Parallel Flow Type Heat Exchanger

Abstract

A heat exchanger is provided and includes a plurality of tubes with refrigerant passages inside of them and a pair of header tanks to which end parts of the tubes are brazed. Brazing materials, which are used for brazing to the header tanks, are arranged at the outer circumferential surfaces of the tubes. Base materials of the metal sheet members which form the header tanks are exposed at the inner circumferential surfaces and outer circumferential surfaces of the header tanks.

Claims

1. A heat exchanger which has a plurality of tubes which is provided with refrigerant passages inside them and a pair of header tanks to which end parts of the tubes are brazed, wherein brazing materials which are used for brazing to the header tanks are arranged at the outer circumferential surfaces of the tubes, and base materials of the metal sheet members which form the header tanks are exposed at the inner circumferential surfaces and outer circumferential surfaces of the header tanks.

2. The heat exchanger according to claim 1 wherein said header tanks have header plates to which said tubes are brazed and tank plates which are assembled to said header plates and wherein the base materials of the metal sheet members which form said header plates are exposed.

3. The heat exchanger according to claim 1 wherein said header tanks have an entry side header tank into which refrigerant flows and an exit side header tank from which refrigerant flows and wherein at least one of said entry side header tank or said exit side header tank is provided inside it with separators at the two surfaces of which the base materials of the metal sheet members which form said separators are exposed.

4. The heat exchanger according to claim 1 wherein said tubes are provided inside them with inner fins which have wavy shapes, in each said tube, a belt-shaped sheet member is folded back to form a curved end part and give different lengths to the two end parts, the folded back sheet member is formed with parallel parts, said two end parts are bent near them to form slanted parts, then are bent so that said two end parts become parallel, and a long end part of said two end parts is folded back to the short end part side and swaged, then is joined to the swaged part, whereby a flat shape is formed, and each said inner fin is brazed to the inside wall surface of said tube at the bent parts of the wavy parts and is formed at one end with a flat plate part which is sandwiched between the end parts of a said belt-shaped sheet member at said swaged part to be joined with said tube.

5. The heat exchanger according to claim 1 wherein said plurality of tubes are provided at their outsides with outer fins for dissipating heat.

6. The heat exchanger according to claim 1 wherein the brazing material which is arranged at the outer circumferential surfaces of said tubes has an amount of Si of 3.5 wt % to 10 wt %.

7. The heat exchanger according to claim 1 wherein the brazing material which is arranged at the outer circumferential surfaces of said tubes has an amount of Si of 3.5 wt % to 7.5 wt %.

8. The heat exchanger according to claim 1 wherein said header tanks are provided with pipes which are comprised of header plates to which said tubes are brazed and tank plates which are attached to said header plates joined together and wherein the base materials of the metal sheet members which form said pipes are exposed.

9. The heat exchanger according to claim 1 wherein said header tanks are provided with pipes which are comprised of header plates to which said tubes are brazed and tank plates which are attached to said header plates joined together and wherein at least one of the inner circumferential surfaces and outer circumferential surfaces of metal sheet members which forms pipes are provided with anticorrosion layers of sacrificial materials with low potentials.

10. The heat exchanger according to claim 1 wherein said header tanks have an entry side header tank into which refrigerant flows and an exit side header tank from which refrigerant flows and wherein at least one of said entry side header tank or said exit side header tank is provided inside it with separators at least at one surface of which a brazing material is provided.

11. The heat exchanger according to claim 8 wherein said pipes have cross-sectional shapes of any of circular shapes, oval shapes, and irregular shapes.

12. The heat exchanger according to claim 2 wherein said header tanks have an entry side header tank into which refrigerant flows and an exit side header tank from which refrigerant flows and wherein at least one of said entry side header tank or said exit side header tank is provided inside it with separators at the two surfaces of which the base materials of the metal sheet members which form said separators are exposed.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0020] FIG. 1 is a front view which shows the streamlined configuration of a heat exchanger of the comparative art.

[0021] FIG. 2 is a perspective view which shows an inner fin tube which is used at the heat exchanger which is shown in FIG. 1.

