JPH0220338B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application This invention relates to a method for manufacturing a heat exchanger used in automobile radiators, heaters for heating devices, and the like.

Conventional technology and its problems Conventionally, two header plates are parallel to each other, and the header plates are arranged at right angles to the header putt and parallel to each other, and both ends are joined to the header plate. a plurality of flat tubes, a corrugated fin disposed between adjacent flat tubes and joined to the flat tubes, and a header tank fixed to a header plate and forming a header tank together with the header plate. Heat exchangers used as automobile radiators and heaters for heating equipment consist of a main body.
Conventionally, it has been manufactured using the following method. That is, first, the flat tubes and corrugated fins are arranged alternately, and after temporarily fixing them with a jig, the flat tubes and the corrugated fins are joined together, and then both ends of each flat tube are attached to header plates. The flat tube and header plate were brazed with the flat tube inserted into the hole drilled in the hole and temporarily fixed with a jig, and then the header tank body was fixed to the header plate.

However, the conventional method involves arranging the flat tubes and corrugated fins alternately, temporarily fixing them with a jig, removing the jig after joining the flat tubes and corrugated fins, and removing the jig from both ends of each flat tube. It is necessary to insert the tube into the hole drilled in the header plate and temporarily fix them with a jig, and to remove the jig after joining the flat tube and header plate, which increases the number of man-hours and makes the work difficult. There was a problem that it became a hassle. Furthermore, care must be taken when handling the flat tube and corrugated fins so that they do not shift when they are moved into a joining furnace after being fixed with a jig. Additionally, the surface of the jig becomes rough during bonding, requiring polishing after several uses, leading to severe wear and tear on the jig, resulting in increased costs. Furthermore, since the jig is naturally heated during bonding, the amount of heat required during bonding increases, leading to the problem that the fuel cost for the bonding furnace increases.

An object of the present invention is to provide a method for manufacturing a heat exchanger that solves the above problems.

Means for Solving the Problems The method for manufacturing a heat exchanger according to the present invention includes at least two header plates that are parallel to each other, and a space between the two header plates that is at right angles to the header plates and parallel to each other. A heat pump comprising a plurality of flat tubes arranged in the same direction, corrugated fins arranged between adjacent flat tubes, and a header tank body fixed to the header plate and forming a header tank together with the header plate. A method for manufacturing an exchanger, wherein a flat tube holder having a plurality of grooves into which flat tubes are fitted is prepared, and each flat tube is inserted into each groove with both ends of each flat tube protruding from the grooves. The header plates and flat tubes can be assembled in advance by fitting the flat tubes into the holes, inserting both ends of each flat tube into holes formed in both header plates, and fixing both header puts and both ends of each flat tube. It is characterized by including the process of building the body.

Embodiments Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following description, the term aluminum includes all aluminum alloys in addition to pure aluminum.

1 to 4 show a heat exchanger for a motor vehicle radiator manufactured by the method according to the invention. In Figures 1 to 4, heat exchanger 1
consists of two aluminum header plates 2 arranged vertically at a predetermined interval and parallel to each other.
A plurality of aluminum flat tubes 3 are arranged between both header plates 2 at right angles to the header plate 2 and parallel to each other, and both ends are welded to the header plate 2. Aluminum corrugated fins 4 with louvers are arranged between the tubes 3 and on the outside of the flat tube 3 at both ends and are joined to the flat tube 3; Aluminum side plate 5 joined to fin 4 and header plate 2
a plastic header fixed to the header plate 2 and forming a header tank 6 together with the header plate 2;
It consists of a tank body 7.

