Heat exchanger

Abstract

[Problem] In heat exchangers with a header tank comprising a partition part partitioning the interior, there is a problem in that the area around an engagement part where a mating part of a partition plate and the tank mate is vulnerable to corrosion because solder material fills up the clearance for mating. [Solution] In a heat exchanger with a header tank comprising a partition part partitioning the interior and a cap that closes up a longitudinal-direction end part, an engagement part between a mating part of the partition part and the header tank is provided at a joint part with at least one cap.

Description

Heat exchanger

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

[0002] For example, a heat exchanger used in a vehicle air conditioner or the like is composed of a plurality of tubes laminated via heat transfer fins and through which a heat medium flows, and a header tank connected to an end of the tube and extending in the lamination direction. A partition plate for partitioning the inside of the header tank is provided in the header tank. By regulating the flow of the heat medium in the header tank by the partition plate, the heat medium is made to flow uniformly in each tube.

[0003] A fitting portion protruding upward is formed on the partition plate, and a slit hole into which the fitting portion of the partition plate fits is formed in the tank constituting the header tank (see, for example, Patent Document 1).

[0004] By adopting such a configuration, the positioning of the partition plate becomes easy, and it is possible to confirm whether the brazing of the partition plate is surely performed by visually observing the engaging portion between the slit hole and the partition plate, so that defective brazing of the partition plate can be appropriately prevented.

[0005] Japanese Unexamined Patent Application Publication No. 2004-205114

[0006] However, since the outside of the cooler is wetted by condensed water accompanying condensation, there is a risk of corrosion. For this countermeasure, various parts use materials with high corrosion resistance. On the other hand, there has been a problem that the periphery of the engaging portion where the partition plate and the tank fit is vulnerable to corrosion because the brazing material fills the clearance for fitting.

[0007] In order to solve such problems, the heat exchanger according to the present invention has the following configuration.

[0008] A heat exchanger comprising: a plurality of tubes through which a heat transfer medium flows; a heat exchange core portion composed of the plurality of tubes; a pair of header tanks provided at both ends in the longitudinal direction of the tubes and extending in the direction of the stacked arrangement of the tubes; a partition portion provided inside the header tanks; and a cap that closes the longitudinal end of the header tanks, wherein the plurality of tubes are arranged in a plurality of rows in a ventilation direction perpendicular to the stacked arrangement direction, the header tanks have a hollow cylindrical structure, the partition portion is disposed between groups of the plurality of tubes so as to divide the hollow portion of the header tanks into a plurality of regions extending in the stacked arrangement direction, and the header tanks are provided with a fitting portion that engages with a fitting portion of the partition portion and engages with at least one of the caps.

[0009] According to the present invention, which has these characteristics, it is possible to improve the corrosion resistance near the engagement portion between the tank and the partition, and consequently the corrosion resistance of the cooler.

[0010] This is a front view showing the external appearance of a heat exchanger according to an embodiment of the present invention. This is an exploded perspective view of the header tank, with the side to which the tubes are connected being the bottom surface. This is a perspective view of the header tank with the cap removed, with the side to which the tubes are connected being the bottom surface. This is a cross-sectional perspective view taken along line A-A in Figure 3. This is a bottom view of the header tank, showing the side to which the tubes are connected. This is a side view of the right end of the partition. This is a top view of the right end of the tank, showing the side opposite to the side to which the header is connected. This is a perspective view of the inside of the first cap. This is a perspective view of the right end of the header tank. This is a cross-sectional perspective view of the header tank in Figure 9, cut vertically along the partition. This is an enlarged cross-sectional side view of section C in Figure 10.

[0011] Embodiments of the present invention will now be described with reference to the drawings. Each drawing shows one embodiment of the present invention and is not intended to limit the invention. In the following description, the same reference numerals in different figures indicate parts with the same function, and redundant explanations in each figure will be omitted as appropriate.

[0012] Furthermore, the dimensional relationships of each element in the drawings are for the purpose of facilitating understanding and are not intended to restrict the actual dimensional ratios.

[0013] Furthermore, in this embodiment, directions are indicated based on the vertical, horizontal (width), and front-to-back directions, as shown by the solid arrows in each drawing. The front-to-back direction is the direction in which the fluid (e.g., air) passes (ventilation direction), and the fluid passes from the rear to the front in the front-to-back direction. In Figure 1, the front of the page is the rear, and the fluid passes from the front to the back of the page.