[0022] FIG. 3 is a partial perspective view of a heat exchanger which shows the state where inner fin tubes which are shown in FIG. 2 are connected to a header plate of a header tank of the heat exchanger which is shown in FIG. 1.

[0023] FIG. 4 is a cross-sectional view of the header tank which is shown in FIG. 3 as seen from an arrow L direction.

[0024] FIG. 5 is a partial perspective view which shows the state where the brazing material of the tank plate flows into the header plate through a separator and the brazing material flows into an inner fin tube.

[0025] FIG. 6 is a partial enlarged cross-sectional view which shows a swaged part of an inner fin tube which is normally brazed.

[0026] FIG. 7 is a partial enlarged cross-sectional view which shows the state where tube melting occurs at the swaged part of the inner fin tube which is shown in FIG. 6.

[0027] FIG. 8 is a cross-sectional view which shows another example of an inner fin tube.

[0028] FIG. 9 is a partial enlarged cross-sectional view which shows the state where tube melting occurs at the swaged part of the inner fin tube which is shown in FIG. 8.

[0029] FIG. 10 is a cross-sectional view of an inner fin tube of a first embodiment of the present invention.

[0030] FIG. 11 is a partial enlarged cross-sectional view which shows a part of a swaged part of the inner fin tube of FIG. 10.

[0031] FIG. 12A is a cross-sectional view of a brazing material-free header plate and tank plate which are used for an inner fin tube and heat exchanger of the first embodiment of the present invention, FIG. 12B is a cross-sectional view of a modification of the first embodiment where there is a sacrificial material at the outside of the header plate of the brazing material-free header plate and tank plate which are shown in FIG. 12A, FIG. 12C is a partial perspective view of a heat exchanger which shows an embodiment of providing a brazing material at one surface of a separator of an entry side and exit side header tank which is provided with a brazing material-free header plate and tank plate, FIG. 12D is a cross-sectional view of an embodiment where the entry side and exit side header tanks are one-piece bodies and have cross-sections of circular shapes, FIG. 12E is a cross-sectional view of an embodiment where the entry side and exit side header tanks are one-piece bodies and have cross-sections of oval shapes, FIG. 12F is a cross-sectional view of an embodiment where the entry side and exit side header tanks are one-piece bodies and have cross-sections of irregular shapes, and FIG. 12G is an enlarged view of a principal part X of FIG. 12B.

[0032] FIG. 13 is an assembled perspective view of a header plate and a brazing material-free separator which is used for the same which shows a second embodiment of the present invention.

[0033] FIG. 14 is an assembled perspective view of a header plate and a brazing material-free separator which is used for the same which shows a modification of the second embodiment of the present invention.

[0034] FIG. 15 is a side cross-sectional view and front view of a first specific example of a separator of a third embodiment of the present invention.

[0035] FIG. 16 is a side cross-sectional view and front view of a second specific example of a separator of a third embodiment of the present invention.

[0036] FIG. 17 is a front view of a third specific example of a separator of a third embodiment of the present invention.

[0037] FIG. 18 is a front view of a fourth specific example of a separator of a third embodiment of the present invention.

[0038] FIG. 19 is a front view of a fifth specific example of a separator of a third embodiment of the present invention.

[0039] FIG. 20 is a front view of a sixth specific example of a separator of a third embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

[0040] Below, referring to the drawings, embodiments of the present invention will be explained. In the embodiments, parts which are configured the same are assigned the same reference notations and explanations will be omitted. Parts of the embodiments of the present invention which are the same in configuration as the comparative art forming the basis of the present invention are assigned the same reference notations and explanations are omitted.

[0041] FIG. 10 shows an inner fin tube 10 of a first embodiment of the present invention. Further, FIG. 11 shows a part X of FIG. 10 enlarged. An inner fin tube 10 is comprised of a belt-shaped sheet member which is folded back to hold an inner fin 12 inside of it. The belt-shaped sheet member is formed by thin (for example thickness 0.2 mm) aluminum. It is folded back into an arc shape at a portion at slightly different distances from the two end parts to form a curved end part 11a. The belt-shaped sheet member is folded back until becoming parallel to form parallel parts 11p. The two end parts of the belt-shaped sheet member are bent at portions of the same distance from the curved end part 11a to form predetermined lengths of slanted parts 11c, then are further bent so that the two end parts become parallel.

