, the connection device 9A is not limited to this. Instead of the columnar member 95, the connection device 9A may include a block member having a recess into which the tip portions 65 of the pipe fittings 61-64 can be inserted.

[0078] A connection device 9B for connecting pipe joints 61-64 and reinforcing plates 30, 40 according to the second embodiment includes a block member 99 instead of the columnar member 95.

[0079] 14 to 17, a description will be given of a connecting device 9B for connecting pipe joints 61-64 and reinforcing plates 30, 40 according to the second embodiment. In the second embodiment, the description will focus on the configuration that differs from the first embodiment.

[0080] Figure 14 is a front view of the connection device 9B of the pipe fittings 61-64 and the reinforcing plates 30, 40 according to the second embodiment when the connection device 9B is in an open state. Figure 15 is a front view of the connection device 9B when the tip portions 65 of the pipe fittings 61-64 abut against the plunger 953 when the connection device 9B is in an open state. Figure 16 is a front view of the connection device 9B when the tip portions 65 of the pipe fittings 61-64 are further pushed in when the connection device 9B is in an open state. Figure 17 is a front view of the connection device 9B when the tip portions 65 of the pipe fittings 61-64 are fully pushed into the plunger 953 of the connection device 9B and the connection device 9B is in a closed state.

[0081] As shown in FIGS. 14 to 17, the connection device 9B includes a block member 99 instead of the columnar member 95 included in the connection device 9A according to the first embodiment.

[0082] The block member 99 has a shape and size that allows it to be housed in the cavity 91 formed by the first block member 93 and the second block member 94. The cavity 91 has a shape similar to that of the cavity 81 of the connector 8 described in the first embodiment. The block member 99 has a cylindrical or prism shape, such as a square prism with rounded corners, that can be housed in the cavity 91. The block member 99 is disposed inside the cavity 91.

[0083] The block member 99 also has recesses 991 on the side of the first block portion 93 and the second block portion 94 where the openings 92 shown in FIGS. 14 to 16 are located, that is, on the upper surface side.

[0084] The recess 991 has a cylindrical shape into which the tip portions 65 of the pipe fittings 61-64 can be inserted. More specifically, as shown in Figure 14, the recess 991 is formed in the shape of a cylinder having an inner diameter D8 that is larger than the outer diameter D7 of the tip portions 65 of the pipe fittings 61-64. As a result of the recess 991 having such a shape and size, the tip portions 65 of the pipe fittings 61-64 can be inserted into it.

[0085] The block member 99 differs in shape and size from the columnar member 95 described in the first embodiment, but its relationship with other components, such as the swing shafts 96, 97, the support base (not shown), and the base 98, is the same as that of the columnar member 95. Therefore, a description of the relationship between the block member 99 and other components, such as the swing shafts 96, 97, the support base (not shown), and the base 98, will be omitted. Since the relationship between the block member 99 and other components is the same as that of the columnar member 95 in the first embodiment, the block member 99 operates in conjunction with the tip end 65 of the pipe fitting 61-64 when the pipe fitting 61-64 is inserted into the recess 991, just like the columnar member 95. In detail, the columnar member 95 described in the first embodiment is fitted into the internal space of the tip end 65 of the pipe fitting 61-64 inserted into the hollow portion 91, and moves up and down in conjunction with the tip end 65. In contrast, the block member 99 of the second embodiment moves up and down in conjunction with the tip portions 65 of the pipe fittings 61-64 inserted into the hollow portion 91, as the tip portions 65 are inserted into and connected to recesses 991 of the block member 99. To enable the tip portions 65 of the pipe fittings 61-64 to be connected to the recesses 991 of the block member 99, a pair of plungers 953, as described in the first embodiment, are provided on the inner wall surface of the recesses 991.

