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[0001] Priority is claimed to Japanese Patent Application No. 2001-350573, filed on Nov. 15, 2001, Japanese Patent Application No. 2002-166686, filed on Jun. 7, 2002 and U.S. Provisional Patent Application No. 60/333,170, filed on Nov. 27, 2001, the disclosure of which are incorporated by reference in their entireties.
[0002] This application is an application filed under 35 U.S.C. §111(a) claiming the benefit pursuant to 35 U.S.C. §119(e)(1) of the filing date of U.S. Provisional Application No. 60/333,170 filed on Nov. 27, 2001 pursuant to 35 U.S.C. §111(b).
[0003] The present invention relates to a heat exchanger, such as a condenser or an evaporator, for use in a refrigeration cycle for an automobile air conditioner, a household air conditioner, a refrigerator or a cooler for electrical/electric equipments, especially for use in a refrigeration cycle using CO
[0004] As a refrigerant for air conditioning apparatuses, Freon family refrigerant such as HCFC (hydro chlorofluorocarbon) and HFC (hydro fluorocarbon) is used widely. However, such Freon family refrigerant is ozone depleting substance and greenhouse substance (heat-trapping substance). Accordingly, their discharge into the atmospheric air is severely limited, and the alternatives of Freon family refrigerant, or the so-called defreonization, has been developing.
[0005] As one of the defreonizations, a refrigeration cycle which uses carbon dioxide (CO
[0006] However, in cases where CO
[0007] Under such a technical background, a high pressure resistance heat exchanger using CO
[0008] However, in the aforementioned conventional heat exchanger using CO
[0009] An object of the present invention is to solve the aforementioned problems of the conventional technique, and to provide a heat exchanger having small refrigerant flow resistance and enough pressure resistance, especially a heat exchanger preferably applied to a refrigeration cycle using CO
[0010] Other objects of the present invention will become apparent from the following explanations.
[0011] In order to attain the aforementioned objects, according to the first aspect of the present invention, a heat exchanger, comprises:
[0012] a pair of header tanks; and
[0013] a plurality of heat exchanging tubes disposed between the pair of header tanks in parallel in a longitudinal direction of the header tanks with opposite ends thereof connected to the pair of header tanks in fluid communication,
[0014] wherein each of the pair of header tanks includes a header tank main body having a plate connecting surface located at a tube connecting side thereof and a cover plate secured to the plate connecting surface,
[0015] wherein the header tank main body is provided with a refrigerant passage continuously extending along a longitudinal direction of the header tank main body and a plurality of tube connecting apertures formed in the plate connecting surface at predetermined intervals in a longitudinal direction of the refrigerant passages and communicated with the refrigerant passage,
[0016] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures, and
[0017] wherein the plurality of heat exchanging tubes, the cover plate and the header tank main body are secured with each other in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication.
[0018] In this heat exchanger, approximately the entire peripheral wall of the header tank is formed by the header tank main body which can be formed integrally and the tube connecting side of the header tank main body is reinforced by the cover plate. Accordingly, enough strength against the inner pressure can be obtained, enabling an increased cross-sectional area of refrigerant passage, which in turn can decrease the flow resistance.
[0019] The heat exchanger according to the first aspect of the present invention can be preferably applied to a heat exchanger in which a plurality of heat exchanging tubes are arranged in plural rows in the front-and-rear direction and the refrigerant is U-turned in one of header tanks.
[0020] According to the 2
[0021] a pair of header tanks; and
[0022] a plurality of heat exchanging tubes disposed between the pair of header tanks in parallel in a longitudinal direction of the header tanks with opposite ends thereof connected to the pair of header tanks in fluid communication, the plurality of heat exchanging tubes being arranged in plural rows in a widthwise direction of the header tank,
[0023] wherein each of the pair of header tanks includes a header tank main body having a plate connecting surface located at a tube connecting side thereof and a cover plate secured to the plate connecting surface,
[0024] wherein the header tank main body is provided with a refrigerant inlet passage continuously extending along a longitudinal direction of the header tank main body at a front side of the header tank main body, a refrigerant outlet passage continuously extending along a longitudinal direction of the header tank main body at a rear side of the header tank main body, and a plurality of tube connecting apertures formed in front and rear sides of the plate connecting surface at predetermined intervals in a longitudinal direction of the refrigerant inlet passages and the refrigerant outlet passages and communicated with the refrigerant inlet passages and the refrigerant outlet passages respectively,
[0025] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures,
[0026] wherein one of the pair of header tanks is provided with a communication aperture communicating with the refrigerant inlet passage and the refrigerant outlet passage, and
[0027] wherein each of the plurality of heat exchanging tubes, the cover plate and the header tank main body are secured with each other in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication.
[0028] In this heat exchanger, like the aforementioned heat exchanger, enough strength against the inner pressure can be secured, and the refrigerant flow resistance can also be decreased.
[0029] Furthermore, since the refrigerant passing through the front side heat exchanging tubes is introduced into the rear side heat exchanging tubes via the communication aperture to thereby U-turn the refrigerant flow, the heat exchanging of the refrigerant can be further enhanced.
