[0001] The present invention relates to a heat exchanger having a pair of tanks and a heat
exchanger arranged between the tanks.
[0002] A conventional heat changer of this kind is disclosed in
Japanese Patent laid-open publication No. 2004 - 219027. The conventional heat exchanger is a condenser, which includes a pair of tanks and
a condenser core having a plurality of tubes and fins and arranged between the tanks.
One of the tanks is fixed at its top portion with an inlet connector for connecting
a pipe, and the other thereof is fixed at its bottom portion with an outlet connector
for connecting a pipe. Specifically, the tanks are formed with a communicating hole
and the connectors are formed with a connecting hole, so that they can be fluidically
communicated with each other.
[0003] The connectors are fixed to the tanks, respectively, by caulking and brazing as follows.
The tank and the connector are arranged so that the communicating hole and the connecting
hole are aligned with each other, and then a punch is press-fitted from a tank side
into the holes to form a burring portion of the tank and caulk the burring portion
on an inner surface of the connecting hole so as to temporarily fix them together.
The punch is drawn out from the holes, and then the temporarily fixed tank and connector
are placed with brazing filler metal in a heating furnace to be blazed. Incidentally,
in this blazing process, a temporarily assembled tanks and condenser core are also
blazed to integrally form a condenser.
[0004] The above known conventional condenser, however, encounters such the following problem.
The temporarily fixed burring portion of the tank and the inner surface of the connecting
hole of the connector cause looseness therebetween at times. In addition, looseness
also occurs at times between the burring portion of the tank and the inner surface
of the connector due to a thermal expansion difference therebetween in the blazing
process. The looseness causes undesirable fixing by blazing.
[0006] Recently, in order to simplify and downsize configurations of tank parts of a heat
exchanger and decrease the number of the tank parts, tanks are constructed by coupling
a tube plate and a tank plate with each other so as to contain at least two partition
plates therein, where the tube plate and the tank plate are shaped in a half-cylinder
and end portions of tubes of the heat exchanger core are inserted into and fixed to
the tube plate.
[0007] In the above-constructed tanks, the tube plate, the tank plate and the partition
plates are temporarily assembled with one another, and upper and lower mounting brackets
are inserted into and temporarily fixed to a top portion and a bottom portion of the
on-lapped, temporarily coupled, tube plate and tank plate, respectively. Then, the
entire temporarily-assembled tank is placed in a heat furnace to be integrally fixed
by blazing.
[0008] The above known conventional heat exchanger, however, encounters such the following
problem. The tube plate and the tank plate often become misaligned in a longitudinal
direction thereof from their proper positions in a temporary assembly process of the
on-lapped tube plate and tank plate and the mounting brackets and/or in a blazing
process thereof. This misalignment between the tube plate and the tank plate in the
above processes may be avoided by restricting their position with using a jig, which
increases its manufacturing processes to deteriorate its productivity rate.
[0009] It is, therefore, a first object of the present invention to provide a heat exchanger
which overcomes the foregoing drawbacks and can temporarily fix a tank and a connector
firmly with each other and blaze them with each other as intended.
[0010] It is, therefore, a second object of the present invention to provide a heat exchanger
which overcomes the foregoing drawbacks and can prevent misalignment between a tube
plate and a tank plate in a longitudinal direction thereof in a temporary assembly
process of the temporarily coupled tube plate and tank plate and a mounting bracket
and/or in a blazing process thereof without using a jig, thereby increasing its productivity
rate.
[0011] According to the first aspect of the present invention there is provided a heat exchanger
including a pair of tanks, at least one of the tanks being formed with a communicating
hole, a heat exchanger core arranged between the tanks and having a plurality of tubes
and fins where one end portions of the tubes are fluidically connected with one of
the tanks and the other end portions of the tubes are fluidically connected with the
other of the tanks, and a connector having a connecting hole that can fluidically
communicate with the communicating hole of the tank when the connector is fixed on
the tank. A peripheral portion of the communicating hole is pressed into the connecting
hole of the connector to form a burring portion which is caulked on an inner face
forming the connecting hole of the connector so that the connector and the tank are
temporarily fixed with each other, and facing portions of the tank and the connector
are integrally fixed with each other by blazing. The inner surface of the connecting
hole is formed with a holding groove to receive an inserted projecting portion formed
on a part of an outer surface of the burring portion for holding the connector to
the tank.
[0012] Therefore, the heat exchanger can temporarily fix the tank and the connector firmly
with each other, thereby blazing them with each other as intended.
[0013] Preferably, the holding groove has a vertical wall portion formed vertically to a
central axis of the connecting hole and a slope wall portion decreasing a depth of
the holding groove as a depth position of the slope wall portion goes away in an axial
direction of the connecting hole from the tank.
[0014] Therefore, the vertical wall portion ensures firm fixing of the tank and the connector,
and the slope wall portion also ensures the fixing by deforming the part of the burring
portion to form the inserted projecting portion, where it is deformed easily into
the bottom of the holding groove so as to be inserted into the bottom of the holding
groove along the vertical wall portion and extend along the slope wall portion the
axial direction of the connecting hole for increasing its axial strength.