[0086] The specific structure and function of each plunger 953 are the same as those in the first embodiment. Therefore, a description of the specific structure and function of the plunger 953 will be omitted. On the other hand, the arrangement of the plungers 953 in the second embodiment is different from that in the first embodiment, and each plunger 953 protrudes from the inner wall surface of the recess 991 toward the inside of the recess 991. The direction of their protrusion is the direction of the cylindrical axis A4 of the recess 991 shown in FIG. 14 and is perpendicular to the cylindrical axis A4. The plungers 953 face each other.

[0087] As described in the first embodiment, the tip of each plunger 953 is supported by a spring and can therefore extend and retract by a small distance. The distance between the tips of the plungers 953 is the same as the outer diameter D7 of the tip portions 65 of the pipe fittings 61-64, such that when the tip portions 65 of the pipe fittings 61-64 are inserted into the recesses 991 of the block member 99, the tip of each plunger 953 can extend and retract to clamp the tip portions 65 of the pipe fittings 61-64. As a result, when the tip portions 65 of the pipe fittings 61-64 are inserted into the recesses 991 of the block member 99, the tips of the pair of plungers 953 abut against the outer peripheral surfaces of the tip portions 65 and clamp the tip portions 65, as shown in FIG. 15 . As a result, the pair of plungers 953 connect the tip portions 65 of the pipe fittings 61-64 to the block member 99 on which the plungers 953 are provided. As a result, the block member 99 moves in conjunction with the movement of the tip portions 65 of the pipe joints 61-64, as described above.

[0088] 16 , when the tip portions 65 of the pipe fittings 61-64 are pushed downward while being sandwiched between a pair of plungers 953, the plungers 953 connect the tip portions 65 of the pipe fittings 61-64 to the block member 99, causing the block member 99 to move downward as the tip portions 65 of the pipe fittings 61-64 move. Similar to the columnar member 95 in the first embodiment, the block member 99 changes the state of the first block portion 93 and the second block portion 94 from an open state to a closed state, or vice versa, depending on its vertical position. Therefore, as the block member 99 moves downward, the state of the first block portion 93 and the second block portion 94 changes from an open state to a closed state. Then, as shown in FIG. 17, when the tip portions 65 of the pipe joints 61-64 are pushed completely downward, the block member 99 descends to a position where it contacts the base 98, bringing the first block portion 93 and the second block portion 94 into a closed state.

[0089] On the other hand, when the tip portions 65 of the pipe joints 61-64 are pulled upward from the closed state, the tip portions 65 remain connected to the block member 99 by the plunger 953, so the block member 99 moves upward. As a result, the first block portion 93 and the second block portion 94 change state to the open state shown in Fig. 16. Then, when the block member 99 shown in Fig. 15 has moved to the structurally highest position, the tip portions 65 of the joints 61-64 are pulled further upward, and when this pulling force exceeds the clamping force of the plunger 953, the tip portions 65 are released from the connection by the plunger 953.

[0090] In this way, when the tip portions 65 of the pipe fittings 61-64 are inserted into the recesses 991, the block member 99 moves in conjunction with the movement of the tip portions 65 of the pipe fittings 61-64 via the plungers 953. Furthermore, by moving in conjunction with the movement of the tip portions 65, the block member 99 changes the state of the first block portion 93 and the second block portion 94. As a result, the block member 99 performs the same function as the columnar member 95 provided in the connection device 9A according to the first embodiment.

[0091] 17, when the first block portion 93 and the second block portion 94 are in the closed state, a recess 921 (not shown in FIG. 17) is formed around the periphery of the opening 92, as shown in FIG. 10, into which the bead portion 67 fits. Therefore, in the second embodiment, as in the first embodiment, the through holes 32, 33, 42, and 43 of the clad materials 35 and 45 described in the first embodiment are passed through the base end portions 66 of the pipe fittings 61-64 in this closed state, and the base end portions 66 are then crimped and expanded using a punch 5. This is because the bead portion 67 is supported by the recess 921, and as a result of the expansion of the base end portions 66, the gap G between the clad materials 35 and 45 and the bead portion 67 becomes uniform in size around the entire circumference. This is because the subsequent brazing increases the brazing strength between the clad materials 35 and 45 and the bead portion 67.