[0030] In the 2
[0031] In this case, the number of partitioning walls partitioning the refrigerant passages can be increased and the most of them function as reinforcing walls, which further enhances the strength against the inner pressure.
[0032] In the 2
[0033] In this case, the ends of the refrigerant passages can be assuredly closed by a simple work such that a cut portion is formed in the end portion of the header tank main body and the blocking plate is inserted therein.
[0034] According to the 3
[0035] a pair of header tanks; and
[0036] a plurality of heat exchanging tubes disposed between the pair of header tanks in parallel in a longitudinal direction of the header tanks with opposite ends thereof connected to the pair of header tanks in fluid communication,
[0037] wherein each of the pair of header tanks includes a header tank main body having a plate connecting surface located at a tube connecting side thereof and a cover plate secured to the plate connecting surface,
[0038] wherein the header tank main body is provided with a refrigerant passage continuously extending along a longitudinal direction of the header tank main body and a plurality of tube connecting apertures formed in the plate connecting surface at predetermined intervals in a longitudinal direction of the refrigerant passages and communicated with the refrigerant passage,
[0039] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures,
[0040] wherein the refrigerant passage in the header tank main body is provided with engaging stepped portions each engaging an end portion of each of the plurality of heat exchanging tubes, and
[0041] wherein the plurality of heat exchanging tubes, the cover plate and the header tank main body are secured with each other in a state in which the end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication with the end portion of each of the plurality of heat exchanging tubes engaged with the engaging stepped portion.
[0042] In this heat exchanger, like the heat exchanger according to the 1
[0043] Furthermore, since engaging stepped portions each engaging an end portion of each of the plurality of heat exchanging tubes are formed at portions corresponding to the tube connecting apertures of the header tank main body, when inserting the heat exchanging tube into the connecting aperture of the header tank main body, the end portion of the heat exchanging tube is engaged with the engaging stepped portion. Thus, the heat exchanging tube can be positioned in the insertion direction thereof, which enables an easy tube connecting work.
[0044] According to the 4
[0045] a pair of header tanks; and
[0046] a plurality of heat exchanging tubes disposed between the pair of header tanks in parallel in a longitudinal direction of the header tanks with opposite ends thereof connected to the pair of header tanks in fluid communication,
[0047] wherein each of the pair of header tanks includes a header tank main body having a plate connecting surface located at a tube connecting side thereof and a cover plate secured to the plate connecting surface,
[0048] wherein the header tank main body is provided with a plurality of refrigerant passages continuously extending along a longitudinal direction of the header tank main body and arranged in a widthwise direction of the header tank main body, and a plurality of tube connecting apertures formed in the plate connecting surface so as to bride the plurality of refrigerant passages at predetermined intervals in a longitudinal direction of the refrigerant passage and communicated with the plurality of refrigerant passages,
[0049] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures,
[0050] wherein a partitioning wall partitioning the plurality of refrigerant passages in the header tank main body is provided with engaging dented stepped portions corresponding to the plurality of tube connecting apertures and engaged with end portions of the plurality of heat exchanging tubes, and
[0051] wherein the plurality of heat exchanging tubes, the cover plate and the header tank main body are secured with each other in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication with the end portion of each of the plurality of heat exchanging tubes engaged with the engaging dented stepped portion.
[0052] In this heat exchanger, like the heat exchanger according to the 3
[0053] Like the 4
[0054] In this 4
[0055] That is, in cases where the end face of the heat exchanging tube is engaged with the bottom surface of the engaging dented stepped portion, some of the end openings of the tube apertures may be blocked by the bottom surface of the engaging dented stepped portion. However, when the aforementioned communication agroove is formed, all of the tube apertures can be communicated with the refrigerant passage, which can prevent the deterioration of the flow amount of refrigerant.
[0056] According to the 5
[0057] a pair of header tanks; and
[0058] a plurality of heat exchanging tubes disposed between the pair of header tanks in parallel in a longitudinal direction of the header tank with opposite ends of each of the plurality of heat exchanging tubes connected to the pair of header tanks in fluid communication, the plurality of heat exchanging tubes being arranged in plural rows in a widthwise direction of the header tank,
[0059] wherein each of the pair of header tanks includes a header tank main body having a plate connecting surface located at a tube connecting side thereof and a cover plate secured to the plate connecting surface,
[0060] wherein the header tank main body is provided with a plurality of refrigerant inlet passage continuously extending along a longitudinal direction of the header tank main body at a front side of the header tank main body and disposed in parallel in a widthwise direction of the header tank main body, a plurality of refrigerant outlet passage continuously extending along a longitudinal direction of the header tank main body at a rear side of the header tank main body and disposed in parallel in a widthwise direction of the header tank main body, a plurality of tube connecting apertures formed in a front side of the plate connecting surface so as to bride the plurality of refrigerant inlet passages at predetermined intervals in a longitudinal direction of the refrigerant inlet passage and communicated with the plurality of refrigerant inlet passages, and a plurality of tube connecting apertures formed in a rear side of the plate connecting surface so as to bride the plurality of refrigerant outlet passages at predetermined intervals in a longitudinal direction of the refrigerant outlet passage and communicated with the plurality of refrigerant outlet passages,
[0061] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures,
[0062] wherein one of the pair of header tanks is provided with a communication aperture communicating with the plurality of refrigerant inlet passages and the plurality of refrigerant outlet passages,
[0063] wherein a partitioning wall partitioning the plurality of refrigerant inlet passages and a partitioning wall partitioning the plurality of refrigerant outlet passages in the header tank main body are provided with engaging dented stepped portions corresponding to the plurality of tube connecting apertures respectively, and
[0064] wherein the plurality of heat exchanging tubes, the cover plate and the header tank main body are secured with each other in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication with the end portion of each of the plurality of heat exchanging tubes engaged with the engaging dented stepped portion.
