TECHNICAL FIELD
[0001] The present invention relates to a heat exchanger including a heat-transfer-tube
unit.
BACKGROUND ART
[0002] Some of heat exchangers intended for air conditioners and the like include heat-transfer-tube
units each formed as a single member including heat transfer tubes for refrigerant
to flow therein and fins for heat exchange. A heat exchanger disclosed by PTL 1 (Japanese
Unexamined Patent Application Publication No.
2013-139965) includes a plurality of such heat-transfer-tube units. The plurality of heat-transfer-tube
units are connected to a shared header. The connection is simplified by dividing the
header into many layers. The heat exchanger is manufactured by alternately stacking
the divided header layers and the heat-transfer-tube units. Then, the stack of the
divided header layers and the heat-transfer-tube units is brazed in a furnace so that
leakage of refrigerant from joints between the divided header layers is prevented.
SUMMARY OF THE INVENTION
<Technical Problem>
[0003] The heat exchanger configured as above with many divided header layers has an increased
number of components. Therefore, the process of manufacturing the heat exchanger is
complicated.
[0004] An object of the present invention is to provide a heat exchanger that is easy to
manufacture.
<Solution to Problem>
[0005] A heat exchanger according to a first aspect of the present invention includes a
heat-transfer-tube unit and a header. The heat-transfer-tube unit includes at least
one fin and a plurality of heat transfer tubes. The heat-transfer-tube unit is connected
to the header. The fin and the heat transfer tubes are arranged alternately side by
side. The plurality of heat transfer tubes each extend in a heat-transfer-tube-extending
direction. The fin has sides extending in the heat-transfer-tube-extending direction
and that are joined to the heat transfer tubes. An end of the fin is positioned nearer
to a center of the heat-transfer-tube unit in the heat-transfer-tube-extending direction
than ends of the heat transfer tubes. The header has holes for insertion of the ends
of the heat transfer tubes.
[0006] In such a configuration, the ends of the heat transfer tubes project from the end
of the fin. Therefore, the heat exchanger can be manufactured easily by inserting
the projecting portions of the heat transfer tubes into the holes in the header.
[0007] A heat exchanger according to a second aspect of the present invention is the heat
exchanger according to the first aspect, in which the header includes a first header
and a second header between which the heat-transfer-tube unit is held.
[0008] In such a configuration, the two ends of the heat-transfer-tube unit are fixed to
the respective headers. Therefore, the heat exchanger exhibits improved durability
against external forces and impacts.
[0009] A heat exchanger according to a third aspect of the present invention is the heat
exchanger according to the second aspect, in which the second header is positioned
below the first header. The second header has a heat-transfer-tube-unit-connecting
surface inclined with respect to a heat-transfer-tube-spacing direction.
[0010] In such a configuration, the heat-transfer-tube-unit-connecting surface of the second
header is inclined. Accordingly, dew condensation water running down the heat-transfer-tube
unit and reaching the heat-transfer-tube-unit-connecting surface further runs down
the second header because of the inclination. Therefore, the heat exchanger exhibits
improved drainability.
[0011] A heat exchanger according to a fourth aspect of the present invention is the heat
exchanger according to any of the first to third aspects, in which the header is a
circular pipe.
[0012] In such a configuration, since the header is a circular pipe, the header is easy
to manufacture. Therefore, the heat exchanger can be manufactured more easily.
[0013] A heat exchanger according to a fifth aspect of the present invention is the heat
exchanger according to any of the first to fourth aspects, in which the end of the
fin is shaped in conformity with a shape of the header in such a manner as to be in
contact with the header with the ends of the heat transfer tubes being in the holes.
[0014] In such a configuration, the end of the fin is in contact with the header. Therefore,
the heat-transfer-tube unit and the header are connected to each other with improved
strength.
[0015] A heat exchanger according to a sixth aspect of the present invention is the heat
exchanger according to any of the first to fourth aspects, in which the end of the
fin is spaced apart from the header.