[0015] Preferably, the facing portions of the tank and the connector are integrally fixed
with each other by blazing.
[0016] Therefore, the tank and the connector can be integrally fixed more firmly with each
other.
[0017] Preferably, the connector has an opening portion that is rimmed to have a slope surface
on an inner edge thereof to be contactable with a root portion of the burring portion.
[0018] Therefore, this can prevent concentration of stress in the root portion of the burring
portion when the burring portion is fixed into the connector.
[0019] According to the second aspect of the present invention there is provided a tank
structure of a heat exchanger including a pair of tanks, and a heat exchanger core
arranged between the tanks and having a plurality of tubes and fins whose one end
portions are fluidically connected with one of the tanks and the other end portions
are fluidically connected with the other of the tanks. The tanks includes a tube plate
connected wit the tubes, a tank plate and at least two partition plates, where the
tube plate, the tank plate and the partition plates are integrally fixed by blazing
after the tube plate and the tank plate are temporarily assembled with each other
to temporarily fix the partition plates between the tube plate and the tank plate.
At least one of the tube plate and the tank plate is formed to have a misalignment
preventing portion for preventing misalignment in a longitudinal direction of the
tube plate and the tank plate between the temporarily assembled tube plate and tank
plate.
[0020] Therefore, the heat exchanger can prevent misalignment between the tube plate and
the tank plate in the longitudinal direction thereof in a temporary assembly process
of the temporarily coupled tube plate and tank plate and the mounting bracket and/or
in a blazing process thereof without using a jig, thereby increasing its productivity
rate.
[0021] Preferably, the misalignment preventing portion is a first projecting portion formed
on an end portion of one of the tube plate and the tank plate by cutting off a part
of the end portion, and the first projecting portion is bent at an axial outer side
of an end portion of the other of the tube plate and the tank plate so that the first
projecting portion is contactable with the end portion of the other of the tube plate
and the tank plate.
[0022] Therefore, the misalignment preventing portion can be formed easily and at low manufacturing
costs by cutting-off and bending.
[0023] Preferably, the misalignment preventing portion is a second projecting portion formed
on an end portion of one of the tube plate and the tank plate, and the second projecting
portion is projected inwardly from an inner surface of the end portion at an axial
outer side of an end portion of the other of the tube plate and the tank plate to
be contactable with the end portion of the other of the tube plate and the tank plate.
[0024] Therefore, the misalignment preventing portion can be formed easily and at low manufacturing
costs by press-forming.
[0025] Preferably, the misalignment preventing portion is formed on the tube plate and the
tank plate to form at least one of a projecting portion, a depression and an opening
for fixing the partition plates so that a relative movement between the tube plate
and the tank plate in the longitudinal direction can be restricted by the partition
plates.
[0026] Therefore, the misalignment preventing portion can be formed easily and at low manufacturing
costs by press-forming for deforming and/or opening.
[0027] The objects, features and advantages of the present invention will become apparent
as the description proceeds when taken in conjunction with the accompanying drawings,
in which:
FIG. 1 is a front view showing a condenser, including a condenser core, a left tank
fixed with upper and lower connectors, and a right tank equipped with a receiver,
as a heat exchanger of a first embodiment according to the present invention;
FIG. 2 is an enlarged fragmentary cross-sectional front view showing the left tank
and the condenser core of the condenser shown in FIG. 1;
FIG. 3 is an expanded view showing the left tank and the upper and lower connectors
of the condenser shown in FIG. 1;
FIG. 4 is an expanded and enlarged fragmentary perspective view showing a top portion,
indicated by a circle A in FIG. 1, of the left tank and the upper connector, which
are shown in FIGS. 1 and 3;
FIG. 5 is an expanded and enlarged fragmentary perspective view showing an intermediate
portion, indicated by a circle B in FIG. 1, of the left tank shown in FIGS. 1 and
3;
FIG. 6 is an expanded and enlarged fragmentary perspective view showing a bottom portion,
indicated by a circle C, of the left tank and the lower connector, which are shown
in FIGS. 1 and 3;
FIG. 7 is an enlarged front view showing the lower connector shown in FIGS. 1, 3 and
6;
FIG. 8 is a plan view showing the lower connector shown in FIG 7;
FIG. 9 is a bottom plan view showing the lower connector shown in FIG 7;
FIG 10 is a right side view showing the lower connector shown in FIG. 7;
FIG. 11 is a left side view showing the lower connector shown in FIG. 7;
FIG 12 is a cross sectional view showing the lower connector shown in FIG 7, taken
along the line S12 - S12 in FIG. 8;
FIG. 13 is an enlarged cross sectional view showing a portion, indicated by a circle
D in FIG. 12, formed with a holding groove of the lower connector shown in FIG. 7;
FIG. 14 is a perspective view explaining how a tank plate of the left tank and the
lower connector are temporarily assembled with each other;
FIG. 15A is an enlarged fragmentary view showing a temporary assembly state before