Header tank body 7 of both header plates 2
A recessed groove 8 into which a flange 7a provided at the periphery of the opening of the header/tank body 7 is fitted is provided around the entire circumference of the surface to which the header/tank body 7 is attached. The groove 8 is formed so as to protrude toward the other header plate 2 side. The other protruding portions toward the header plate 2 form engagement protrusions 10 that engage with both ends of the side plate 5, as will be described later. The header plate 2 also has flat tube insertion holes 9 that are long in the width direction of the header plate 2 at predetermined intervals in the length direction.
are formed. A flange 1 is attached to the periphery of the flat tube insertion hole 9 on the surface of the header plate 22 where the header tank body 7 is attached.
1 is formed. Both ends of the flat tube 3 are expanded to form expanded tube portions 3a, and with the expanded tube portions 3a inserted into the holes 9 and in close contact with the inner peripheral surface of the flange 11, the header plate 2 and the flat tube are connected. 3
are welded. Also, Hetsuda Brate 2
On the surface facing the other header plate 2, the space between the periphery of the flat tube 3 and the hole 9 is sealed with a sealing material 12 made of epoxy resin or the like. The upper and lower ends of the side plate 5 are
Once bent diagonally outward, it is bent toward the flat tube 3 side located at both left and right ends, and its tip is folded back to the outside to provide an elastic engaging portion 13. The side plate 5 is joined to the header plate 2 with the tip of the engaging portion 13 engaged with the protrusion 10 of the header plate 2. Hetsuda・
In the tank body 7, the flange 7a is inserted into the groove 8 via the O-ring 14, and the flange 7a is arranged at a predetermined interval in the length direction on the outer wall of the groove 8 on the long side of the header plate 2. It is fixed to the header plate 2 by being pressed by a flange holding projection 15 formed to project inward. The flange holding protrusion 15 is approximately semicircular when viewed from the plane or the bottom, and the edge on the bottom wall side of the groove 8 is cut away from the other part of the outer wall of the groove 8. , the flange 7a is held down by this edge.

Next, a method for manufacturing the heat exchanger 1 will be described with reference to FIGS. 5 to 13.

First, as shown in FIGS. 5 and 6, a plurality of grooves 16 into which the flat tubes 3 are tightly fitted are inserted into the heat exchanger 1.
A flat tube holder 17 formed at the same pitch as the adjacent flat tube 3 of the product is prepared, and both ends thereof are inserted into the grooves 16 by a feeding device (not shown).
The flat tube 3 is fitted in the state in which it protrudes from. It is preferable to form a larger number of grooves 16 in the holder 17.
Each flat tube 3 is placed in the groove 16 of the flat tube holder 17.
After fitting, both ends of the flat tube 3 are inserted into the tube expansion device 2.
6 to expand the tube to form the expanded tube portion 3a (7th
(see figure). The tube expansion device 26 is located on both sides of the flat tube holder 17 and approaches the flat tube holder 17,
A slide 27 that can be separated freely, and a plurality of tube expansion members 28 that are attached to the surface of the slide 27 on the flat tube holder 17 side so as to correspond to the flat tube 3 and that are inserted into the end of the flat tube 3 to expand this portion. It becomes more. The tip of the tube expanding member 28 is tapered. Then, this tube expanding member 28 is inserted into both ends of the flat tube 3 to expand this portion, thereby creating a tube expanded portion 3a. Next, insert the expanded tube portions 3a at both ends of each flat tube 3 into the flat tube insertion holes 9 of the header plate 2,
Bringing the expanded tube portion 3a and flange 11 into close contact (eighth
(see figure). If both ends of the flat tube 3 are expanded in advance,
When the tube expansion part 3a is inserted into the hole 9, the flange 11
A force is applied to expand the pipe, and the expanded part 3
Since a force is applied to a to contract it, the reaction of these forces brings them into close contact.
Thereafter, the flange 11 and the expanded tube portion 33a of the flat tube 3 are welded together by an automatic welding device 31 having a plurality of welding torches 30 (see FIG. 9), and the header
A combination 32 consisting of the plate 2 and the flat tube 3 is made (see FIG. 10).

After making the combination 32 as described above,
When the corrugated fins 4 are forcibly fitted between adjacent flat tubes 3 in the combination body 32 by an appropriate method, and the corrugated fins 4 are arranged along the outside of the flat tubes 3 at both ends. (See Figure 11), each flat tube 3 bends slightly, so that the middle part of the length of the flat tube 3 located at both ends is bent outward, and the corrugated fins 4 at the outer ends are bent outward. curve in one direction. Next, the side plate 5 is pushed in from the outside of the corrugated fin 4 at the outer end in the direction shown by the arrow in FIG.
2 to be engaged with the protrusion 10 of No. At this time, the engaging part 13 is once bent (see the solid line in Figure 12), and then restored by its own elastic force, and the engaging part 13 and the protruding part 10 are firmly engaged (see the two-dot chain line in Figure 12). ). In the engaged state, each flat tube 3 and the corrugated fins 4 disposed on the outside of the flat tube 3 at both ends are deformed from the state before engagement, and the side plate 5 is pushed outward due to the spring back. Being pushed. Therefore, the engaging portion 13 of the side plate 5 is firmly engaged with the protruding portion 10 of the header plate 2, and the side plate 5 is prevented from coming off. The corrugated fins 4 located outside the flat tube 3 at the end are prevented from falling off.