[0042] The belt-shaped sheet member is folded back as explained above to form the flat tube 11. At the inside, an inner fin 12 is housed whereby a flat shaped flow path of the medium is formed. The inner fin 12 is formed into a wave shape by rolling a thin (for example thickness 0.1 mm) aluminum belt-shaped sheet member in the same way as the tube 11. At the two end parts, flat plate parts 15 and 16 are provided. The bent parts 14 of the wave shaped parts of the inner fin 12 are brazed to the inside wall surface 13 of the tube 11. The end part of the flat plate part 16 is also brazed to the inside wall surface 13 of the curved end part 11a. On the other hand, the end part of the other flat plate part 15 of the inner fin 12 is sandwiched between the two end parts bent to become parallel.

[0043] The two end parts 11e and 11f of the belt-shaped sheet member which sandwich the flat plate part 15 of the inner fin 12 in the first embodiment become longer at the end part 11e than the end part 11f. Accordingly, the end part 11e is folded back to the end part 11f side in a state sandwiching the flat plate part 15 and the end part 11f and is swaged to join them whereby the swaged part 11b is formed. In the first embodiment, a brazing material 8 is arranged (clad) at the outer surface as a whole at the thus formed inner fin tube 10. The amount of this brazing material 8 becomes an amount which is required for brazing the inner fin tube 10 to the entry side and exit side header tanks 3 and 4 when inserting and brazing the two end parts of the inner fin tube 10, as shown in FIG. 3, to the entry side and exit side header tanks 3 and 4.

[0044] In this case, the inner circumferential surfaces N and outer circumferential surfaces S of the header plates 31 and 41 which form the entry side header tank 3 and the exit side header tank 4, as shown in FIG. 12A, are made brazing material-free. That is, the metal sheet members which form the header plates 31 and 41 are made sheet members with the base material exposed (bare materials) and can be made single layer members with no brazing material. By this configuration, the brazing material which is used when joining the inner fin tube 10 to the entry side and exit side header tanks 3 and 4 is supplied from the sufficient amount of brazing material 8 which was clad at the outer surface of the inner fin tube 10 (see FIG. 10 and FIG. 11). The brazing material is not present at the tank plates 32 and 42, so the brazing material no longer flows from the tank plates 32 and 42 to the inner fin tube 10 and the tube melting of the inner fin tube 10 no longer occurs. As a result, the stability at the time of brazing the inner fin tube 10 is improved and the scope of application of the brazing temperature can be broadened.

[0045] As explained above, the brazing material which flows to the inside of the inner fin tube 10 is a sufficient amount of brazing material 8 which is clad over the entire outer surface of the inner fin tube 10. For this reason, the amount of the brazing material which is supplied to the brazing part of the inner fin tube 10 becomes sufficient, and the brazing fillet of the inner fin tube 10 can be made larger. Further, a fillet commensurate with the amount of brazing material of the part itself is formed and the brazeability of parts other than the inner fin tube 10 is also improved.

[0046] Here, consider the case of the comparative art where the brazing material which is at the entry side and exit side header tanks 3 and 4 flows into the inner fin tube 10 and where the brazing material which is at the entry side and exit side header tanks 3 and 4 and the brazing material of the inner fin tube 10 are connected. In this case, the size of the fillet radius of the fillet which is formed at the inner fin 12 and the size of the fillet radius which is formed at the tank plate 32 and header plate 31 become substantially equal. However, in this case, the amounts of brazing material at the entry side and exit side header tanks 3 and 4 are small, so the size of the fillet radius of the tank plate 32 and header plate 31 ends up becoming the same 0.1 mm or so as the fillet radius of the fillet which is formed at the inner fin 12. That is, sometimes the size of the fillet radius which is formed at the tank plate 32 and the header plate 31 is extremely small and the gap at the part requiring brazing cannot be filled resulting in leakage.