a punch is inserted into a communicating hole of the tank plate and a connecting hole
of the lower connector where the communicating hole and the connecting hole are aligned
with each other, FIG. 15B is an enlarged fragmentary view showing the contemporary
assembly state where the punch is inserted into the communicating hole and the connecting
hole to caulk a burring portion of the tank plate and the lower connector on each
other, and FIG. 15C is an enlarged fragmentary view showing the temporary state after
the punch is drawn out from the communicating hole and the connecting hole;
FIG. 16 is a perspective view showing the temporary state where the upper connector
is temporarily fixed to the top portion of the temporarily assembled left tank;
FIG. 17 is a perspective view showing the temporary assembly state where the intermediate
portion of the left tank is temporarily assembled;
FIG. 18 is a perspective view showing the temporary state where the lower connector
is temporarily fixed to the bottom portion of the temporarily assembled left tank;
FIG. 19 is a perspective view explaining how an upper mounting bracket is temporarily
fixed to the top portion of the temporarily assembled left tank;
FIG. 20 is a perspective view explaining how a lower mounting bracket is temporarily
fixed to the bottom portion of the temporarily assembled left tank;
FIG. 21 is a perspective view showing the temporary state of the intermediate portion
of the left tank;
FIG. 22 is an expanded fragmentary perspective view showing a top end portion of a
left tank used in a heat exchanger of a second embodiment according to the present
invention;
FIG. 23 is a perspective view showing the top end portion of the left tank shown in
FIG. 22, where a tube plate and a tank plate, which are temporarily coupled, and an
upper mounting bracket are to be temporarily assembled;
FIG. 24 is a fragmentary cross-sectional front view showing a left tank and a condenser
core of a condenser which is a heat exchanger of a third embodiment according to the
present invention; and
FIG. 25 is fragmentary cross-sectional front view showing a left tank and a condenser
core of a condenser which is a heat exchanger of a fourth embodiment according to
the present invention.
[0028] Throughout the following detailed description, similar reference characters and numbers
refer to similar elements in all figures of the drawings.
[0029] A heat exchanger of an embodiment according to the present invention will be described
with reference to the accompanying drawings.
[0030] A condenser 100 of the first embodiment, as the heat exchanger of the present invention,
is used for an air conditioning system and mounted on a front portion of a not-shown
vehicle body of a motor vehicle. In this description, terms "left" and "right" are
used with respect to the vehicle body, not corresponding to those in the drawings.
[0031] As shown in FIG. 1, the condenser 100 includes a pair of tanks consisting of a left
tank 1 and a right tank 2 that are arranged apart from each other in a lateral direction
of the vehicle body and a condenser core 3 that is arranged between the left and right
tanks 1 and 2 for cooling refrigerant flowing therethrough. The condense core 3 acts
as a heat exchanger core of the present invention.
[0032] The condenser core 3 has a plurality of tubes 5 for flowing the refrigerant therethrough
from one of the left and right tanks 1 and 2 to the other thereof and corrugated fins
6 for radiating heat of the refrigerant flowing in the tubes 5, where the tubes 5
and the corrugated fins 6 are arranged alternately to each other in a vertical direction
of the condenser 100 and extend in a horizontal direction thereof. The tubes 5 are
fluidically connected with the left and right tanks 1 and 2 at their left and right
end portions. The condenser core 3 further has an upper reinforcement member 7a and
a lower reinforcement member 7b at its highest position and its lowest position, respectively,
their left and right end portions being fixed to the left and right tanks 1 and 2
for ensuring strength of the condenser 100.
[0033] The left and right tanks 1 and 2 are constructed almost similarly to each other and
arranged in directions opposite to each other.
[0034] The left tank 1 is fixed with a left upper mounting bracket T1 and a left lower mounting
bracket T2 at its top and bottom end portions, respectively. Similarly, the right
tank 2 is fixed with a right upper mounting bracket T3 and a right lower mounting
bracket T4 at its top and bottom end portions, respectively.
[0035] The left tank 1 is provided with an upper connector P1 and a lower connector P2 at
an upper portion and a lower portion thereof, respectively, for fluidically connecting
not-shown units, such as a compressor, and an evaporator, of the air conditioning
system via not-shown pipes. The right tank 2 is provided with a receiver 12 for gas-liquid
separating and temporarily storing excessive refrigerant to regulate a variation of
a circulating refrigerant amount, and the receiver 12 is fluidically connected with
the right tank 2 through a first connecting pipe 12a and a second connecting pipe
12b.
[0036] As shown in FIGS. 2 to 6, the left tank 1 is constructed by coupling a tube plate
8 and a tank plate, both of which are shaped in a half-cylinder, with each other to
form an interior space having a four-round-cornered rectangle shape in cross section.
The interior space of the left tank 1 is divided by four partition plates, consisting
of a first partition plate D1, a second partition plate D2, a third partition plate
D3 and a fourth partition plate D4, to define the interior space into three rooms,
a first room R1, a third room R3, and a sixth room R6 as shown in FIG. 1.