[0016] In such a configuration, the occurrence of a phenomenon in which brazing metal moves
into a space between the fins by capillarity can be suppressed.
[0017] A heat exchanger according to a seventh aspect of the present invention is the heat
exchanger according to the fifth aspect, in which the heat-transfer-tube unit includes
stoppers. The stoppers are provided on the heat transfer tubes and between the ends
of the heat transfer tubes and the end of the fin. The stoppers are each shaped in
such a manner as not to be allowed to pass through the holes in the header.
[0018] In such a configuration, the occurrence of the phenomenon in which the brazing metal
moves into the space between the fins by capillarity can be suppressed further.
[0019] A heat exchanger according to an eighth aspect of the present invention is the heat
exchanger according to any of the first to seventh aspects, in which the heat-transfer-tube
unit is a single member.
[0020] In such a configuration, the heat-transfer-tube unit is a single member. Therefore,
the heat-transfer-tube unit is easy to handle. Accordingly, the heat exchanger is
easy to assemble.
[0021] A heat exchanger manufacturing method according to a ninth aspect of the present
invention includes forming a heat-transfer-tube unit including a fin and heat transfer
tubes; providing a cutout by removing a portion of the fin such that an end of the
fin is positioned nearer to a center of the heat-transfer-tube unit in a heat-transfer-tube-extending
direction than ends of the heat transfer tubes; providing holes in a header, the holes
being provided for insertion of the ends of the heat transfer tubes; inserting the
ends of the heat transfer tubes into the respective holes; and brazing the heat-transfer-tube
unit and the header to each other.
[0022] In such a method, since the cutout is provided by removing a portion of the fin,
the ends of the heat transfer tubes project from the end of the fin. Therefore, the
heat exchanger can be manufactured easily by inserting the projecting portions of
the heat transfer tubes into the holes in the header.
[0023] A heat exchanger manufacturing method according to a tenth aspect of the present
invention is the method according to the ninth aspect, in which the forming the heat-transfer-tube
unit includes integrally forming the fin and the heat transfer tubes from a metal
material by extrusion molding.
[0024] In such a method, the heat-transfer-tube unit is formed as a single member from a
metal material by extrusion molding. Therefore, the heat-transfer-tube unit is easy
to handle. Accordingly, the heat exchanger is easy to assemble.
[0025] A heat exchanger manufacturing method according to an eleventh aspect of the present
invention is the method according to the ninth or tenth aspect, in which a plurality
of portions of the fin are punched off in the providing the cutout.
[0026] In such a method, the plurality of portions are removed by punching. Therefore, the
heat exchanger is manufactured efficiently.
[0027] A heat exchanger manufacturing method according to a twelfth aspect of the present
invention is the method according to any of the ninth to eleventh aspects, in which
the holes are provided by drilling in the providing the holes.
[0028] In such a method, the holes in the header are provided simply by using a drill. Therefore,
the heat exchanger is manufactured more easily.
<Advantageous Effects of Invention>
[0029] The first, fourth, and eighth aspects of the present invention each provide a heat
exchanger that can be manufactured easily.
[0030] The second aspect of the present invention provides a heat exchanger that exhibits
improved durability against external forces and impacts.
[0031] The third aspect of the present invention provides a heat exchanger that exhibits
improved drainability.
[0032] The fifth aspect of the present invention provides a heat exchanger in which the
heat-transfer-tube unit and the header are connected to each other with improved strength.
[0033] The sixth and seventh aspects of the present invention each provide a heat exchanger
in which the occurrence of a phenomenon in which brazing metal moves into a space
between the fins by capillarity can be suppressed.
[0034] The ninth to twelfth aspects of the present invention each provide a heat-exchanger-manufacturing
method by which a heat exchanger can be manufactured easily.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035]
[Fig. 1] Fig. 1 is a diagram illustrating an outline of a heat exchanger 10 according
to a first embodiment of the present invention.