[0047] As opposed to this, if making the inner circumferential surfaces N and outer circumferential surfaces S of the header plates 31 and 41 brazing material-free, the connection of the brazing material of the fillet which is formed between the tank plate 32 and header plate 31 and the brazing material of the fillet 52 or 53 which is formed at the inner fin 12 can be broken. As a result, it is possible to form a large fillet at the joint of the tank plate 32 and header plate 31 or the joint of the tank plate 32 and a cap 24. That is, it is possible to form a large fillet of the fillet radius 0.3 mm to 0.6 mm or so which can inherently be obtained at the joint of the tank plate 32 and header plate 31 or the joint of the tank plate 32 and a cap 24, the gap can be easily filled, and the brazeability can be improved. Note that, the size of the fillet radius which is referred to here envisions the case of using the generally widely used brazing material with 10 wt % of amount of Si.

[0048] Further, the surface of the inner fin tube 10 sometimes has an anticorrosion layer or sacrificial brazing material on which the brazing material layer is superposed arranged on it, but by making the header plates 31 and 41 brazing material-free, it is possible to prevent the inflow of brazing material from the entry side and the exit side header tanks 3 and 4, so the flow of brazing material to the surface of the inner fin tube 10 is also prevented. The brazing material ends up obstructing the action of the anticorrosion layer, so by preventing the flow of brazing material to the surface of the inner fin tube 10, it is possible to improve the corrosion resistance of the inner fin tube 10.

[0049] Further, it is possible to use as the material of the header plates 31 and 41 a metal material which does not contain a brazing material and provide the inner circumferential surfaces N or outer circumferential surfaces S of the header plates 31 and 41 with a low potential anticorrosion layer constituted by a sacrificial material. FIG. 12B shows an embodiment which provides the outer circumferential surfaces S of the header plates 31 and 41 with a sacrificial material (anticorrosion layer) 9. In this case, as shown in FIG. 12G, as the header plates 31 and 41, the surfaces of the metal sheet members (for example, comprised of aluminum alloy etc.) at the inner circumferential surface N sides may be made states with the base materials 311 and 411 exposed and the surfaces of the metal sheet members at the outer circumferential surface S sides of the header plates 31 and 41 may be made states with the surfaces of the base materials 311 and 411 clad by the sacrificial material 9. Furthermore, as shown in FIG. 12C, the header plates 31 and 41 are made brazing material-free, but one or both surfaces of the separators 26 may be provided with the brazing material 8. In FIG. 12C, the brazing material 8 are shown shaded.

[0050] Still further, the inner circumferential surfaces N and outer circumferential surfaces S of the entry side and exit side header tanks 3 and 4 may be made brazing material-free even in the case where the entry side and exit side header tanks 3 and 4 are single-piece pipes 30 not split into header plates 31 and 41 and tank plates 32 and 42. Further, the single-piece pipes 30 which are used for the entry side and exit side header tanks 3 and 4 are effective regardless of their cross-sectional shapes such as the circular shape which is shown in FIG. 12D, the oval shape which is shown in FIG. 12E, and the irregular shape which is shown in FIG. 12F. Further, even when the entry side and exit side header tanks 3 and 4 are formed by single-piece pipes 30, the materials which form the tanks may be exposed single layer types and may be provided at least at one of the inner circumferential surfaces N and outer circumferential surfaces S of the pipes 30 with a low potential sacrificial material (anticorrosion layer) 9. In the entry side and exit side header tanks 3 and 4 which are shown from FIG. 12D to FIG. 12F, the inner circumferential surface N of the pipe 30 which is shown in FIG. 12E is provided with the sacrificial material 9, while the outer circumferential surface S of the pipe 30 which is shown in FIG. 12F is provided with the sacrificial material 9.