[0014] Figure 1 shows an example of the schematic configuration of the heat exchanger 1 according to this embodiment. As shown in Figure 1, the heat exchanger 1 comprises a first header tank 11, a second header tank 12, and a heat exchange core 10 formed between the first header tank 11 and the second header tank 12.

[0015] The heat exchange core section 10 includes a plurality of tubes 100, fins (not shown) provided between adjacent tubes 100, and a pair of side plates 101 provided at both ends in the stacking direction (width direction) of the plurality of tubes 100. In the heat exchanger 1, heat exchange takes place between a heat transfer medium (including a refrigerant) flowing vertically in the diagram through the tubes 100 of the heat exchange core section 10 via a first header tank 11 and a second header tank 12, and a fluid (for example, air) passing through the heat exchange core section 10 from rear to front along the front-rear direction in the diagram.

[0016] The first header tank 11 and the second header tank 12 are hollow cylindrical structural members that extend in the width direction shown in the figure. Along this extending direction, a plurality of tubes 100 are stacked between the first header tank 11 and the second header tank 12 at predetermined intervals. More specifically, the plurality of tubes 100 are arranged in a two-dimensional configuration, with groups of tubes 100 arranged in the width direction shown in the figure, and multiple rows arranged in the front-to-back direction shown (the direction of airflow perpendicular to the stacking direction of the plurality of tubes 100). Both ends of each tube 100 are connected to the first header tank 11 and the second header tank 12, respectively. A first cap 40 is provided at one end of the longitudinal direction of the first header tank 11 and the second header tank 12, and a second cap 46 is provided at the other end. The first cap 40 and the second cap 46 close both ends of the longitudinal direction of the first header tank 11 and the second header tank 12. The first cap 40 provided on the first header tank 11 has an opening 41 for the inflow and outflow of the heat transfer medium, while the first caps 40 and second caps 46 provided in other locations are closed lids that do not have an opening 41.

[0017] The following explanation will use the first header tank 11 as an example, but the second header tank 12 is basically the same as the first header tank 11. Furthermore, an example will be given in which a group of tubes 100 are arranged in two rows in the front-to-back direction shown in the figure.

[0018] The first header tank 11 is located at the top of the heat exchanger 1. As shown in Figure 2, the first header tank 11 consists of a tank 5, a header 6, a partition 30, a first cap 40, and a second cap 46. The tank 5 forms the upper part of the first header tank 11 in the vertical direction, and the header 6 forms the lower part of the first header tank 11.

[0019] As shown in Figure 3, the first header tank 11 is a hollow cylindrical structure extending in the left-right direction shown in the figure. The first header tank 11 is provided with partitions 30 that divide the internal hollow portion into multiple regions. The partitions 30 are plate-shaped members provided inside the first header tank 11 along the longitudinal direction (left-right direction shown in the figure).

[0020] As shown in Figure 4, the first header tank 11 has a substantially rectangular cross-section, and at the center of the first header tank 11 in the front-to-back direction shown, a pair of long sides of the partition 30 are provided so as to be joined to the lower surface of the tank 5 and the upper surface of the header 6, respectively.

[0021] The interior of the first header tank 11 is divided by a partition 30 into two regions: a first region 21 corresponding to a group of tubes 100 arranged in the front row of the heat exchange core 10, and a second region 22 corresponding to a group of tubes 100 arranged in the rear row.

[0022] The inner walls of the tank 5 and header 6 that constitute the first header tank 11 are provided with grooves 24 that run along the long side of the partition 30 when the partition 30 is joined together.

[0023] As shown in Figure 5, the header 6 has communication holes 23 extending in the left-right direction, through which multiple tubes 100 are connected, arranged in two rows along the front-to-back direction.

[0024] One longitudinal end of the first header tank 11 is provided with an inlet E1 for introducing a heat transfer medium into the first region 21 via the opening 41 of the first cap 40, and an outlet E2 for discharging the heat transfer medium from the second region 22 (see Figure 1). An inlet pipe (not shown) is connected to the inlet E1, and an outlet pipe (not shown) is connected to the outlet E2.

[0025] Generally, brazing sheets, which consist of a core material clad with brazing material, are used in the manufacture of the first header tank 11 and the second header tank 12. For the core material, for example, an aluminum alloy containing Mn is used, and for the brazing material, an aluminum alloy containing Si, Zn, etc. is used. After assembling these components, the heat exchanger 1 is manufactured by brazing.