Then, the combination body 32 and the corrugated fin 4
With the side plate 5 set as described above, the flat tube 3 and the corrugated fin 4, the header plate 2 and the side plate 5, and the corrugated fin 4 and the side plate are assembled without using a jig. 5 and 5 at the same time. This bonding was performed by adding a liquid bonding composition containing zinc chloride (Japanese Patent Publication No. 49,
-Refer to Publication No. 36864) and then heated in a furnace. When spraying the liquid bonding composition, it is preferable to prevent the composition from coming into contact with the surface of the header plate 2 on which the header tank body 7 is attached. After the joining is completed, a sealing material 12 made of epoxy resin or the like is applied to the joint between the flat tube 3 and the header plate 2 and dried.

Finally, the flange 7a of the header tank body 7
into the groove 8 of the header plate 2 through the O-ring 14, and then attach the main body 7 to the header plate 2.
The header tank body 7 is attached to the header plate 2 by forming a protrusion 15 on the outer wall located on the long side of the header plate 2 by a fixing device 41 having a plurality of punches 40 while being pressed to the side. It is fixed to form a header tank 6 (see FIG. 13).

In this way, the heat exchanger 1 is manufactured.

In the above embodiment, a flat tube holder is prepared in which a plurality of grooves into which the flat tubes are closely fitted are formed at the same pitch as adjacent flat tubes of the manufactured heat exchanger, and each flat tube is inserted into each of the grooves. After fitting, both ends of each flat tube are expanded, the expanded portions are inserted into holes formed in both header plates, and both header plates and flat tubes are welded to form a combination body. Therefore, it is possible to easily create a combination of adjacent flat tubes with accurate pitch.

In the above embodiment, the combination body 32 is made by welding the header plate 2 and the flat tube 3, but instead of this, the combination body is made by temporarily fixing both by a mechanical method such as caulking. You can also make 32. In this case, the flat tube 3 and side plate 5 are made from a brazing sheet, the corrugated fins 4 and the side plate 5 are set, and then the header plate 2, flat tube 3, and flat tube are assembled by vacuum brazing. Pipe 3, corrugated fin 4, side plate 5
and header plate 2 and side plate 5
It is preferable to join the and corrugated fins 4 to each other.

Further, in the above embodiment, the flat tubes 3 are arranged in one row in the width direction of the header plate 2, that is, in the air circulation direction, but they may be arranged in two rows or more than two rows.

In addition, in the above embodiment, the flat tube 3 and the corrugated fin 4, the corrugated fin 4 and the side plate 5, and the header plate 2 and the side plate are bonded using a liquid bonding composition containing zinc chloride. 5 are joined to each other,
Alternatively, the corrugated fins 4 may be made of a plating sheet, and the flat tube 3 and the corrugated fins 4, and the corrugated fins 4 and the side plate 5 may be vacuum brazed, respectively.

Further, in the above embodiment, the flat tube holder 7
A plate-like plate with grooves 16 formed on its upper surface is used, but instead of this, a pair of rod-shaped bodies parallel to each other and grooves formed on the upper surface of the rod-shaped bodies are used. You may also use In this case, if the distance between the two rod-like bodies is adjustable, it is possible to apply the present invention even if the lengths of the flat tubes are different.