[0037] The right tank 2 is also constructed by coupling a tube plate and a tank plate, both
of which are shaped in a half-cylinder, with each other to form an interior space
having a four-round-cornered rectangle shape in cross section. The interior space
of the right tank 2 is divided by four partition plates, consisting of a fifth partition
plate D5, a sixth partition plate D6, a seventh partition plate D7 and an eighth partition
plate D8, to define the interior space into three rooms, a second room R2, a fourth
room R4, and a fifth room R5 as shown in FIG. 1.
[0038] The first and fifth partition plates D1 and D5 of the left and right tanks 1 and
2 are located in the same height and at a position higher than those of the other
partition plates. The second partition plate D2 of the left tank 1 is located higher
than the sixth partition plate D6 of the right tank 2, which is located higher than
the third partition plate D3 of the left tank 1. The third partition plate D3 of the
left tank 1 and the seventh partition plate D7 of the right tank 2 are located in
the same height and higher than the fourth partition plate D4 of the left tank 1 and
the eighth partition plate D8 of the right tank 2. The fourth partition plate D4 and
the eighth partition plate D8 are in the same height. Although the seventh partition
plate D7 and the third partition plate D3 are located in the same height, the fourth
room R4 is fluidically connected with the fifth room R5 through the first connecting
pipe 12a, the receiver 12 and the second connecting pipe 12b.
[0039] Accordingly, the refrigerant can flow in turn from the upper connector P1 through
the first room R1 of the left tank 1, the tubes 5 connecting the first room R1 and
the second room 2, the second room R2 of the right tank 2, the tubes 5 connecting
the second room R2 and the third room R3, the third room R3 of the left tank 1, the
tubes 5 connecting the third room R3 and the fourth room R4, the fourth room R4 of
the right tank 5, the first connecting pipe 12a, the receiver 12, the second connecting
pipe 12b, the fifth room R5 of the right tank 2, the pipes 5 connecting the fifth
room R5 and the sixth room R6, the sixth room R6 of the left tank 1 toward the lower
connector P2.
[0040] In order to fix the first to eighth partition plates D1 to D8 on the left and right
tanks 1 and 2, as shown in FIGS. 4 to 6, the tube plates 8 of the left and right tanks
1 and 2 are formed on their inner surfaces with four pairs of inwardly projecting
portions 8c for clamping one side portions of the first to fourth partition plates
D1 to D4 and the fifth to eighth partition plates D5 to D8, respectively, and the
tank plates 9 of the left and right tanks 1 and 2 are formed with four openings 9a
for receiving projecting portions 10 formed on the other side portions of the first
to fourth partition plates D1 to D4 and the fifth to eighth partition plates D5 to
D8, respectively. The inwardly projecting portions 8c are formed in a half-cylindrical
shape in this embodiment, but their configuration may be set arbitrarily. The inwardly
projecting portions 8c, the openings 9a, and the projecting portions 10 act as a misalignment
preventing portion of the present invention.
[0041] The tube plates 8 of the left and right tanks 1 and 2 are formed with a plurality
of tube-holes 4 so that the tube-holes 4 are inserted by the end portions the tubes
5 of the condenser cores 3 and receive them.
[0042] The upper portions and the lower portions of the tube plates 8 respectively have
a pair of cut-off portions 8a at their side walls to form a pair of first projecting
portions 8b projecting toward the tank plates 9. The first projecting portions 8b
act as the misalignment preventing portion of the present invention. The tube plates
8 are formed longer in its longitudinal direction than the tank plates 9 so that the
first projecting portions 8b can be located over or on top and bottom portions of
the tank plates 9 in the vertical direction when the tube plate 8 and the tank plate
9 are coupled with each other as shown in FIGS. 16 and 18. The intermediate portions
of the tube plates 8 are formed with eight pairs of cut-off portions 8d at their side
walls, two closing pairs thereof being apart from other two closing pairs in the vertical
direction, to form a pair of clawing portions 8e located between the two closing pairs
of the cut-off portions 8d and projecting toward the tank plates 9. Configuration,
positions and the number of the clawing portions 8e may be set arbitrarily.
[0043] The tank plate 9 of the left tank 1 is formed at its upper and lower portions with
upper and lower communicating holes 9c for fluidically communicating with connecting
holes 21, shown in FIGS. 11 and 12, of the upper and lower connectors P1 and P2, respectively.
The tank plate of the right tank 2 is formed at its intermediate portion with not-shown
upper and lower communicating holes for fluidically communicating with the first and
second connecting pipes 12a and 12b.
[0044] The left and right upper mounting brackets T1 and T3 and the left and right lower
mounting brackets T2 and T4 are used for fixing the condenser 100 to a vehicle side,
such as a not-shown radiator or a not-shown radiator core support member. As shown
in FIGS. 19 and 20, they are formed to have a disc portion 11a, a mounting portion
11b and a fixing portion 11c, where the mounting portions 11b are shaped in a cylindrical
column projecting from one-side surface of the disc portion 11 a in a direction opposite
to the left and right tanks 1 and 2, and the fixing portions 11c are shaped in a cylindrical
column projecting from the other-side surface of the disc portion 11 a in a direction
toward the left and right tanks 1 and 2. Configuration of the mounting brackets T1
to T4 may be set arbitrarily according to a structure fixing the condenser 100 to
the vehicle side.