[0092] As described above, the connection device 9B according to the second embodiment includes a block member 99 instead of the columnar member 95 included in the connection device 9A according to the first embodiment. The block member 99 has a recess 991 into which the tip end 65 of the pipe fitting 61-64 can be inserted, and a pair of plungers 953 that protrude from the inner wall surface of the recess 991 into the recess 991. When the tip end 65 of the pipe fitting 61-64 is inserted into the recess 991, the pair of plungers 953 clamps the tip end 65 to connect the pipe fitting 61-64 to the block member 99. In this way, the block member 99 has the same function as the columnar member 95 of the connection device 9A according to the first embodiment. As a result, the connection device 9B according to the second embodiment achieves the same effects as the connection device 9A according to the first embodiment.

[0093] The above has described the method for connecting the pipe fittings 61-64 and the reinforcing plates 30, 40, the method for manufacturing the plate heat exchanger 1, and the connecting fixture 8 and connection device 9A for the pipe fittings 61-64 and the reinforcing plates 30, 40 according to the first and second embodiments of the present disclosure. In other words, the method for connecting the pipe members and plates, the method for manufacturing the heat exchanger, and the device for connecting the pipe members and plates according to the first and second embodiments have been described. However, the method for connecting the pipe members and plates, the method for manufacturing the heat exchanger, and the device for connecting the pipe members and plates are not limited to this.

[0094] In the first and second embodiments, brazing rings 70 formed of brazing material are used to connect the pipe joints 61-64 and the reinforcing plates 30, 40. However, the methods for connecting pipe members and plates, the methods for manufacturing heat exchangers, and the devices for connecting pipe members and plates according to the first and second embodiments are not limited to this. They are applicable to any connection between pipe members and plates. Therefore, brazing material does not have to be used to connect the pipe members and plates. In other words, the pipe members and plates may be connected by crimping the pipe members.

[0095] In the first and second embodiments, the pipe fittings 61-64 have a bead portion 67 formed by a convex outward protrusion of the sidewall portion of the pipe. However, the pipe members to be connected are not limited to this. The pipe member only needs to have a large-diameter portion disposed between the distal end and proximal end and having a larger outer diameter than the proximal end. Therefore, for example, the pipe fittings 61-64 may have a flange formed by locally increasing the thickness of the sidewall portion of the pipe instead of the bead portion 67. Alternatively, the pipe fittings 61-64 may be pipe members formed by cutting that satisfy the above conditions.

[0096] In the first and second embodiments, metal foils 31, 41 are attached to the reinforcing plates 30, 40, and as a result, the reinforcing plates 30, 40 and the metal foils 31, 41 form clad materials 35, 45. That is, the plates to be connected in the present disclosure are the clad materials 35, 45. However, the plates to be connected are not limited to this. The plates only need to have through holes with a diameter larger than the outer diameter of the base end of the above-described tubular member and smaller than the outer diameter of the large-diameter portion. Therefore, the plates may be reinforcing plates 30, 40 to which metal foils 31, 41 are not attached. Alternatively, the plates may be flat plates without peripheral walls.

[0097] Furthermore, in embodiments 1 and 2, the peripheral edge of the opening 82 in the connection tool 8 is flat. Furthermore, in the connection device 9A, the peripheral edge of the opening 92 is a recess 921 that is adjacent to and surrounds the opening 92. However, the connection devices for connecting a pipe member and a plate according to embodiments 1 and 2 are not limited to this. The connection tool 8 and the connection device 9A may be any type that includes a support mechanism that supports the entire circumference of the large-diameter portion of the pipe member described above.