[0026] The present invention will be described below with reference to Figures 6 to 8.

[0027] As shown in Figure 6, the partition portion 30 is composed of a plate-shaped portion 33, a fitting portion 31, and a protruding portion 32.

[0028] A rectangular fitting portion 31 is formed on the upper edge of the plate-like portion 33 of the partition portion 30, with a flat top extending in the left-right direction as shown in the figure. The height of the fitting portion 31 (length in the vertical direction as shown in the figure) is equal to the wall thickness of the tank 5. The length of the plate-like portion 33 in the longitudinal direction (left-right direction as shown in the figure) is equal to the length of the tank 5 in the longitudinal direction. Specifically, as will be described later, the fitting portion 31 is provided in a position that is covered by the first cap 40.

[0029] Furthermore, a projection 32 is formed at the longitudinal end of the partition portion 30. The projection 32 corresponds to the portion that is fitted into the slit hole 42 formed in the first cap 40, which will be described later. Although there is also a configuration without the projection 32, it is more preferable to provide the projection 32 because, in addition to the same positioning and visual confirmation effect of the partition portion 30 and the joint as the fitting portion 31, it also has the effect of ensuring that the partition portion 30 is properly engaged with the first header tank 11.

[0030] As shown in Figure 7, the tank 5 has a notch 25 formed at a position corresponding to the fitting portion 31 of the partition portion 30. The length of the notch 25 in the left-right direction is equal to the length of the fitting portion 31 in the left-right direction, and the length in the front-back direction is also formed to match that of the fitting portion 31.

[0031] The first cap 40 is a lid formed to close one end of the first header tank 11 in the longitudinal direction (left-right direction in the illustration). As shown in Figure 8, the first cap 40 has two openings 41 for connecting inlet and outlet pipes, a vertically extending slit hole 42 into which the protruding portion 32 of the partition portion 30 is fitted, a flange portion 43 that covers the outer circumferential surface of the ends of the header 6 and tank 5, and a plurality of locking claws 44 that protrude from the flange portion 43 in the longitudinal direction of the first header tank 11 for locking the header 6 and tank 5.

[0032] The vertical length of the slit hole 42 is formed to be equal to the vertical length of the partition portion 30, that is, the maximum vertical length of the protruding portion 32. This allows the protruding portion 32 and the slit hole 42 to engage without any gaps. The longitudinal length of the flange portion 43 of the first header tank 11 is such that the fitting portion 31 of the partition portion 30 is covered.

[0033] The second cap 46 is a lid that closes the other end of the first header tank 11 in the longitudinal direction (left-right direction in the illustration) and engages with the first header tank 11.

[0034] The second cap 46 closes the other end of the first header tank 11 so that the heat transfer medium cannot move between the first region 21 and the second region 22. The shape of the second cap 46 is such that, for example, the outer circumference of the second cap 46 matches the outer circumference of the other end of the first header tank 11, and it is provided with a projection that fits onto the inner surface of the first header tank 11 and a locking claw that engages with the outer circumference of the other end of the first header tank 11. In addition, a groove is formed on the inner surface of the second cap 46 (the side with the partition 30) where the longitudinal end of the partition 30 joins. Furthermore, the partition 30 on the side where the second cap 46 is installed consists only of a plate-like portion 33. In this case, the notch 25 in the tank 5 at the other end of the first header tank 11 is not required.

[0035] After assembling these components, the heat exchanger 1 is manufactured by brazing.

[0036] Next, the partition portion 30 and the first cap 40, which are characteristic features of the present invention, will be described in detail using Figures 9 to 11.

[0037] As shown in Figure 9, the first cap 40 closes the longitudinal end of the first header tank 11, and the protruding portion 32 of the partition portion 30 is fitted through the slit hole 42 of the first cap 40.

[0038] As shown in Figures 10 and 11, the first cap 40 is joined without gaps to the outer surface of the tank 5, the upper and right sides of the fitting portion 31 of the partition portion 30, and the upper surface of the protruding portion 32 of the partition portion 30, and is fixed by brazing. With this configuration, the brazing material that fills the clearance between the fitting portion 31 and the notch 25 around the fitting portion 31 is prevented from coming into direct contact with the air, so condensation does not occur around the fitting portion 31, and corrosion due to moisture caused by condensation is prevented.