[Fig. 2] Fig. 2 is a diagram illustrating an outline of a heat-transfer-tube unit
30.
[Fig. 3] Fig. 3 is a sectional view of the heat-transfer-tube unit 30.
[Fig. 4] Fig. 4 is a sectional view of part of the heat exchanger 10.
[Fig. 5] Fig. 5 is a sectional view of part of a heat exchanger 10' according to a
first modification of the first embodiment of the present invention.
[Fig. 6] Fig. 6 is a sectional view of part of a heat exchanger 10" according to a
second modification of the first embodiment of the present invention.
[Fig. 7] Fig. 7 is a sectional view of part of a heat exchanger 10A according to a
second embodiment of the present invention.
[Fig. 8] Fig. 8 is a sectional view of part of a heat exchanger 10B according to a
third embodiment of the present invention.
[Fig. 9] Fig. 9 is a sectional view of part of a heat exchanger 10C according to a
fourth embodiment of the present invention.
[Fig. 10] Fig. 10 is a diagram illustrating an outline of a heat exchanger 10D according
to a fifth embodiment of the present invention.
[Fig. 11] Fig. 11 is a diagram illustrating an outline of a heat-transfer-tube unit
30.
DESCRIPTION OF EMBODIMENTS
<First Embodiment>
(1) Overall Configuration
[0036] Fig. 1 illustrates a heat exchanger 10 according to a first embodiment of the present
invention. The heat exchanger 10 is provided for heat exchange between refrigerant
and air and is to be included in, for example, an air conditioner. The heat exchanger
10 includes a first pipe 41, a second pipe 42, a first header 21, a second header
22, and a heat-transfer-tube-unit group 39. The heat-transfer-tube-unit group 39 includes
a plurality of heat-transfer-tube units 30.
(2) Configurations of Relevant Elements
(2-1) Headers and Pipes
[0037] The first pipe 41 and the second pipe 42 are provided for refrigerant to flow therethrough.
The first pipe 41 and the second pipe 42 each serve as an inlet and an outlet for
the refrigerant, which can be in any of different forms such as gas, liquid, and a
gas-liquid two-phase form. The first pipe 41 is connected to the first header 21 so
as to supply and receive the refrigerant to and from the first header 21. The second
pipe 42 is connected to the second header 22 so as to supply and receive the refrigerant
to and from the second header 22. The first header 21 and the second header 22 are
each a hollow member and have respective heat-transfer-tube-unit-connecting surfaces
23. The first header 21 and the second header 22 are arranged such that the respective
heat-transfer-tube-unit-connecting surfaces 23 face each other or substantially face
each other. In the present embodiment, the second header 22 is positioned below the
first header 21.
(2-2) Heat-Transfer-Tube Unit
[0038] The plurality of heat-transfer-tube units 30 included in the heat-transfer-tube-unit
group 39 are arranged side by side at intervals in a heat-transfer-tube-unit-arranging
direction x. Each of the heat-transfer-tube units 30 is connected to the first header
21 and to the second header at the respective heat-transfer-tube-unit-connecting surfaces
23.
[0039] Fig. 2 illustrates one of the heat-transfer-tube units 30. The heat-transfer-tube
unit 30 includes a plurality of heat transfer tubes 31 and a plurality of fins 32.
The number of heat transfer tubes 31 included in the heat-transfer-tube unit 30 is,
for example, six or greater but is not limited thereto.
[0040] The heat transfer tubes 31 are provided for moving the refrigerant between the first
header 21 and the second header 22. Two ends of each of the heat transfer tubes 31
are connected to the heat-transfer-tube-unit-connecting surfaces 23 of the first header
21 and the second header 22, respectively. The heat transfer tube 31 includes at least
a portion extending in a heat-transfer-tube-extending direction z and preferably has
a linear shape. The plurality of heat transfer tubes 31 are arranged side by side
in a heat-transfer-tube-spacing direction y.