[0098] Here, supporting the entire circumference of the large diameter portion is not limited to supporting the large diameter portion 360° in the circumferential direction. Supporting the entire circumference of the large diameter portion may be supporting most of the large diameter portion to an extent that variation in the crimping of the base end portion of the tubular member is suppressed. For example, it may be sufficient to support the large diameter portion only 10° in the circumferential direction and support most of the remaining portion.

[0099] Furthermore, when the support mechanism includes a peripheral edge portion of the openings 82, 92, the peripheral edge portion of the openings 82, 92 preferably supports the large diameter portion over the entire circumferential direction when the tip end of the pipe member is housed in the hollow portion 81, 91 and the portion of the tip end of the pipe member adjacent to the large diameter portion is fitted into the openings 82, 92. For example, when the pipe member is a pipe fitting 61-64 and the bead portion 67 of the pipe fitting 61-64 protrudes from the pipe side surface portion in a semicircular shape in cross section, the peripheral edge portion of the opening 92 preferably is a recess that fits into the semicircular shape of the bead portion 67 in cross section.

[0100] In the first and second embodiments, the connector 8 is composed of a first block portion 83 and a second block portion 84. The connector device 9A is composed of a first block portion 93 and a second block portion 94. That is, the connector 8 and the connector device 9A are composed of two block portions. However, the connector devices for connecting pipe members and plates according to the first and second embodiments are not limited to this. The connector 8 and the connector device 9A for connecting pipe members and plates may have multiple block portions divided around the cylindrical axis of the hollow portions 81 and 91, and may be formed by combining these multiple block portions. For example, the connector 8 and the connector device 9A may be formed by combining three block portions divided at 120° intervals around the cylindrical axis of the hollow portions 81 and 91, and these three block portions may change between the open state and the closed state described above. In short, the connection fixture 8 and the connection device 9A are formed by combining multiple block sections divided at equal angles around the cylindrical axis of the hollow sections 81 and 91, and these multiple block sections can change state between the open and closed states described above.

[0101] Furthermore, although the first and second embodiments relate to the connection of the reinforcing plates 30, 40 of the plate-type heat exchanger 1 with the pipe joints 61-64, the methods for connecting pipe members and plates, the methods for manufacturing a heat exchanger, and the devices for connecting pipe members and plates according to the first and second embodiments are not limited to this. It is sufficient that the pipe members have a tip end, a base end, and a large-diameter portion located between the tip and base ends and having an outer diameter larger than that of the base end, and the plates have through-holes whose diameters are larger than the outer diameter of the base end of the pipe members and smaller than the outer diameter of the large-diameter portion of the pipe members, and the methods are applicable to all such connections between pipe members and plates.

[0102] As described above, the methods for connecting tube members and plates, the methods for manufacturing a heat exchanger, and the devices for connecting tube members and plates according to the first and second embodiments are not limited to the first and second embodiments, and various modifications and substitutions can be made. Various aspects of the present disclosure are described below as appendices.