[0039] The fitting portion 31 is completely covered by the flange portion 43 of the first cap 40. As the configuration is such that the separation distance d shown in FIG. 11 becomes longer, the distance at which the periphery of the fitting portion 31 comes into contact with air can be extended, so that the resistance to corrosion is enhanced.

[0040] As described above, in the present invention, the first cap 40, the fitting portion 31 formed in the partition portion 30, and the notch portion 25 formed in the tank 5 are integrally configured (hereinafter, this configuration is referred to as the "present invention configuration").

[0041] In the present embodiment, a form in which the present invention configuration is applied only to one end portion of the first header tank 11 and the second header tank 12 is shown. However, the present invention is not limited to this, and a configuration in which it is applied to both end portions may be adopted.

[0042] In the present embodiment, a configuration in which one fitting portion 31 is formed on the tank 5 side is shown. However, the present invention is not limited to this, and by providing it also on the opposing header 6 side, a configuration in which two fitting portions 31 are joined to one first cap 40 may be adopted. In that case, the partition portion 30 has a T shape. Further, a notch portion 25 similar to that of the tank 5 is formed in the header 6.

[0043] In the present embodiment, the notch portion 25 provided at the longitudinal end portion of the tank 5 is shown as the fitting portion to be fitted to the fitting portion 31. However, the fitting portion does not necessarily have to be at the longitudinal end portion of the tank 5. Even when it is a slit-shaped hole portion provided at a location slightly separated from the longitudinal end portion, the effects of the present invention can be achieved if it is at a position where it joins with the flange portion 43 of the first cap 40.

[0044] In the present embodiment, the heat exchanger of the present invention applied to a vehicle air conditioner is shown. However, the present invention is not limited to this. For example, the present invention can be applied to heat exchangers used in building room air conditioners, refrigerated display cases, refrigerators, and the like.

[0045] In the present embodiment, the present invention applied to a heat exchanger that exchanges heat between a refrigerant and air is shown. However, the present invention is not limited to this. For example, the present invention may be applied to a heat exchanger that exchanges heat between water or antifreeze and air.

[0046] Furthermore, although this embodiment shows a configuration in which the present invention is applied to a heat exchanger in which a pair of header tanks are arranged vertically, the present invention is not limited to this. For example, the present invention may also be applied to a heat exchanger in which a pair of header tanks are arranged horizontally.

[0047] Although embodiments of the present invention have been described in detail above with reference to the drawings, the configuration of the present invention is not limited to the embodiments described, and any changes in design, etc., that do not depart from the spirit of the present invention are also included.

[0048] 1: Heat exchanger, 5: Tank, 6: Header, 10: Heat exchange core, 11: First header tank, 12: Second header tank, 21: First region, 22: Second region, 23: Communication hole, 24: Groove, 25: Notch, 30: Partition, 31: Fitting part, 32: Protrusion, 33: Plate-shaped part, 40: First cap, 41: Opening, 42: Slit hole, 43: Flange, 44: Locking claw, 46: Second cap, 100: Tube, 101: Side plate, E1: Inlet, E2: Outlet, d: Separation distance

Claims

1. A heat exchanger comprising: a plurality of tubes through which a heat transfer medium flows; a heat exchange core portion composed of the plurality of tubes; a pair of header tanks provided at both ends in the longitudinal direction of the tubes and extending in the direction of stacking the tubes; a partition portion provided inside the header tanks; and a cap that closes the longitudinal end of the header tanks, wherein the plurality of tubes are arranged in multiple rows in a ventilation direction perpendicular to the direction of stacking the tubes, the header tanks are hollow cylindrical structures, the partition portion is disposed between groups of the plurality of tubes so as to divide the hollow portion of the header tanks into multiple regions extending in the direction of stacking, and the header tanks are provided with a fitting portion that engages with at least one of the caps, which engages with a fitting portion of the partition portion.

2. The heat exchanger according to claim 1, wherein the header tank is composed of a plurality of members, the cap closes the opening at the longitudinal end of the header tank composed of the plurality of members and has a flange that covers the outer circumferential surface of the end, and the flange is joined to the fitting portion of the partition.

3. The heat exchanger according to claim 2, characterized in that the cap has an opening for connecting inlet and outlet pipes for the heat transfer medium.

4. The heat exchanger according to any one of claims 1 to 3, characterized in that the fitted portion is notched or slit-shaped.

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