[0041] The fins 32 are provided for heat exchange between the refrigerant flowing in adjacent
ones of the heat transfer tubes 31 and ambient air. The fins 32 are each provided
between adjacent two of the heat transfer tubes 31. Additional fins 32 may be provided
on the outer side of outermost ones, respectively, of the heat transfer tubes 31 included
in the heat-transfer-tube unit 30. The fins 32 each have sides extending in the heat-transfer-tube-extending
direction z, and the sides are joined to corresponding ones of the heat transfer tubes
31. The fins 32 and the heat transfer tubes 31 are arranged alternately side by side
in the heat-transfer-tube-spacing direction y. A fan or the like, not illustrated,
causes air to flow in a direction parallel to a y-z plane. The direction of the airflow
may be the heat-transfer-tube-spacing direction y.
[0042] The heat-transfer-tube-unit-arranging direction x, the heat-transfer-tube-spacing
direction y, and the heat-transfer-tube-extending direction z intersect one another.
The heat-transfer-tube-unit-arranging direction x, the heat-transfer-tube-spacing
direction y, and the heat-transfer-tube-extending direction z may be perpendicular
to one another. The heat-transfer-tube-unit-arranging direction x and the heat-transfer-tube-spacing
direction y may each be a horizontal direction, and the heat-transfer-tube-extending
direction z may be a vertical direction.
[0043] Fig. 3 illustrates a section of the heat-transfer-tube unit 30. The heat transfer
tubes 31 each have an inside diameter D of, for example, 1.5 mm or smaller, and preferably
0.8 mm or smaller. The fins 32 each have a thickness T of, for example, 0.3 mm or
smaller, preferably 0.2 mm or smaller, and more preferably 0.1 mm or smaller.
(3) Connection between Heat-Transfer-Tube Unit and Header
[0044] As illustrated in Fig. 2, the heat-transfer-tube unit 30 has cutouts 33 at ends thereof
in the fins 32. The presence of the cutouts 33 makes ends 32e of the fins 32 be positioned
nearer to the center of the heat-transfer-tube unit 30 in the heat-transfer-tube-extending
direction z than ends 31e of the heat transfer tubes 31.
[0045] Fig. 4 is a sectional view of the heat exchanger 10. The second header 22 has holes
24 for insertion of the ends 31e of the heat transfer tubes 31. The ends 32e of the
fins 32 are shaped in conformity with the shape of the second header 22 in such a
manner as to be in contact with at least the heat-transfer-tube-unit-connecting surface
23 of the second header 22 with the ends 31e of the heat transfer tubes 31 being in
the holes 24. The points of contact are fixed by brazing or the like, whereby the
path for the refrigerant is sealed.
[0046] While Fig. 4 illustrates the second header 22 and the periphery thereof, the first
header 21 and the periphery thereof are also configured as above.
(4) Method of Manufacturing Heat Exchanger 10
[0047] The heat-transfer-tube unit 30 is manufactured from a metal material such as aluminum
or an aluminum alloy. Firstly, fins 32 and heat transfer tubes 31 are integrally formed
from the metal material by extrusion molding with a mold corresponding to the shape
of the section illustrated in Fig. 3. Subsequently, portions of the fins 32 are removed
to provide cutouts 33. Thus, the ends 32e of the fins 32 are positioned nearer to
the center of the heat-transfer-tube unit 30 in the heat-transfer-tube-extending direction
z than the ends 31e of the heat transfer tubes 31. The cutouts 33 are desirably provided
by removing a plurality of portions of the fins 32 by punching.