[0103] (Supplementary Note 1) A method for connecting a pipe member and a plate, the method comprising: connecting a pipe member having a distal end, a proximal end, and a large-diameter portion disposed between the distal end and the proximal end and having a larger outer diameter than the proximal end; and a plate having a through hole having a diameter larger than the outer diameter of the proximal end and smaller than the outer diameter of the large-diameter portion, the method comprising: passing the proximal end through the through hole and positioning the pipe member and the plate so that the large-diameter portion is adjacent to a peripheral edge of the through hole; and fixing the proximal end of the pipe member, with the proximal end passed through the through hole and the large-diameter portion adjacent to the peripheral edge of the through hole, to the plate by crimping and expanding the proximal end while supporting the entire circumference of the large-diameter portion. (Supplementary Note 2) The method for connecting a pipe member and a plate according to Supplementary Note 1, wherein the large-diameter portion is a bead portion formed by bending a side wall portion of the pipe member and protruding outward in a convex shape. (Supplementary Note 3) The method for connecting a tube member and a plate according to Supplementary Note 1 or 2, wherein the step of arranging the tube member and the plate includes arranging a ring member formed of brazing material between the large diameter portion and the peripheral edge of the through hole so as to sandwich the ring member between the large diameter portion and the peripheral edge. (Supplementary Note 4) The method for connecting a tube member and a plate according to any one of Supplementary Note 1 to Supplementary Note 3, wherein the plate is a clad material having a layer formed of brazing material on the one surface side, and the step of arranging the tube member and the plate is such that the large diameter portion is adjacent to the one surface of the plate. (Supplementary Note 5) The method for connecting a tube member and a plate according to Supplementary Note 3 or 4, further comprising the step of melting the brazing material to braze the tube member to the plate after fixing the base end to the plate by crimping to expand the tube. (Supplementary Note 6) The method for connecting a tube member and a plate according to any one of Supplementary Note 1 to Supplementary Note 5, wherein the tube member is for allowing a fluid to flow in and out, and the plate is an outermost heat transfer plate located outermost among a plurality of heat transfer plates stacked with flow path spaces through which the fluid flows provided therebetween. (Supplementary Note 7) A method for manufacturing a heat exchanger, comprising the method for connecting a plate and a tube member according to Supplementary Note 6.(Supplementary Note 8) A connecting device for a pipe member and a plate that connects a pipe member having a tip end, a base end, and a large diameter portion provided between the tip end and the base end and having an outer diameter larger than that of the base end, to a plate having a through hole whose diameter is larger than the outer diameter of the base end and smaller than the outer diameter of the large diameter portion, the connecting device for a pipe member and a plate comprising: a support mechanism that supports the entire circumference of the large diameter portion adjacent to the tip end side of the large diameter portion of the pipe member in a state in which the base end is passed through the through hole and the large diameter portion is adjacent to the periphery of the through hole, and that supports the entire circumference of the large diameter portion when a punch is pressed into an internal space of the base end to expand the base end. (Supplementary Note 9) The connecting device for a pipe member and a plate according to Supplementary Note 8, wherein the support mechanism comprises a main body having a hollow portion capable of accommodating the tip portion, and an opening that is connected to the hollow portion and into which the portion of the tip portion adjacent to the large diameter portion can be fitted, and a peripheral portion of the opening supports the large diameter portion over the entire circumferential direction when the tip portion is accommodated in the hollow portion and the portion adjacent to the tip portion is fitted into the opening. (Supplementary Note 10) The connecting device for a pipe member and a plate according to Supplementary Note 9, wherein the hollow portion extends in a columnar shape from the opening, and the main body portion has a plurality of block portions formed by dividing the main body portion about an axis in the direction in which the hollow portion extends, and is formed by combining the plurality of block portions. (Appendix 11) The connecting device for a pipe member and a plate described in Appendix 10, wherein the plurality of block portions have a shape in which the main body portion is divided by a plane passing through the axis of the hollow portion, and are composed of a first block portion and a second block portion that form the hollow portion by joining together on the plane.(Supplementary Note 12) The support mechanism comprises a columnar member provided in the hollow portion, and arranged on the bottom portion with its column axis facing in a direction from the opening toward the bottom portion on the opposite side, the columnar member is formed to be insertable into the tip portion, and when the tip portion is accommodated in the hollow portion, the tip portion is moved from the opening side to the bottom side, thereby being inserted into the tip portion from the side opposite to the side where the large diameter portion is located, the columnar member is movable from a first position to a second position closer to the bottom than the first position, or vice versa, and moves from the first position to the second position by insertion into the tip portion, and each of the first block portion and the second block portion is the first and second block portions are spaced apart on the opening side when the columnar member is moved to the first position, and the second block portion is closed on the plane when the columnar member is moved to the second position; and when the tip end is inserted between the first and second block portions in the open position and the columnar member is inserted into the tip end, the insertion of the tip end moves the columnar member from the first position to the second position, causing the first and second block portions to be in the closed state, and the periphery of the through hole formed by the first and second block portions in the closed position to be adjacent to the large diameter portion, thereby supporting the entire circumference of the large diameter portion. (Appendix 13) The connecting device between a pipe member and a plate described in Appendix 12, wherein the columnar member has a plunger protruding from a side portion and is insertable into the internal space of the tip portion, and when the columnar member is inserted into the internal space of the tip portion, the plunger abuts against an inner wall of the tip portion to move the columnar member itself from the first position to the second position in conjunction with the insertion operation of the tip portion.(Supplementary Note 14) The support mechanism comprises a block member that is provided in the hollow portion and has a recess on the side where the opening is located, the recess having a shape that allows the tip portion to be inserted into the recess, and when the tip portion is accommodated in the hollow portion, the tip portion is moved from the side of the opening to the opposite bottom side, thereby inserting the tip portion into the recess from the side opposite to the side where the large diameter portion is located, the block member is movable from a first position to a second position that is closer to the bottom than the first position, or vice versa, and moves from the first position to the second position by inserting the tip portion into the recess, and each of the first block portion and the second block portion is the first and second block portions are spaced apart on the opening side when the block member is moved to the first position, and the second block portion is closed on the flat surface when the block member is moved to the second position; and when the tip end is inserted between the first and second block portions in the open position and the tip end is inserted into the recess, the insertion of the tip end into the recess moves the block member from the first position to the second position, causing the first and second block portions to be in the closed state, and the periphery of the through hole formed by the first and second block portions in the closed position to be adjacent to the large diameter portion, thereby supporting the entire circumference of the large diameter portion. (Appendix 15) The connecting device between a pipe member and a plate described in Appendix 14, wherein the block member has a plunger that protrudes from an inner wall surface of the recess toward the inside of the recess, and when the tip portion is inserted into the recess, the plunger abuts against an outer wall of the tip portion, thereby moving the block member itself from the first position to the second position in conjunction with the insertion action of the tip portion.(Supplementary Note 16) The connecting device for a pipe member and a plate described in Supplementary Note 11, wherein each of the first block portion and the second block portion can be changed in state between an open state in which they are separated from the plane and a closed state in which they are joined at the plane by moving in a direction perpendicular to the plane, and in the open state, the base end portion can be inserted into the hollow portion, and in the closed state, the peripheral portion of the through hole formed by the first block portion and the second block portion is adjacent to the large diameter portion and supports the entire circumference of the large diameter portion.