[0051] Note that, in the entry side and exit side header tanks 3 and 4 which are shown from FIG. 12D to FIG. 12F as well, the outer circumferential surface S of the pipe 30 which is shown in FIG. 12E may be provided with the sacrificial material and the inner circumferential surface N of the pipe 30 which is shown in FIG. 12F may be provided with the sacrificial material 9 needless to say. Whether the sacrificial material 9 is provided at the inner circumferential surface N of the pipe 30 or is provided at the outer circumferential surface S does not depend on the shape and structure of the pipe 30. Further, both of the inner circumferential surface N and the outer circumferential surface S of the pipe 30 may be provided with the sacrificial material 9.

[0052] FIG. 13 shows a second embodiment of the heat exchanger of the present invention. In the second embodiment, the entry side header plate 31 and the exit side header plate 41 are made brazing material-free, and the separator 26 which is attached as a partition wall at the inside of the entry side header tank 3 and the exit side header tank 4 is made brazing material-free. The separator 26 of the second embodiment is used in the case of a structure where the header plates 31 and 41 have holes 33 and 43 (hole 33 at entry side header tank 3 and hole 43 at exit side header tank 4). That is, the metal sheet member which forms the separator 26 is made the exposed sheet member (bare material) where no brazing material is provided.

[0053] In the case of this arrangement, the header plates 31 and 41 and the separator 26 are brazing material-free, but brazing material which is arranged at the tank plates 32 and 42 is supplied, whereby the header plates 31 and 41 and the separator 26 can be brazed. Tank brazing material flows through the fine clearances between the separator 26 and header plates 31 and 41 whereby these are brazed together. In this case, as the brazing material of the tank plates 32 and 42, a brazing material with an amount of Si of 6 wt % or more is suitable.

[0054] FIG. 14 shows a modification of the separator 26 of the second embodiment of the present invention which is shown in FIG. 13. The separator 26 of the modification is used in the case of a structure with grooves 34 and 44 at the two sides of the header plates 31 and 41 (groove 34 at entry side header tank 3 and groove 44 at exit side header tank 4). In the modification of the second embodiment as well, the metal sheet member which forms the separator 26 is made the exposed sheet member (bare material) where no brazing material is provided. Further, in the modification of the second embodiment, the holes at the header plates 31 and 41 at the joining sides with the inner fin tubes are eliminated, and grooves 34 and 44 are provided for attachment of the separator 26 at the two sides of the header plates 31 and 41. For this reason, the flow paths of inflow of the brazing material from the outsides of the header plates 31 and 41 are cut.

[0055] If, in this way, making the metal sheet member which forms the separator 26 a sheet member with the base material exposed and not providing a brazing material, that is, making it brazing material-free, it is possible to cut the flow paths of brazing material to the header plates 31 and 41 resulting in a further reduction in the occurrence of tube melting.

[0056] FIG. 15 to FIG. 17 show the configurations of separators 26 of a third embodiment of the heat exchanger of the present invention. The figures give cross-sectional views and front views of separator 26. The third embodiment provides the two surfaces of the separator 26 with structures for holding the brazing material in the case where the two surfaces of the entry side header tank 3 or exit side header tank 4 are provided with brazing material and thereby prevents the inflow of the brazing material to the inner fin tubes 10.

[0057] FIG. 15 shows a first specific example of the separator 26. A separator 26 of the same type as the separator 26 which was explained in FIG. 13 is shown. In the first specific example of the separator 26, the two surfaces of the separator 26 are provided with a plurality of parallel grooves 27. FIG. 16 shows a second specific example of the separator 26. A separator 26 of the same type as the separator 26 which was explained in FIG. 13 is shown. In the second specific example of the separator 26, the two surfaces of the separator 26 are provided with a plurality of circular depressions 28 which are regularly arranged to the top and bottom and the left and right. These depressions 28 serve as brazing reservoirs in which melted brazing material is held. The depressions 28 may also be provided irregularly arranged. FIG. 17 shows a third specific example of the separator 26. A separator 26 of the same type as the separator 26 which was explained in FIG. 13 is shown. In the third specific example of the separator 26, the two surfaces of the separator 26 are provided with a plurality of oval depressions 29 which are regularly arranged to the top and bottom and the left and right. Oval depressions 29 may also be provided irregularly arranged.

