HEAT EXCHANGER AND HEAT EXCHANGER MANUFACTURING METHOD
20220120503 · 2022-04-21
Inventors
Cpc classification
F28F9/0221
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D7/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D1/0316
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F1/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F1/022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F9/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F9/0224
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F2260/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F28D7/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The present disclosure relates to a heat exchanger. The heat exchanger includes: a tube panel module elongated in an up-down direction and including a plurality of first tube panels and second tube panels that are alternately arranged in a left-right direction; header panel modules respectively formed at an upper end and a lower end of the tube panel module and elongated in a left-right direction; and a header case having an open one side, providing a space therein, and covered on the one side by the cover module such that the first tube panels and the second tube panels communicate with the space, in which the first tube panel is formed by bonding a first panel and a second panel, the second tube panel is formed by bonding a third panel and a fourth panel, and the header panel module includes: a first header panel formed by bending both ends of the first panel and the second panel in opposite directions; and a second header panel formed by bending both ends of the third panel and the fourth panel in opposite directions and bonded to the first header panel between every first tube panel and second tube panel. Accordingly, it is possible to increase the efficiency of manufacturing a heat exchanger, manufacture a heat exchanger flexibly in a custom-made type in accordance with the size of a product having the heat exchanger, reduce tolerance due to brazing, and improve stability of a product.
Claims
1. A heat exchanger comprising: a tube panel module elongated in an up-down direction and including a plurality of first tube panels and second tube panels that are alternately arranged in a left-right direction; header panel modules respectively formed at an upper end and a lower end of the tube panel module and elongated in a left-right direction; and a header case having an open one side, providing a space therein, and covered on the one side by the cover module such that the first tube panels and the second tube panels communicate with the space, wherein the first tube panel is formed by bonding a first panel and a second panel, the second tube panel is formed by bonding a third panel and a fourth panel, and the header panel module includes: a first header panel formed by bending both ends of the first panel and the second panel in opposite directions; and a second header panel formed by bending both ends of the third panel and the fourth panel in opposite directions and bonded to the first header panel between every first tube panel and second tube panel.
2. The heat exchanger of claim 1, wherein the first header panel is disposed perpendicular to the first tube panel, and the second header panel is disposed perpendicular to the second tube panel.
3. The heat exchanger of claim 1, wherein the first header panel has first flat portions and first recessions that are alternately formed, the second header panel has second flat portions and second recessions that are alternately formed, and the first flat portion and the second flat portion are in contact with each other, and the first recession and the second recession are in contact with each other at a portion where the first header panel and the second header panel are bonded.
4. The heat exchanger of claim 1, wherein the first header panel is formed by bending both ends of the first panel and the second panel that are flat, and the second header panel is formed by bending both ends of the third panel and the fourth panel that are flat.
5. The heat exchanger of claim 4, wherein the first tube panel and the second tube panel each have a channel through which a refrigerant flows, and the channels are exposed to the outside of the first tube panel and the second tube panel by punching the first header panel and the second header panel.
6. The heat exchanger of claim 1, wherein the first header panel is formed by inserting a jig between both ends of the first panel and the second panel and then opening the ends to both sides, and the second header panel is formed by inserting a jig between both ends of the third panel and the fourth panel and then opening the ends to both sides.
7. The heat exchanger of claim 1, wherein the plurality of first header panels are disposed in the same plane, and the plurality of second header panels are disposed in the same plane and bonded to tops of the first header panels.
8. The heat exchanger of claim 1, wherein when portions positioned at a left end and a right end of the header panel module and protruding left and right from the tube panel module are defined as insertion panels, the header case further includes first insertion grooves that are recessed on a left side and a right side of the header case to face the space and in which the insertion panels are inserted.
9. The heat exchanger of claim 8, wherein the first insertion grooves are elongated rearward from a front end of the header case and guide insertion of the insertion panels, and a front surface of the header case is formed lower than a height of the first insertion grooves and the header panel module moves over a top of the front surface.
10. The heat exchanger of claim 9, wherein the header case includes a cap block inserted in the first insertion grooves and being in contact with the header panel module and the front surface of the header case.
11. The heat exchanger of claim 10, wherein a rear surface of the header case and the cap block include a second insertion groove that is recessed to face the space and in which the header panel module and a portion of the tube panel module are inserted.