[0104] 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.

[0105] This application is based on Japanese Patent Application No. 2024-131009, filed on August 7, 2024. The entire specification, claims, and drawings of Japanese Patent Application No. 2024-131009 are incorporated herein by reference.

[0106] 1 Plate type heat exchanger, 5 Punch, 8 Connection tool, 9A, 9B Connection device, 10 Heat transfer plate, 11 Standing wall, 12 Inner fin, 13 Metal foil, 14, 15 Inlet / outlet holes, 16, 17 Communication holes, 20 Heat transfer plate, 21 Standing wall, 22 Inner fin, 23 Metal foil, 24, 25 Communication holes, 26, 27 Inlet / outlet holes, 30 Reinforcing plate, 31 Metal foil, 32, 33 Through hole, 35 Clad material, 40 Reinforcing plate, 41 Metal foil, 42, 43 Through hole, 45 Clad material, 50 Laminate, 61-64 Pipe joint, 65 Tip portion, 66 Base end portion, 67 Bead portion, 68 Groove, 70 Brazing ring, 81 Cavity portion, 82 Opening, 83 First block portion, 84 Second block portion, 91 hollow portion, 92 opening portion, 93 first block portion, 94 second block portion, 95 columnar member, 96, 97 oscillation axis, 98 base, 99 block member, 921 recess, 951 axis portion, 953 plunger, 991 recess, A1 tube axis, A2, A3 column axis, A4 cylinder axis, D1-D3 outer diameter, D4 inner diameter, D5, D6 distance, D7 outer diameter, D8 inner diameter, G gap, T1-T3 thickness.