[0048] The first header 21 and the second header 22 are each manufactured by processing
a metal material into a tubular shape. The holes 24 for insertion of the ends 31e
of the heat transfer tubes 31 are formed in the first header 21 and the second header
22. The holes 24 are circular holes provided by, for example, drilling.
[0049] The heat exchanger 10 is assembled by inserting the ends 31e of the heat transfer
tubes 31 of the heat-transfer-tube unit 30 into the respective holes 24 in the first
header 21 and the second header 22. Thus, the ends 32e of the fins 32 come into contact
with the heat-transfer-tube-unit-connecting surface 23 of the second header 22. The
heat-transfer-tube unit 30 and the first header 21 or the second header 22 are brazed
to each other at the points of contact. Specifically, brazing metal is applied in
advance to the heat-transfer-tube-unit-connecting surfaces 23 of the first header
21 and the second header 22. After the ends 31e of the heat transfer tubes 31 of the
heat-transfer-tube unit 30 are inserted into the respective holes 24 in the heat-transfer-tube-unit-connecting
surfaces 23, the heat exchanger 10 is put into a furnace. Thus, the brazing metal
is melted and fills the gaps between the edges of the holes 24 and the respective
heat transfer tubes 31.
(5) Features
(5-1)
[0050] Since the cutouts 33 are provided by removing portions of the fins 32, the ends 31e
of the heat transfer tubes 31 project from the ends 32e of the fins 32. Therefore,
the heat exchanger 10 can be manufactured easily by inserting the projecting portions
of the heat transfer tubes 31 into the holes 24 in the first header 21 and the second
header 22.
(5-2)
[0051] The two ends of the heat-transfer-tube unit 30 are fixed to the first header 21 and
the second header 22, respectively. Therefore, the heat exchanger exhibits improved
durability against external forces and impacts.
(5-3)
[0052] The ends 32e of the fins 32 are in contact with the first header 21 and the second
header 22. Therefore, the heat-transfer-tube unit 30 and each of the first header
21 and the second header 22 are connected to each other with improved strength.
(5-4)
[0053] The heat-transfer-tube unit 30 is formed as a single member from a metal material
by extrusion molding. Therefore, the heat-transfer-tube unit 30 is easy to handle.
Accordingly, the heat exchanger 10 is easy to assemble.
(5-5)
[0054] The plurality of cutouts 33 are provided at a time by punching. Therefore, the heat
exchanger 10 is manufactured efficiently.
(5-6)
[0055] The holes in the first header 21 and the second header 22 may be provided simply
by using a drill. In that case, the heat exchanger 10 is manufactured more easily.
(6) Modifications
[0056] Modifications of the present embodiment will now be described.
(6-1) First Modification
[0057] Fig. 5 illustrates a heat exchanger 10' according to a first modification of the
first embodiment of the present invention. The heat exchanger 10' is different from
the heat exchanger 10 according to the first embodiment in that the ends 32e of the
fins 32 are spaced apart from the heat-transfer-tube-unit-connecting surfaces 23 of
the first header 21 and the second header 22. Such a configuration is realized with
stoppers 35 provided on the heat transfer tubes 31. The stoppers 35 are provided between
the ends 31e of the heat transfer tubes 31 and the ends 32e of the fins 32. The stoppers
35 are shaped in such a manner as not to be allowed to pass through the holes 24 in
the first header 21 and the second header 22. A gap 36 is provided between each of
the stoppers 35 and a corresponding one of the fins 32, whereby the stoppers 35 are
spaced apart from the ends 32e of the fins 32. In the first modification, the stoppers
35 are provided to all of the heat transfer tubes 31 of the heat-transfer-tube unit
30, respectively.
[0058] The stoppers 35 are formed as fins 32 at the beginning of the manufacturing process.
Then, in a step of punching off portions of the fins 32 for providing cutouts 33,
stoppers 35 are obtained as portions that are not punched off, and remain on the heat
transfer tubes 31.