12. The heat exchanger of claim 11, wherein the second insertion groove includes: a plurality of tube panel grooves that are elongated in the up-down direction and are arranged in the left-right direction and in which the plurality of tube panels are inserted; and a header panel groove that is elongated in the left-right direction and in which the header panel module is inserted.
13. A method of manufacturing a heat exchanger, the method comprising: forming a plurality of tube panels by bonding a pair of panels; forming a plurality of header panels by bending ends of the plurality of tube panels; forming a header panel module by overlapping the plurality of header panels; inserting the header panel module in an open one side of a header case; and brazing contact portions between the plurality of header panels and the header case.
14. The method of claim 13, wherein the forming of a plurality of header panels bends ends of the pair of panels in opposite directions.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0102] The advantages and features of the present disclosure, and methods of achieving them will be clear by referring to the exemplary embodiments that will be described hereafter in detail with reference to the accompanying drawings. However, the present disclosure is not limited to the exemplary embodiments described hereafter and may be implemented in various ways, and the exemplary embodiments are provided to complete the description of the present disclosure and let those skilled in the art completely know the scope of the present disclosure and the present disclosure is defined by claims. Like reference numerals indicate like components throughout the specification.
[0103] Spatial relative terms “below”, “beneath”, “lower”, “above”, “upper”, etc. may be used to easily describe the correlation of one component and another component, as shown in the drawings. The spatially relative terms should be construed as terminologies including different directions of components in using or in operating in addition to the directions shown in drawings. For example, when components shown in the drawings are turned upside down, a component described as being “below” or “beneath” another component may be positioned “over” the another component. Accordingly, “below” and “beneath” that are exemplary terms may include both of up and down directions. A component may be oriented in different directions, so the spatially relative terms may be construed in accordance with orientation.
[0104] The terms used herein are provided to describe embodiments without limiting the present disclosure. In the specification, a singular form includes a plural form unless specifically stated in the sentences. The terms “comprise” and/or “comprising” used herein do not exclude that another component, step, and/or operation exist or are added in the stated component, step, and/or operation.
[0105] Unless defined otherwise, all terms (including technological and scientific terminologies) used herein may be used as meanings that those skilled in the art can commonly understand. Terms defined in common dictionaries are not construed ideally or excessively unless specifically clearly defined.
[0106] The thickness or size of components is exaggerated, omitted, or schematically shown in the drawings for convenience and clarity of description. The size or area of components does not generally reflect the actual size or area.
[0107] Hereinafter, the present disclosure will be described with reference to the drawings illustrating a heat exchanger according to exemplary embodiments of the present disclosure.
[0108] Hereafter, directions are defined for a heat exchanger according to an embodiment of the present disclosure and components thereof on the basis of the coordinate system shown in
[0109] The directions in which the x-axis extends may be defined as up and down directions. The direction in which the +x-axis extends from the origin may be the up direction and the direction in which the −x-axis extends from the origin may be the down direction. The directions in which the y-axis extends may be defined as front and rear directions. The direction in which the +y-axis extends from the origin may be the front direction and the direction in which the −y-axis extends from the origin may be the rear direction. The directions in which the z-axis extends may be defined as left and right directions. The direction in which the +z-axis extends may be the right direction and the direction in which the −z-axis extends may be the left direction.
[0110] Referring to
[0111] The heat exchanger according to the present disclosure includes a header H. The header H may be provided in a pair and may be coupled to both ends of the tube panel 10. The header H may be elongated to a side. A plurality of tube panels 10 may be spaced apart from each other and arranged in the longitudinal direction of the header H. The header H may be formed by combining a header case 30 and a header panel module 200 (see
[0112] A refrigerant can flow into any one of the pair of headers H. The refrigerant flowing inside can pass through the channels 101 of the tube panel 10. The refrigerant that has passed through the channels 101 can flow into the other one of the pair of headers H and then can be discharged out of the heat exchanger. Air can exchange heat with the refrigerant while passing through between a plurality of tube panels 10.
[0113] Referring to
[0114] The tube panel 10 may be formed by bonding a first panel 11 and a second panel 12 to each other. The first panel 11 may be composed of a plurality of flat portions and a plurality of recessions that is convex on a side. The second panel 12, similar to the first panel, may be composed of a plurality of flat portions and a plurality of recessions that is convex on another side. The flat portions and the recessions may be elongated in the up-down direction.
[0115] The first panel 11 and the second panel 12 may have the same shape. The first panel 11 and the second panel 12 may have the same shape and may be turned over 180 degrees and bonded to each other.