Claims

1. A method for connecting a pipe member and a plate, the method comprising: connecting a pipe member having a distal end, a proximal end, and a large-diameter portion disposed between the distal end and the proximal end and having a larger outer diameter than the proximal end; and a plate having a through hole having a diameter larger than the outer diameter of the proximal end and smaller than the outer diameter of the large-diameter portion, the method comprising: a step of passing the proximal end through the through hole and further arranging the pipe member and the plate so that the large-diameter portion is adjacent to the periphery of the through hole; and a step of fixing the proximal end of the pipe member, with the proximal end passed through the through hole and the large-diameter portion adjacent to the periphery of the through hole, to the plate by crimping and expanding the proximal end while supporting the entire circumference of the large-diameter portion.

2. The method for connecting a pipe member and a plate according to claim 1, wherein the large diameter portion is a bead portion formed by bending a side wall portion of the pipe member and protruding outward in a convex shape.

3. A method for connecting a pipe member and a plate according to claim 1 or 2, wherein in the step of arranging the pipe member and the plate, a ring member formed of brazing material is arranged between the large diameter portion and the peripheral edge of the through hole, and the ring member is sandwiched between the large diameter portion and the peripheral edge.

4. A method for connecting a tube member and a plate according to any one of claims 1 to 3, wherein the plate is a clad material having a layer formed of a brazing material on one side, and in the step of arranging the tube member and the plate, the large diameter portion is adjacent to the one side of the plate.

5. The method for connecting a tube member and a plate according to claim 3 or 4, further comprising the step of melting the brazing material to braze the tube member to the plate after the base end has been fixed to the plate by crimping and expanding the tube.

6. A method for connecting a tube member and a plate according to any one of claims 1 to 5, wherein the tube member is for allowing a fluid to flow in and out, and the plate is an outermost heat transfer plate located at the outermost position among a plurality of heat transfer plates stacked one on top of the other with flow path spaces provided between them through which the fluid flows.

7. A method for manufacturing a heat exchanger, comprising the method for connecting plates and tube members according to claim 6.

8. A connecting device for a pipe member and a plate that connects a pipe member having a tip end, a base end, and a large diameter portion provided between the tip end and the base end and having an outer diameter larger than that of the base end, to a plate having a through hole whose diameter is larger than the outer diameter of the base end and smaller than the outer diameter of the large diameter portion, the connecting device for a pipe member and a plate comprising: a support mechanism that supports the entire circumference of the large diameter portion when the base end is passed through the through hole and the large diameter portion is adjacent to the periphery of the through hole from the tip end side, and when a punch is forced into the internal space of the base end to expand the base end.

9. A connecting device for a pipe member and a plate as described in claim 8, wherein the support mechanism comprises a main body having a hollow portion capable of accommodating the tip portion and an opening connected to the hollow portion and into which the portion of the tip portion adjacent to the large diameter portion can be fitted, and the peripheral portion of the opening supports the large diameter portion over the entire circumferential direction when the tip portion is accommodated in the hollow portion and the adjacent portion of the tip portion is fitted into the opening.

10. A connecting device for a pipe member and a plate as described in claim 9, wherein the hollow portion extends in a columnar shape from the opening, and the main body portion has a plurality of block portions formed by dividing the main body portion around an axis in the direction in which the hollow portion extends, and the connecting device is formed by combining the plurality of block portions.

11. A connecting device for pipe members and plates as described in claim 10, wherein the plurality of block portions are configured by first block portions and second block portions which have a shape obtained by dividing the main body portion by a plane passing through the axis of the hollow portion, and which form the hollow portion by joining together on said plane.