[0045] The upper and lower connectors P1 and P2 are constructed similarly to each other,
and arranged in different directions as shown in FIGS. 4 and 6.
[0046] As shown in FIGS. 7 to 11, the lower connector P2 is shaped like a rectangular solid
to have a screw hole 20 and the connecting hole 21. The screw hole 20 is formed on
a side wall 19 to have a predetermined depth for connecting a not-shown vehicle-side
adapter, and the connecting hole 21 is formed in almost parallel to the screw hole
20 to pass through the lower connector P2 from the side wall 19 toward a tube-plate-side
side wall 22 for passing the refrigerant therethrough. The connecting hole 21 consists
of a large-diameter hole 21a, a small-diameter hole 21b, and a slope hole 21c connecting
the large-diameter hole 21 a and the small-diameter hole 21b as shown in FIGS. 11
and 12.
[0047] As shown in FIGS. 12 and 13, a holding groove 24 is provided on an inner surface
forming the small-diameter hole 21b at a position in close proximity of an opening
portion 23 thereof. The holding groove 24 is formed in a circular shape by a vertical
wall portion 24a and slope wall portion 24b, where the vertical wall portion 24a extends
vertically with respect to a central axis of the small-diameter hole 21b and the slope
wall portion 24b extends toward the large-diameter hole 21a, decreasing its depth
as a depth position of the slope wall portion 24b goes away from the tank plate 9
in the axial direction of the holding groove 24. The angle α of the slope wall portion
24b, defined by its slope surface and a vertical surface of the vertical wall portion
24a, is set to be approximately 60 degrees in this embodiment. The angle α, a depth
β of the vertical wall portion 24a and an axial length γ of the slope wall portion
24b, which are shown in FIG. 13, may be set arbitrarily.
[0048] Incidentally, the tube-plate-side side wall portion 22 of the lower connecter P2
is formed to have an arc surface fittable to an outer surface of the tank plate 9.
Configuration of the upper and lower connector P1 and P2 may be set arbitrarily according
to a fixing structure of a vehicle-side adapter, and profile of the connecting hole
21 is not limited to that of the embodiment in which it is bent in the embodiment.
[0049] All parts of the condenser 100, including the left and right tanks 1 and 2, the condenser
core 3, the upper and lower reinforcement members 7a and 7b, the receiver 12, the
first and second connecting pipes 12a and 12b, the mounting brackets T1 to T4 and
the upper and lower connectors P1 and P2, are made of aluminum. The condenser 100
is obtained by blazing connecting portions of the parts.
[0050] The condenser 100 of the first embodiment is manufactured as follows.
[0051] In order to build the left and right tanks 1 and 2, the lower connector P2 is brought
to contact with the tank plate 9 as shown in FIG. 14 so that the connecting hole 21
of the lower connecter P2 is aligned with the communicating hole 9c of the tank plate
9 as shown in FIG. 15A.
[0052] Then, as shown in FIG. 15B, a punch 26 is pressed into the communicating hole 9c
and the connecting hole 21 from the tank plate 9 side to deform a communicating-hole
peripheral portion of the tank plate 9 and form a burring portion 27 extending into
the connecting hole 21. This burring portion 27 is caulked to be temporarily fixed
on the inner surface of the connecting hole. In addition, a part of outer peripheral
portion of the burring portion 27 is press-fitted into the holding groove 24 of the
lower connector P2.
[0053] The temporary fixing of the tank plate 9 and the lower connector P2 by caulking is
maintained after the punch 26 is drawn out from the connecting hole 21 and the communicating
hole 9c as shown in FIG. 15C.
[0054] In this caulking process, root portion of the burring portion 27 can be formed to
contact with the opening portion 23 of the lower connector P2, since the opening portion
23 is rimmed to have a slope surface on an inner edge thereof. The part of the outer
peripheral portion of the burring portion 27 can be easily deformed and fit into the
holding groove 24, by being flown toward the vertical wall portion 24a, since the
slope wall portion 24b forces it to direct toward a bottom of the holding groove 24.
That is, the part of the burring portion 27 forms an inserted projecting portion 27a,
where it is inserted into the bottom of the holding groove 24 along the vertical wall
portion 24a and extends along the slope wall portion 24b in the axial direction for
increasing its axial strength.
[0055] The vertical wall portion 24a firmly holds the part of the outer peripheral portion
of the burring portion 27, improving their temporary fixing.
[0056] The upper connector P1 is temporarily fixed to the upper portion of the tank plate
9 similarly to the lower connector P2, and therefore its description is omitted.