[0116] A plurality of fins 102 and tubes 102 may be formed by bonding the first panel 11 and the second panel 12 to each other. The fins 102 may be formed by bonding the flat portions of the first panel 11 and the flat portions of the second panel 12. The plurality of tubes may be formed by disposing the recessions of the first panel 11 and the recessions of the second panel 12 to be convex in opposite directions. Channels 101 may be formed in the tubes 102.
[0117] The header panels 20 may be formed by bending both ends of the tube panel 10. The header panels 20 may be formed by bending both ends of the first panel 11 and the second panel 12 in opposite directions. The first panel 11 and the second panel 12 may be bent perpendicular to the tube panel 10. The header panels 20 each may be divided into a header panel portion 21 formed by bending an end of the first panel 11 and a header panel portion 22 formed by bending an end of the second panel 12.
[0118] The first panel 11 and the second panel 12 may be made of metal such as stainless steel, copper, and aluminum. The header panel 20 may be formed by inserting a jig between both ends of the first panel 11 and the second panel 12 and then opening the ends to both sides. The properties of the first panel 11 and the second panel 12 may be adjusted through heat treatment before the first panel 11 and the second panel 12 are opened by a jig.
[0119] When the header panels 20 are formed, the channels 101 of the tube panel 10 are formed through the header panels 20 and may be exposed to the outside of the tube panel 10.
[0120] The header panels 20 are formed by bending both ends of the first panel 11 and the second panel 12, whereby they may have a plurality of flat portions 202 and recessions 203 alternately arranged.
[0121] A tube panel 10′ according to another embodiment of the present disclosure is described hereafter with reference to
[0122] Both ends of the tube panel 10′ according to an embodiment of the present disclosure may be formed flat. Both ends of the tube panel 10′ may be formed by flattening after heat treatment. Both ends of the tube panel 10′ may be formed by bonding a first panel 11′ and a second panel 12′ of which both ends are flat.
[0123] Header panels 20′ may be formed by bending both ends of the tube panel 10′. The header panels 20′ may be formed by bending both ends of the first panel 11′ and the second panel 12′ in opposite directions. The first panel 11′ and the second panel 12′ may be bent perpendicular to the tube panel 10′.
[0124] The first panel 11′ and the second panel 12′ may be made of metal such as stainless steel, copper, and aluminum. The header panel 20′ may be formed by inserting a jig between both ends of the first panel 11′ and the second panel 12′ and then opening the ends to both sides. The properties of the first panel 11′ and the second panel 12′ may be adjusted through heat treatment before the first panel 11′ and the second panel 12′ are opened by a jig.
[0125] The header panels 20′ may be formed flat. When the header panels 20′ are formed by bending the first panel 11′ and the second panel 12′, channels 101′ formed at the tube panel 10 may not be exposed to the outside by the header panels 20′ (see
[0126] Referring to
[0127] The first tube panel 10a may be formed by bonding a first panel 11a and a second panel 12a. The second tube panel 10b may be formed by bonding a third panel 11b and a fourth panel 12b. The first panel 11a and the second panel 12a are the same as the first panel 11 and the second panel 12 described above, so they are not described. The third panel 11b and the fourth panel 12b are the same as the first panel 11 and the second panel 12 described above, so they are not described.
[0128] The header panels 20 may be divided into first header panels 20a formed at both ends of the first tube panel 10a and second header panels 20b formed at both ends of the second tube panel 10b. The first header panels 20a may be formed by bending both ends of the first panel 11a and the second panel 12a in opposite directions. The second header panel 20b may be formed by bending both ends of the third panel 11b and the fourth panel 12b in opposite directions. The first header panel 20a and the second header panel 20b may have the same shape.
[0129] The first header panel 20a and the second header panel 20b may be overlapped and bonded to each other. The first header panel 20a and the second header panel 20b may be overlapped and bonded between every first tube panel 10a and second tube panel 10.
[0130] A plurality of first tube panels 10a may be spaced apart from each other in parallel with each other. A plurality of first header panels 20a formed at the plurality of first tube panels 10a may be disposed in the same plane. The plurality of first header panels 20a may be spaced apart from each other.
[0131] A plurality of first tube panels 10a may be spaced apart from each other in parallel with each other. A plurality of second header panels 20b may be disposed in the same plane. The plurality of second header panels 20b may be spaced apart from each other. The first header panels 20a and the second header panels 20b may be formed in parallel with each other.