12. The support mechanism is provided in the hollow portion and includes a columnar member arranged on the bottom with its column axis facing from the opening toward the bottom on the opposite side, the columnar member is formed so as to be insertable into the tip portion, and when the tip portion is housed in the hollow portion, the tip portion is moved from the opening side to the bottom side, thereby being inserted into the tip portion from the side opposite to the side where the large diameter portion is located, and is movable from a first position to a second position closer to the bottom than the first position, or vice versa, and moves from the first position to the second position by insertion into the tip portion, and each of the first block portion and the second block portion is 12. The connecting device for a pipe member and a plate according to claim 11, further comprising: a swing shaft on the side of the bottom portion that swingably supports each of the block portions, and swings in conjunction with movement of the columnar member, thereby changing states between an open state in which the first block portion and the second block portion are separated from each other on the side of the opening when the columnar member is moved to the first position, and a closed state in which the first block portion and the second block portion are joined to each other on the same plane when the columnar member is moved to the second position; and when the tip end is inserted between the first block portion and the second block portion in the open state and the columnar member is inserted into the tip end, the insertion of the tip end moves the columnar member from the first position to the second position, thereby changing the first block portion and the second block portion to the closed state, and the periphery of the through hole formed by the first block portion and the second block portion in the closed state is brought adjacent to the large diameter portion, thereby supporting the entire circumference of the large diameter portion.

13. A connecting device for a tubular member and a plate as set forth in claim 12, wherein the columnar member has a plunger protruding from a side portion and is insertable into the internal space of the tip portion, and when the columnar member is inserted into the internal space of the tip portion, the plunger abuts against the inner wall of the tip portion, moving the columnar member itself from the first position to the second position in conjunction with the insertion movement of the tip portion.

14. The support mechanism comprises a block member provided in the hollow portion and having a recess on the side where the opening is located, the recess having a shape that allows the tip portion to be inserted into the recess, and when the tip portion is accommodated in the hollow portion, the tip portion is inserted into the recess from the side opposite the side where the large diameter portion is located by moving the tip portion from the side where the opening is located to the opposite side of the bottom, the block member is movable from a first position to a second position that is closer to the bottom than the first position, or vice versa, and moves from the first position to the second position by inserting the tip portion into the recess, and each of the first block portion and the second block portion is 12. The connecting device of claim 11, further comprising: a swing shaft on the side of the bottom portion that swingably supports each of the block members, the swing shaft swinging in conjunction with movement of the block member to change states between an open state in which the first block portion and the second block portion are separated from each other on the opening side when the block member is moved to the first position, and a closed state in which the first block portion and the second block portion are brought together on the same plane when the block member is moved to the second position; and when the tip end is inserted between the first block portion and the second block portion in the open state and the tip end is inserted into the recess, the insertion of the tip end into the recess moves the block member from the first position to the second position, bringing the first block portion and the second block portion into the closed state, and supporting the entire circumference of the large diameter portion by making the peripheral edge of the through hole formed by the first block portion and the second block portion in the closed state adjacent to the large diameter portion.

15. A connecting device for a pipe member and a plate as described in claim 14, wherein the block member has a plunger that protrudes from the inner wall surface of the recess into the inside of the recess, and when the tip portion is inserted into the recess, the plunger abuts against the outer wall of the tip portion, thereby moving the block member itself from the first position to the second position in conjunction with the insertion action of the tip portion.

16. A connecting device for pipe members and plates as described in claim 11, wherein each of the first and second block members can be changed in state between an open state in which they are spaced apart from the plane and a closed state in which they are joined together on the plane by moving in a direction perpendicular to the plane, and in the open state the base end can be inserted into the hollow portion, and in the closed state the peripheral portion of the through hole formed by the first and second block members is adjacent to the large diameter portion and supports the entire circumference of the large diameter portion.

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