[0058] If in this way providing the two surfaces of the separator 26 with grooves or holes, even if the two surfaces of the entry side header tank 3 and the exit side header tank 4 are provided with brazing material, the excess brazing material can be held at the grooves or holes and flow of excess brazing material to the header plate side can be prevented. As a result, excess brazing material no longer flows into the inner fin tubes and tube melting can be prevented.

[0059] FIG. 18 to FIG. 20 show fourth to sixth specific examples of the separator 26 of the third embodiment of the heat exchanger of the present invention. In the fourth specific example which is shown in FIG. 18, the two surfaces of the separator 26 are provided at a slant with grooves 35 which cut the brazing material flow paths. The grooves 35 are provided at the separator 26 asymmetrically. The grooves 35 may also be ribs. In the fifth specific example which is shown in FIG. 19, the two surfaces of the separator 26 are provided with grooves 36 which cut the brazing material flow path at an angle symmetrically with respect to the centerline of the separator 26. The grooves 36 may also be ribs. In the sixth specific example which is shown in FIG. 20, the two surfaces of the separator 26 are provided with not only the grooves 36 which were explained in the fifth example, but also ribs 37 which cut the brazing material flow paths at an angle symmetrically with respect to the centerline of the separator 26. The ribs 37 may also be grooves.

[0060] The brazing material which causes tube melting flows to an inner fin tube through a brazing part of a separator 26 and an inside of a tank. Therefore, as shown in the first to the sixth specific examples, by providing the two surfaces of the separator 26 with grooves 36 or ribs 37, it is possible to reduce or delay the amount of brazing material which flows from the inside of the tank through the separator 26 to the inner fin tube. That is, the grooves 36 or ribs 37 which are provided at the two surfaces of the separator 26 can extend the flow paths from the inside of the tank to the inner fin tube and can increase the time it takes for the brazing material to reach the inner fin tube due to the large flow resistance of the brazing material. As a result, it is possible to reduce the temperature difference from the core part before the brazing material reaches the inner fin tube, so tube melting is reduced.

[0061] In the embodiments which were explained above, the type and thickness of the brazing material which was actually used was a brazing material with a 4 wt % to 5 wt % amount of Si and with a clad rate of 20% (since the sheet thickness t was 0.2 mm, the film thickness was 40 m). However, in the present invention, as the brazing material which is clad at the tube surface, a usually used 10 wt % brazing material is also possible. The invention is effective even for a tube provided with a clad rate 10% (film thickness 20 m) or so brazing material. That is, the invention is effective even for a tube with an amount of Si of the brazing material 8 at the tube surface of 3.5 wt % to 10 wt %. However, the amount of the brazing material at the tube surface is preferably 3.5 wt % to 7.5 wt %.

[0062] As explained above, in the present invention, there is provided a heat exchanger which employs tubes which were produced by sheet bending wherein the brazing materials which are required at the time of brazing the tubes are supplied from the outer circumferential surfaces of the tubes, so tube melting at the time of brazing the tubes to the header tanks is prevented and the productivity of the heat exchanger is improved. Further, by making the separators which are provided at the inside of the header tanks brazing material-free or by providing the separators with structures for holding the brazing materials, tube melting at the time of brazing the tubes to the header tanks is prevented. Further, by combining the above-mentioned first to third embodiments, it is possible to further reduce the tube melting at the time of brazing the tubes to the header tanks.

[0063] Note that, in the above-mentioned embodiments, examples of using tubes with inner fins at their insides as the tubes which were brazed to the header plates were explained, but it is also possible to use tubes in which no inner fins are arranged. In particular, if the tubes which are brazed to the header plates are tubes of structures comprised of sheet members which are folded back and are superposed at their two end parts, the brazing materials are sucked in at the superposed parts due to the capillary phenomenon, so the brazing materials easily pool near the superposed parts, but it is possible to prevent tube melting by application of the present invention.

[0064] Further, in the above-mentioned embodiments, the example of use of aluminum as the material of the inner fin tubes and inner fins was explained, but in all of the above embodiments, it is possible to use aluminum alloy as the material of the inner fin tubes and inner fins.