[0132] The first tube panel 10a and the second tube panel 10b may be alternately arranged and may be disposed in parallel to face each other. The second header panel 20b may be bonded to the top of the first header panel 20a. The first header panel 20a and the second header panel 20b may be alternately disposed and may overlap each other between the first tube panel 10a and the second tube panel 10.
[0133] The first header panel 20a may be spaced apart from the channels 101 (
[0134] The other first header panels 20a except for the outermost first header panel 20a of the plurality of first header panels 20a may be bonded to two second header panels 20b. The other second header panels 20b except for the outermost second header panel 20b of the plurality of second header panels 20b may be bonded to two first header panels 20a.
[0135] Although only the tube panel 10 and the header panel 20 according to an embodiment of the present disclosure were described above, the configuration may also be applied to the tube panel 10′ and the header panel 20′ according to another embodiment of the present disclosure.
[0136] Referring to
[0137] The first flat portion 202a and the second flat portion 202b may be bonded to each other at the portion where the first header panel 20a and the second header panel 20b are bonded. The first recession 203a and the second recession 230b may be in contact with each other at the portion where the first header panel 20a and the second header panel 20b are bonded.
[0138] The second flat portion 202b may be bonded to the top of the first flat portion 202a. The second recession 203b may be bonded to the top of the first recession 203a. The first recession 203a may be inserted under the second recession 203b.
[0139] Referring to
[0140] A refrigerant may flow into the header case 30 or may be discharged from the header case 30. The heat exchanger may include a pair of header cases 30. A refrigerant flowing in any one of the pair of header cases 30 may be discharged outside through the other one of the pair of header cases 30.
[0141] A tube panel module 100 may be composed of a plurality of tube panels 10 disposed in parallel. The tube panel module 100 may include a plurality of first tube panels 10a and second tube panels 10b.
[0142] A header panel module 200 may be formed at the upper end and the lower end of the tube panel module 100. The header panel module 200 may be elongated in the left-right direction. The header panel module 200 may be disposed perpendicular to the tube panel module 100.
[0143] The header panel module 200 may be composed of a plurality of header panels 20 overlapping each other. The header panel module 200 may include a first header panel 20a and a second header panel 20b.
[0144] The header panel module 200 is inserted in one side of the header case 200, thereby being able to cover the open one side of the header case 30. When the header panel module 200 covers the one side of the header case 200, the channels 101 formed in the tube panels 10 can communicate with the space 31 of the header case 30.
[0145] The portions positioned at the left end and the right end of the header panel module 200 and protruding left and right from the tube panel module 100 may be defined as insertion panels 201. The insertion panels 201, which are a part of the header panel 20, may be portions that do not overlapping other header panel 20.
[0146] A first insertion groove 321 may be formed on both sides 32 of the header case 30. That is, the first insertion groove 321 may be formed on the left side 32 and the right side 32 of the header case 30. The first insertion grooves 32 may be recessed on both sides 32 of the header case 30 to face the space 31 of the header case 30. The first insertion grooves 32 may have a shape elongated in the front-rear direction.
[0147] The insertion panels 201 may be inserted and coupled in the first insertion grooves 321. When the insertion panels 201 are inserted in the first insertion grooves 321, the header panel module 200 can cover the open one side of the case 30.
[0148] Referring to
[0149] The front surface 34 of the header case 30 may be formed lower than the height of the first insertion grooves 321. Accordingly, when the insertion panels 201 are inserted into the front ends of the first insertion grooves 321 and then guided rearward, the header panel module 200 can move over the top of the front surface 34.
[0150] The header case 30 may include a cap block 342 disposed on the front surface 34 of the header case. The cap block 342 may face the space 31 of the header case 30. The cap block 342 may be positioned in the same plane as the front surface 34 of the header case 30. The cap block 342 can cover the front of the header case 30 in cooperation with the front surface 34.
[0151] The cap block 342 may be inserted in the front ends of the first insertion grooves 321. After the insertion panels 201 are inserted in the first insertion grooves 321, the cap block 342 may be inserted into the front ends of the first insertion grooves 321. The cap block 342 may come in contact with the header module panel 200 inserted in the first insertion grooves 321 and the front surface 34 of the header case.
[0152] The cap block 342 may have protrusions 341 having a shape corresponding to the first insertion groove 321. The protrusions 341 may be formed in a pair at both sides of the cap block 342 and inserted in the first insertion grooves 321.