[0057] Then, as shown in FIGS. 16, 17 and 18, the first to fourth partition plates D1 to
D4 are placed in the tank plate 9, with their projecting portions 10 being inserted
into the openings 9a of the tank plate 9. Then, the tube plate 8 is brought to face
and lap on the tank plate 9, and their side portions opposite to the projecting portions
10 are inserted between and held by the closing inwardly projecting portions 8c. The
tube plate 8 and the tank plate 9 are laid on each other, holding the first to fourth
partition plates D 1 to D4 therein. In this state where the tube plate 8 receives
the tank plate 9 therein, the first projecting portions 8b are positioned over or
on the top and bottom end portions of the tank plate 9 as shown in FIGS. 16 and 18.
[0058] The upper and lower first projecting portions 8b are bent inwardly to come closer
to or contact with the top and bottom end portions of the tank plate 9, respectively,
as shown in FIGS. 19 and 20.
[0059] The clawing portions 8e are bent inwardly to fix the tank plate 9 by caulking as
shown in FIGS. 19 to 21.
[0060] Then, the left upper and lower mounting brackets T1 and T2 are temporarily assembled,
being inserted between and temporarily fixed by the tube plate 8 and the tank plate
9 at the top and bottom end portions of the left tank 1 as shown in FIGS. 19 and 20.
[0061] The right tank 2 is temporarily assembled similarly to the left tank 1 in addition
to fixing the receiver 12 and the first and second connecting pipes 12a and 12b instead
of the upper and lower connectors P1 and P2, and therefore its description is omitted.
[0062] The tubes 5, the corrugated fins 6 and the upper and lower reinforcement members
7a and 7b are temporarily assembled with the left and right tanks 1 and 2. At least
one sides of the connecting portions of the condenser 100 are provided with cladding
layers, blazing sheets, made of blazing filler metal, and then this temporarily assembled
condenser 100 is fed to be placed in a heat furnace, where it is heated so that all
the connecting portions can be integrally fixed with each other by blazing.
[0063] Incidentally, temporary assembly of the condenser core 3, consisting of the tubes
5, the corrugated fins 6, and the upper and lower reinforcement members 7a and 7b,
and the left and right tanks 1 and 2 may be carried out in a proper process. In this
embodiment, outer surfaces of the both edge portions of at least the tank plate 9
are provided with cladding layers for fixing it to the tube plate 8 by blazing, and
outer surfaces of its intermediate portion are also provided with cladding layer for
fixing the upper and lower connectors P1 and P2 thereto by blazing. In addition, the
inner surfaces, facing the outer surface of the burring portion 27, of the connecting
holes 21 of the upper and lower connectors P1 and P2 may be provided with cladding
layers for fixing the burring portions 27 of the tank plate 9 thereto by blazing.
[0064] Note that relative movements between the tube plate 8 and the tank plate 9 in the
axial direction thereof are restricted by the first projecting portions 8b, and the
inwardly projecting portions 8c and the openings 9a both for receiving the partition
plates D1 to D8 in a temporary assembly process and in a blazing process.
[0065] After a blazing process, the condenser 100 is conveyed and attached on a not-shown
radiator core by fixing the mounting brackets T1 to T4 to not-shown radiator-core
connectors, and then they are mounted on the front portion of the vehicle body to
be connected with the vehicle-side units through the pipes.
[0066] The operation of the condenser 100 will be described hereinafter.
[0067] The first room R1 of the condenser 100 is fed with the refrigerant at approximately
70 °C through the connecting hole 21 of the upper connector P1 from a not-shown compressor.
The refrigerant in the first room R1 flows toward the second room R2 via the tubes
5 connecting between the first and second rooms R1 and R2, where it is cooled by heat
radiation through the corrugated fins 6 hit by air flow caused by vehicle-running
and/or a not-shown motor fan.
[0068] Then, the refrigerant in the second room R2 flows toward the third room R3 via the
tubes 5 connecting therebetween, where it is cooled similarly to that flowing between
the first and second rooms R1 and R2. The refrigerant in the third room R3 flows toward
the fourth room R4 via the tubes 5 connecting therebetween, being cooled similarly,
and the refrigerant in the fourth room R4 flows via the first connecting pipe 12a
to the receiver 12, where the refrigerant is separated into gas and liquid to be temporarily
stored for regulating a variation of the circulating refrigerant amount. The refrigerant
in the receiver 12 goes to the fifth room R5 via the second connecting pipe 12b, and
then flows toward the sixth room R6 via the tubes 5 connecting therebetween, being
cooled down to approximately 45 °C. This cooled refrigerant is discharged through
the connecting hole 21 of the lower connector P2 toward a not-shown evaporator.
[0069] The condenser 100 of the first embodiment has the following advantages.
[0070] The burring portions formed on the tank plates 9 are deformed so that its part can
be inserted in the holding grooves 24, formed on the inner surface forming the connecting
holes 21 of the upper and lower connectors P1 and P2. This provides temporarily and
firmly fixing thereof, thereby ensuring desirable and firm blazing.
[0071] The holding groove 24 is formed to have the vertical wall portion 24a and the slope
wall portion 24b decreasing its depth as the depth position of the slope wall portion
24b goes away from the tank plate 9 in the axial direction of the holding groove 24.