[0059] Such a configuration in which the stoppers 35 are spaced apart from the ends 32e
of the fins 32 suppresses the occurrence of a phenomenon in which the brazing metal
melted in the furnace moves into spaces between the fins 32 by capillarity. Therefore,
concentration of the brazing metal is suppressed, and the occurrence of erosion of
the brazing metal or the fins 32 is reduced.
(6-2) Second Modification
[0060] Fig. 6 illustrates a heat exchanger 10" according to a first modification of the
first embodiment of the present invention. The heat exchanger 10" is different from
the heat exchanger 10' according to the first modification of the first embodiment
in that the stoppers 35 are provided on only some of the heat transfer tubes 31 of
the heat-transfer-tube unit 30.
[0061] Such a configuration further suppresses the occurrence of the phenomenon in which
the brazing metal moves into spaces between the fins 32 by capillarity.
<Second Embodiment>
(1) Configuration
[0062] Fig. 7 illustrates a heat exchanger 10A according to a second embodiment of the present
invention. The heat exchanger 10A is configured such that at least the second header
22 has a trapezoidal sectional shape. Therefore, the heat-transfer-tube-unit-connecting
surface 23 of the second header 22 is inclined with respect to the heat-transfer-tube-spacing
direction y. The ends 32e of the fins 32 are shaped in conformity with the shape of
the second header 22 in such a manner as to be in contact with at least the heat-transfer-tube-unit-connecting
surface 23 of the second header 22 with the ends 31e of the heat transfer tubes 31
being in the holes 24.
[0063] Such a configuration causes dew condensation water running down the heat-transfer-tube
unit 30 and reaching the heat-transfer-tube-unit-connecting surface 23 to further
run down the second header 22 because of the inclination. Therefore, the heat exchanger
10A exhibits improved drainability.
(2) Modifications
[0064] The modifications of the first embodiment may be applied to the present embodiment.
<Third Embodiment>
(1) Configuration
[0065] Fig. 8 illustrates a heat exchanger 10B according to a third embodiment of the present
invention. The heat exchanger 10B is configured such that at least the second header
22 has a sectional shape pointed upward. Therefore, the heat-transfer-tube-unit-connecting
surface 23 of the second header 22 includes two inclined surfaces inclining with respect
to the heat-transfer-tube-spacing direction y. The ends 32e of the fins 32 are shaped
in conformity with the shape of the second header 22 in such a manner as to be in
contact with at least the heat-transfer-tube-unit-connecting surface 23 of the second
header 22 with the ends 31e of the heat transfer tubes 31 being in the holes 24.
[0066] Such a configuration also causes dew condensation water running down the heat-transfer-tube
unit 30 and reaching the heat-transfer-tube-unit-connecting surface 23 to further
run down the second header 22 because of the inclination. Therefore, the heat exchanger
10B exhibits improved drainability.
(2) Modifications
[0067] The modifications of the first embodiment may be applied to the present embodiment.
<Fourth Embodiment>
(1) Configuration
[0068] Fig. 9 illustrates a heat exchanger 10C according to a fourth embodiment of the present
invention. The heat exchanger 10C is configured such that at least the second header
22 is a circular pipe. Therefore, most part of the heat-transfer-tube-unit-connecting
surface 23 of the second header 22 is inclined with respect to the heat-transfer-tube-spacing
direction y. The ends 32e of the fins 32 are shaped in conformity with the shape of
the second header 22 in such a manner as to be in contact with at least the heat-transfer-tube-unit-connecting
surface 23 of the second header 22 with the ends 31e of the heat transfer tubes 31
being in the holes 24.
[0069] In such a configuration, since at least the second header 22 is a circular pipe,
the second header 22 is easy to manufacture. Therefore, the heat exchanger 10 can
be manufactured more easily.
[0070] In addition, since the heat-transfer-tube-unit-connecting surface 23 of the second
header 22 is inclined, dew condensation water running down the heat-transfer-tube
unit 30 and reaching the heat-transfer-tube-unit-connecting surface 23 further runs
down the second header 22. Therefore, the heat exchanger 10C exhibits improved drainability.