[0153] Referring to
[0154] The second insertion groove 331 may include a plurality of tube panel grooves 331a and header panel grooves 331b. The tube panel grooves 331a may have a shape corresponding to the tube panel 10. The tube panel grooves 331a may be elongated in the up-down direction. The tube panel grooves 331a may be formed in the same number as the tube panels 10 and may be arranged in the left-right direction. The plurality of tube panels 10 may be inserted in the plurality of tube panel grooves 331a.
[0155] The header panel grooves 331b may have a shape corresponding to the header panel module 200. The header panel grooves 331b may be elongated in the left-right direction. The header panel module 200 may be inserted in the header panel grooves 331b. The plurality of tube panel grooves 331a and header panel grooves 331b may be continuously formed.
[0156] The second insertion groove 331 may be formed in a pair on the rear and front of the header case 30. For example, the second insertion groove 331 may be formed on the front surface 34 of the header case 30. The second insertion groove 331 may be recessed on the inner side of the front surface 34 to face the space 31. Alternatively, the second insertion groove 331 may be formed at the cap block 342. The second insertion groove 331 may be recessed on the cap block 342 to face the space 31.
[0157] Referring to
[0158] For example, as described above, the first tube panel 10a may be formed by bonding a first panel 11a and a second panel 12a. The second tube panel 10b may be formed by bonding a third panel 11b and the second panel 12b.
[0159] The method of manufacturing a heat exchanger may include a step X2 of forming a header panel 20. In the step X2, the header panel 20 may be formed by bending both ends of the tube panel 10.
[0160] For example, the first header panel 20a may be formed by bending both ends of the first panel 11a and the second panel 12a of the first tube panel 10a in opposite directions. The second header panel 20b may be formed by bending both ends of the third panel 11b and the fourth panel 12b of the second tube panel 10b in opposite directions.
[0161] The first header panel 20a may be formed by inserting a jig between both ends of the first panel 11 a and the second panel 12a and then opening the ends to both sides. The second header panel 20b may be formed by inserting a jig between both ends of the third panel 11b and the fourth panel 12b and then opening the ends to both sides. Properties of both ends of the panels may be adjusted through heat treatment before the panels are opened by a jig.
[0162] The step X2 may further include a step of making both ends of the tube panel 10 flat through flattening after heat treatment. In this case, a step of exposing channels 101 to the outside of the tube panel 10 by punching the header panel 20 at positions corresponding to the channels 101 after forming the header panel 20 may be further included.
[0163] The method of manufacturing a heat exchanger may include a step X3 of overlapping a plurality of header panels 20.
[0164] In the step X3, the plurality of tube panels 10 may be arranged, and a plurality of first tube panels 10a and a plurality of second tube panels 10b may be arranged in parallel to face each other. The plurality of first tube panels 10a and the plurality of second tube panels 10b may be alternately arranged.
[0165] The second header panel 20b may be brought in contact with the first header panel 20b. The second header panel 20b and the first header panel 20a may be in contact with each other between the first and second tube panels 10 and 10b. The second header panel 20b may be disposed on the first header panel 20a.
[0166] A component formed by combining the plurality of tube panels 10 may be referred to as a tube panel module 100. A component formed by combining the plurality of overlapping header panels 20 may be referred to as a header panel module 200.
[0167] The method of manufacturing a heat exchanger may include a step X4 of inserting the header panel module 200 in a header case 30. The header panel module 200 can cover an open one side of the header case 30 by being inserted in the header case 30. This was described above, so it is not described here.
[0168] The method of manufacturing a heat exchanger may include a brazing step X5. In the step X5, the contact portions between the plurality of header panels 20 and the header case 30 may be brazed.
[0169] In a step before the brazing step X5, a filter material may be applied to all of the portions where the components of the heat exchanger are in contact with each other. In the step X5, it is possible to bond the components in a brazing type by selectively melting only the filler material by applying high-temperature heat to the heat exchanger and then cooling it. The heat exchanger may be put and brazed in a high-temperature furnace.
[0170] The steps X1 to X5 may be sequentially performed.
[0171] Although exemplary embodiments of the present disclosure were illustrated and described above, the present disclosure is not limited to the specific exemplary embodiments and may be modified in various ways by those skilled in the art without departing from the scope of the present disclosure described in claims, and the modified examples should not be construed independently from the spirit of the scope of the present disclosure.