The vertical wall portion 24a ensures firm fixing of the tank plates 9 and the upper
and lower connectors P1 and P2, and the slope wall portion 24b also ensures the fixing
by deforming the part of the burring portion 27 to form the inserted projecting portion
27a, where it is deformed easily into the bottom of the holding groove 24 so as to
be inserted into the bottom of the holding groove 24 along the vertical wall portion
24a and extend along the slope wall portion 24b in the axial direction of the connecting
hole 21 for increasing its axial strength.
[0072] Next, a condenser of a second embodiment according to the present invention will
be described with reference to the accompanying drawings.
[0073] Referring to FIGS. 22 and 23, there is shown an upper portion of a left tank of the
condenser of the second embodiment.
[0074] The left tank includes a tube plate 20, a tank plate 9, a plurality of partition
plates (only a first partition plate D1 being illustrated in FIG. 22), an upper mounting
bracket T1 and a not-shown lower mounting bracket. The tube plate 20 is set longer
in a longitudinal direction thereof than the tank plate 9, and is formed with a pair
of second projecting portions 21 instead of the first projecting portions 8b of the
first embodiment. The second projecting portions 21 are formed by press-forming to
project inwardly from its inner surfaces at an upper and lower end portions of the
tube plate 20 so that the second projecting portions 21 is over or on top and bottom
end portions of the tank plate 9, restricting a relative movement between the tube
plate 20 and the tank plate 9 in the longitudinal direction. The second projecting
portions 21 has a half-cylinder shape, but their configurations are not limited to
this half-cylinder.
[0075] In addition, inwardly projecting portions 8c of the tube plate 20 and openings 9a
(only a first opening being illustrated in FIG. 22) receive one-side portions of the
partition plates and their projections 10, respectively, restricting the relative
movement between the tube plate 20 and the tank plate 9 in the longitudinal direction.
[0076] The right tank is constructed similarly to the left tank 1, and is arranged in directions
opposite to each other. The other parts of the condenser of the second embodiment
is similar to those of the first embodiment.
[0077] In this second embodiment, the second projecting portions 21, and the inwardly projecting
portions 8c and the openings 9a can be easily formed by press-forming. Therefore,
this condenser can improve its productivity rate easily and at low manufacturing costs.
[0078] Next, a condenser of a third embodiment according to the present invention will be
described with reference to the accompanying drawing.
[0079] Referring to FIG. 24, there is shown a part of a tank and a condenser core of the
condenser of the third embodiment.
[0080] A tube plate 8 is formed on its inner surfaces with inwardly projecting portions
30 instead of the pairs of the inwardly projecting portions 8c of the first embodiment
sandwiching the partition plates. The inwardly projecting portions 30 restrict the
adjacent partition plates D2 and D3 (or D6 and D7) at facing sides of the adjacent
partition plates. This structure of the inwardly projecting portions 30 is useful
when many partition plates are fixed on the tube plate 8 and a tank plate 9, since
the number of the inwardly projecting portions 30 can be decreased.
[0081] In this third embodiment, the inwardly projecting portions 30 and the openings 9a
can be easily formed by press-forming. Therefore, this condenser can be constructed
in a small dimensions and improve its productivity rate easily and at low manufacturing
costs.
[0082] Next, a condenser of a fourth embodiment according to the present invention will
be described with reference to the accompanying drawing.
[0083] As shown in FIG. 25, a tube plate 8 is formed on its inner surfaces with inwardly
projecting portions 31 instead of the pairs of the inwardly projecting portions 8c
of the first embodiment sandwiching the partition plates. The inwardly projecting
portions 31 restrict the adjacent partition plates D2 and D3 (or D6 and D7) at outer
sides of the adjacent partition plates. This structure of the inwardly projecting
portions 31 is useful when many partition plates are fixed on the tube plate 8 and
a tank plate 9, since the number of the inwardly projecting portions 31 can be decreased.
[0084] In the forth embodiment, the inwardly projecting portions 31 and the openings 9a
can be easily formed by press-forming. Therefore, this condenser can be constructed
in a small dimensions and improve its productivity rate easily and at low manufacturing
costs.
[0085] While there have been particularly shown and described with reference to preferred
embodiments thereof, it will be understood that various modifications may be made
therein.
[0086] For example, the holding groove 24 may be formed in a different shape, and may consist
of a plurality of holding grooves arranged in the axial direction.
[0087] The upper and lower connectors P1 and P2 may be located at the positions different
from those of the embodiment, for example, the upper connector P1 may be fixed on
one of the left and right tanks 1 and 2 and the lower connector P2 may be fixed on
the other thereof. Their configuration, including the holes thereof, may be formed
arbitrarily according to need.
[0088] The rooms of the left and right tanks 1 and 2 may be set arbitrarily.
[0089] The first projecting portions 8b, and the second projecting portion 21 may be set
arbitrarily in their configurations, their setting positions and/or their numbers.
In addition, they may be formed on the tank plate 9 instead of the tube plate 8.