(2) Modifications
[0071] The modifications of the first embodiment may be applied to the present embodiment.
<Fifth Embodiment>
(1) Configuration
[0072] Fig. 10 illustrates a heat exchanger 10D according to the above embodiment of the
present invention. The heat exchanger 10D is configured such that the first header
21 and the second header 22 are provided on the same side of the heat-transfer-tube-unit
group 39. The first header 21 and the second header 22 are connected to the first
pipe 41 and the second pipe 42, respectively.
[0073] Fig. 11 illustrates one of a plurality of heat-transfer-tube units 30 included in
the heat-transfer-tube-unit group 39 of the heat exchanger 10D. The heat-transfer-tube
unit 30 includes a plurality of heat transfer tubes 31 and at least one fin 32. The
heat transfer tubes 31 each include at least a portion extending in the heat-transfer-tube-extending
direction z and each preferably have a linear shape. The plurality of heat transfer
tubes 31 are arranged side by side in the heat-transfer-tube-spacing direction y.
Furthermore, adjacent ones of the heat transfer tubes 31 are coupled to each other
with a curved coupling pipe 31c. That is, the heat-transfer-tube unit 30 has a single
refrigerant path formed of the heat transfer tubes 31 and the coupling pipes 31c.
The refrigerant path allows the refrigerant to move between the first header 21 and
the second header 22. The ends 31e of the heat transfer tubes 31 are connected to
the heat-transfer-tube-unit-connecting surfaces 23 of both the first header 21 and
the second header 22.
[0074] The heat-transfer-tube unit 30 includes the fin 32 that is present between adjacent
ones of the heat transfer tubes 31. Additional fins 32 may be provided on the outer
side of outermost ones, respectively, of the heat transfer tubes 31 of the heat-transfer-tube
unit 30. Such a plurality of fins 32 may be connected to one another at the upper
end or the lower end of the heat-transfer-tube unit 30. The fins 32 each have sides
extending in the heat-transfer-tube-extending direction z, and the sides are joined
to corresponding ones of the heat transfer tubes 31. The fins 32 and the heat transfer
tubes 31 are arranged alternately side by side in the heat-transfer-tube-spacing direction
y. A fan or the like, not illustrated, causes air to flow in a direction parallel
to the y-z plane. The direction of the airflow may be the heat-transfer-tube-spacing
direction y. The heat-transfer-tube unit 30 may be manufactured by a method other
than extrusion molding of a metal material.
[0075] The heat-transfer-tube unit 30 has cutouts 33 at ends thereof in the fins 32. The
presence of the cutouts 33 makes ends 32e of the fins 32 be positioned nearer to the
center of the heat-transfer-tube unit 30 in the heat-transfer-tube-extending direction
z than ends 31e of the heat transfer tubes 31. The ends 32e of the fins 32 are shaped
in conformity with the shapes of the first header 21 and the second header 22 in such
a manner as to be in contact with the heat-transfer-tube-unit-connecting surfaces
23 with the ends 31e of the heat transfer tubes 31 being in the holes 24 in the first
header 21 and the second header 22. The points of contact are fixed by brazing or
the like, whereby the refrigerant path is sealed.
[0076] Such a configuration allows three of the four sides of the heat-transfer-tube unit
30 to be open to a peripheral space. Therefore, dew condensation water is drained
more easily.
(2) Modifications
[0077] The modifications of the first embodiment may be applied to the present embodiment.
<Sixth Embodiment>
[0078] The embodiments described above concern an exemplary arrangement in which the heat-transfer-tube-unit-arranging
direction x and the heat-transfer-tube-spacing direction y are each a horizontal direction,
and the heat-transfer-tube-extending direction z is a vertical direction. Alternatively,
the heat exchanger 10 may be oriented in another way. For example, the heat-transfer-tube-spacing
direction y and the heat-transfer-tube-extending direction z may each be a horizontal
direction, and the heat-transfer-tube-unit-arranging direction x may be a vertical
direction.