Furthermore, in the above embodiment, the combination 32
After forming the adjacent flat tubes 3 of the combination body 32
The corrugated fins 4 are forcibly fitted between them, and the corrugated fins 4 are placed on the outside of the flat tube 3 located at both ends, and then the engaging portions 13 at both ends of the side plate 5 are fitted into both headers. - The corrugated fins 4 located on the outside of the flat tube 3 at both ends are engaged with the protrusions 10 of the plate 2 to prevent them from falling off, so when moving them into the welding furnace or during welding. There is no need for a jig to fix the flat tube, corrugated fins, and side plates, and the following problems that occur when using a jig can be solved at once. If a jig is used, it takes time and effort to set and remove the jig, which increases the number of man-hours and has the disadvantage that the process cannot be automated. In addition, care must be taken when handling the flat tube and corrugated fins so that they do not shift when they are moved into a furnace after being fixed with a jig. In addition, the surface of the jig becomes rough during bonding, requiring polishing after several uses, resulting in significant wear and tear on the jig, resulting in increased costs. Furthermore, since the jig is naturally heated during bonding, the amount of heat required during bonding increases, leading to a problem in that the fuel cost for the bonding furnace increases.

Effects of the Invention In the method according to the present invention, a flat tube holder having a plurality of grooves into which flat tubes are fitted is prepared, and each flat tube is inserted into each of the grooves with both ends of the tube protruding from the grooves. A combination of header plates and flat tubes is prepared in advance by fitting the flat tubes into the holes, inserting both ends of each flat tube into holes formed in both header plates, and fixing both header plates and both ends of each flat tube. Since the method includes the step of making a corrugated fin, by forcibly fitting the corrugated fins between adjacent flat tubes, it becomes possible to temporarily fix them to the assembly without using a jig. Therefore, the work of arranging the flat tubes and corrugated fins alternately, temporarily fixing them with a jig, and removing the joining jig between the flat tubes and corrugated fins is unnecessary, as in the conventional method. becomes necessary,
It reduces man-hours and makes work easier. Furthermore, automation of work becomes possible, improving manufacturing efficiency. In addition, when moving flat pipes and corrugated pipes into a joining furnace, as in the case of fixing them with a jig,
There is no risk of the fins shifting. Moreover, since there is no need to use a jig, the cost is reduced. Furthermore, since there is no need to heat the jig during bonding as in conventional methods, the amount of heat required during bonding is small, and the fuel cost for the bonding furnace is reduced.

[Brief explanation of drawings]

Fig. 1 is a perspective view showing a heat exchanger manufactured by the method of the present invention, Fig. 2 is a partially cutaway enlarged view of Fig. 1, and Fig. 3 is a part taken along the - line in Fig. 1. 4 is a partial enlarged view of FIG. 3, FIGS. 5 to 13 show the method of the present invention in the order of steps, and FIG. 5 shows a state in which the flat tube is placed in a flat tube holder. 6 is a side view showing a method of arranging a flat tube in a flat tube holder, and FIG. 7 is a partially cutaway partial plan view showing a method of expanding both ends of a flat tube.
Figure 8 is a partially cutaway plan view showing the state in which both ends of the flat tube are inserted into the holes in the header plate;
The figure is a partially cutaway plan view showing a method of welding a flat tube and a header plate, FIG. 10 is a perspective view of a combination of a header plate and a flat tube, and FIG. 11 is a view of adjacent flats of the combination. Fig. 12 is a partially cutaway side view showing a method of forcibly fitting corrugated fins between pipes, and Fig. 12 is a partially cutaway plan view showing a method of engaging both ends of a side plate with a header plate. , FIG. 13 is a partially cutaway front view showing a method of fixing the header tank body to the header plate. 1... Heat exchanger, 2... Header plate, 4
... Corrugate fin, 6 ... Header tank, 7 ... Header tank body, 9 ... Flat tube insertion hole, 16 ... Groove, 17 ... Flat tube holder, 3
2...A combination of a header plate and a flat tube.

Claims (1)

[Claims] 1 At least two header plates parallel to each other, a plurality of flat tubes arranged between both header plates at right angles to the header plate and parallel to each other, and arranged between adjacent flat tubes. A method for manufacturing a heat exchanger comprising corrugated fins and a header tank body fixed to a header plate and forming a header plate together with the header plate, the method comprising: a flat tube fitted into the header tank body; Prepare a flat tube holder with a plurality of grooves, fit each flat tube into each groove with both ends protruding from the groove, and insert both ends of each flat tube into both header plates. Manufacture of a heat exchanger characterized by including a step of preparing a combination of a header plate and a flat tube in advance by inserting the header plate into a formed hole and fixing both header plates and both ends of each flat tube. Method.