[0090] The partition plates in the left and right tanks 1 and 2 may be set arbitrarily.
[0091] Instead of the inwardly projecting portions 8c, 30 or 31, depressions formed, by
outwardly projecting portions, may be formed to receive the partition plates.
[0092] Although the heat changer is the condenser 100 in the embodiments, the heat exchanger
may employ a radiator.
1. A heat exchanger (100) comprising:
a pair of tanks (1, 2), at least one of the tanks (1, 2) being formed with a communicating
hole (9c);
a heat exchanger core (3) arranged between the tanks (1, 2) and having a plurality
of tubes (5) and fins (6) where one end portions of the tubes (5) are fluidically
connected with one of the tanks (1; 2) and the other end portions of the tubes (5)
are fluidically connected with the other of the tanks (1, 2); and
a connector (P1; P2) having a connecting hole (21) that can fluidically communicate
with the communicating hole (9c) of the tank (9; 8) when the connector (P1; P2) is
fixed on the tank (9; 8), wherein
a peripheral portion of the communicating hole (9c) is pressed into the connecting
hole (21) of the connector (P1; P2) to form a burring portion (27) which is caulked
on an inner face forming the connecting hole (21) of the connector (P1; P2) so that
the connector (P1; P2) and the tank (1; 2) are temporarily fixed with each other,
and facing portions of the tank (1; 2) and the connector (P1; P2) are integrally fixed
with each other by blazing, wherein
the inner surface of the connecting hole (21) is provided with a holding groove (24)
to receive an inserted projecting portion (27a) formed on a part of an outer surface
of the burring portion (27) for holding the connector (P1; P2) to the tank (1; 2).
2. The heat exchanger (100) according to claim 1, wherein
the holding groove (24) has a vertical wall portion (24a) formed vertically to a central
axis of the connecting hole (21) and a slope wall portion (24b) decreasing a depth
of the holding groove (24) as a depth position of the slope wall portion (24b) goes
away in an axial direction of the connecting hole (21) from the tank (1; 2).
3. The heat exchanger (100) according to claim 1 or claim 2, wherein
the facing portions of the tank and the connector are integrally fixed with each other
by blazing.
4. The heat exchanger (100) according to any one of claims 1 to 3, wherein
the connector has an opening portion that is rimmed to have a slope surface on an
inner edge thereof to be contactable with a root portion of the burring portion.
5. A heat exchanger (100) comprising:
a pair of tanks (1,2); and
a heat exchanger core (3) arranged between the tanks (1, 2) and having a plurality
of tubes (5) and fins (6) whose one end portions are fluidically connected with one
of the tanks (1, 2) and the other end portions are fluidically connected with the
other of the tanks (1,2), wherein
the tanks (1, 2) include a tube plate (8) connected with the tubes (5), a tank plate
(9) and at least two partition plates (D1, D2, D3, D4, D5, D6, D7, D8) where the tube
plate (8; 20), the tank plate (9) and the partition plates (D1, D2, D3, D4, D5, D6,
D7, D8) are integrally fixed by blazing after the tube plate (8; 20) and the tank
plate (9) are temporarily assembled with each other to temporarily fix the partition
plates (D1, D2, D3, D4, D5, D6, D7, D8) between the tube plate (8; 20) and the tank
plate (9), wherein
at least one of the tube plate (8; 20) and the tank plate (9) is formed to have a
misalignment preventing portion (8b; 21; 8c, 9a, 10; 30, 1Q; 31; 10) for preventing
misalignment in a longitudinal direction of the tube plate (8; 20) and the tank plate
(9) between the temporarily assembled tube plate (8; 20) and tank plate (9).
6. The heat exchanger (100) according to claim 5, wherein
the misalignment preventing portion (8b) is a first projecting portion (8b) formed
on an end portion of one of the tube plate (8) and the tank plate (9) by cutting off
a part of the end portion, and the first projecting portion (8b) is bent at an axial
outer side of an end portion of the other of the tube plate (8) and the tank plate
(9) so that the first projecting portion (8b) is contactable with the end portion
of the other of the tube plate (8) and the tank plate (9).
7. The heat exchanger (100) according to claim 5, wherein
the misalignment preventing portion (21) is a second projecting portion formed on
an end portion of one of the tube plate (20) and the tank plate (9), and the second
projecting portion (21) is projected inwardly from an inner surface of the end portion
at an axial outer side of an end portion of the other of the tube plate (20) and tank
plate (9) to be contactable with the end portion of the other of the tube plate (20)
and the tank plate (9).
8. The heat exchanger (100) according to claim 5, wherein
the misalignment preventing portion (8c, 9c; 30, 9c; 30, 9c) is formed on the tube
plate and the tank plate to form at least one of a projecting portion (8c; 30; 31),
a depression and an opening (9c) for fixing the partition plates (D1, D2, D3, D4,
D5, D6, D7, D8) so that a relative movement between the tube plate (8) and the tank
plates (9) in the longitudinal direction can be restricted by the partition plates(D1,
D2, D3, D4, D5, D6, D7, D8).