REFERENCE SIGNS LIST
[0079]
- 10
- heat exchanger
- 21
- first header
- 22
- second header
- 23
- heat-transfer-tube-unit-connecting surface
- 24
- hole
- 30
- heat-transfer-tube unit
- 31
- heat transfer tube
- 31e
- end of heat transfer tube
- 32
- fin
- 32e
- end of fin
- 33
- cutout
- 35
- stopper
- 36
- gap
- 41
- first pipe
- 42
- second pipe
CITATION LIST
PATENT LITERATURE
[0080] [PTL 1] Japanese Unexamined Patent Application Publication No.
2013-139965
1. A heat exchanger (10) comprising:
a heat-transfer-tube unit (30) including at least one fin (32) and a plurality of
heat transfer tubes (31); and
a header (21, 22) to which the heat-transfer-tube unit is connected,
wherein the fin and the heat transfer tubes are arranged alternately side by side,
wherein the plurality of heat transfer tubes each extend in a heat-transfer-tube-extending
direction (z),
wherein the fin has sides extending in the heat-transfer-tube-extending direction
(z) and that are joined to the heat transfer tubes,
wherein an end (32e) of the fin is positioned nearer to a center of the heat-transfer-tube
unit in the heat-transfer-tube-extending direction (z) than ends (31e) of the heat
transfer tubes, and
wherein the header has holes (24) for insertion of the ends of the heat transfer tubes.
2. The heat exchanger according to claim 1,
wherein the header includes a first header (21) and a second header (22) between which
the heat-transfer-tube unit is held.
3. The heat exchanger according to claim 2,
wherein the second header is positioned below the first header, and
wherein the second header has a heat-transfer-tube-unit-connecting surface (23) inclined
with respect to a heat-transfer-tube-spacing direction.
4. The heat exchanger according to any of claims 1 to 3,
wherein the header is a circular pipe.
5. The heat exchanger according to any of claims 1 to 4,
wherein the end of the fin is shaped in conformity with a shape of the header in such
a manner as to be in contact with the header with the ends of the heat transfer tubes
being in the holes.
6. The heat exchanger according to any of claims 1 to 4,
wherein the end (32e) of the fin is spaced apart from the header (21, 22).
7. The heat exchanger according to claim 6,
wherein the heat-transfer-tube unit further includes stoppers (35) provided on the
heat transfer tubes (31) and between the ends (31e) of the heat transfer tubes and
the end (32e) of the fin, and
wherein the stoppers are each shaped in such a manner as not to be allowed to pass
through the holes in the header.
8. The heat exchanger according to any of claims 1 to 7, wherein the heat-transfer-tube
unit is a single member.
9. A heat exchanger manufacturing method, comprising:
forming a heat-transfer-tube unit (30) including a fin (32) and heat transfer tubes
(31);
providing a cutout (33) by removing a portion of the fin such that an end (32e) of
the fin is positioned nearer to a center of the heat-transfer-tube unit in a heat-transfer-tube-extending
direction (z) than ends (31e) of the heat transfer tubes;
providing holes (24) in a header (21, 22), the holes being provided for insertion
of the ends of the heat transfer tubes;
inserting the ends of the heat transfer tubes into the respective holes; and
brazing the heat-transfer-tube unit and the header to each other.
10. The heat exchanger manufacturing method according to claim 9,
wherein the forming the heat-transfer-tube unit includes integrally forming the fin
and the heat transfer tubes from a metal material by extrusion molding.
11. The heat exchanger manufacturing method according to claim 9 or 10,
wherein a plurality of portions of the fin are punched off in the providing the cutout.
12. The heat exchanger manufacturing method according to any of claims 9 to 11,
wherein the holes are provided by drilling in the providing the holes.