[0065] In this heat exchanger according to the 5
[0066] In the 5
[0067] In this case, all of the tube apertures can be communicated with the refrigerant inlet passages and the refrigerant outlet passages, which secures an sufficient refrigerant flow amount.
[0068] As the configuration of the communication aperture, the following can be exemplified.
[0069] In the 5
[0070] In the heat exchanger according to the 1
[0071] That is, in the heat exchanger according to the 1
[0072] The 6
[0073] According to the 6
[0074] preparing an intermediate having a flat plate connecting surface at a tube connecting side thereof and a refrigerant passage extending in a longitudinal direction of the intermediate;
[0075] obtaining a header tank main body by forming a plurality of tube connecting apertures communicating with the refrigerant passage in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate;
[0076] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0077] integrally joining the header tank main body, the cover plate and the plurality of heat exchanging tubes in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication.
[0078] The 7
[0079] According to the 7
[0080] preparing an intermediate having a flat plate connecting surface at a tube connecting side, a refrigerant inlet passage extending in a longitudinal direction of the intermediate at a front side of the intermediate, and a refrigerant outlet passage extending in a longitudinal direction of the intermediate at a rear side of the intermediate;
[0081] obtaining a header tank main body by forming a plurality of tube connecting apertures communicating with the refrigerant inlet passage in a front side of the plate connecting surface of the intermediate at predetermined intervals, in a longitudinal direction of the intermediate and a plurality of tube connecting apertures communicating with the refrigerant outlet passage in a rear side of the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate;
[0082] forming a communication aperture communicating with the refrigerant inlet passage and the refrigerant outlet passage in the plate connecting surface of the header tank main body corresponding to one of the pair of header tanks;
[0083] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0084] integrally joining the header tank main body, the cover plate and the plurality of heat exchanging tubes in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication.
[0085] In the 7
[0086] In this case, the number of partitioning walls partitioning the refrigerant passages can be increased, which further enhances the strength against the inner pressure.
[0087] In the 7
[0088] In this case, the intermediate can be formed easily, which in turn can manufacture the heat exchanger efficiently. Furthermore, the header tank main body can be formed as an integral formed member having high strength, which can further enhance the strength against the inner pressure.
[0089] The 7
[0090] In this case, the plate connecting surface can be formed into a flat and smooth surface, resulting in strong joining of the cover plate, which in turn can further enhance the strength against the inner pressure.
[0091] In the 7
[0092] In this case, the tube connecting apertures and the communication apertures can be formed in high accuracy.
[0093] In the 7
[0094] In this case, the simultaneous forming of these apertures can decreases the number of working processes, resulting in further enhanced productivity.
[0095] The 8
[0096] According to the 8
[0097] preparing an intermediate having a flat plate connecting surface at a tube connecting side thereof and a refrigerant passage extending in a longitudinal direction of the intermediate;
[0098] obtaining a header tank main body by forming a plurality of tube connecting apertures communicating with the refrigerant passage in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate and engaging stepped portions each capable of engaging with an end portion of the heat exchanging tube at a portion corresponding to each of the plurality of tube connecting apertures;
[0099] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0100] integrally joining the header tank main body, the cover plate and the plurality of heat exchanging tubes in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication with the end portion of each of the plurality of heat exchanging tubes engaged with the engaging stepped portion.
[0101] The 9
[0102] According to the 9
[0103] preparing an intermediate having a flat plate connecting surface at a tube connecting side thereof and a plurality of refrigerant passages extending in a longitudinal direction of the intermediate and disposed in a widthwise direction of the intermediate;
[0104] obtaining a header tank main body by forming a plurality of tube connecting apertures communicating with the plurality of refrigerant passages so as to bridge the plurality of refrigerant passages in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate and engaging dented stepped portions each capable of engaging with an end portion of the heat exchanging tube at a partitioning walls partitioning the plurality of refrigerant passages portion corresponding to each of the plurality of tube connecting apertures;
[0105] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0106] integrally joining the header tank main body, the cover plate and the plurality of heat exchanging tubes in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication with the end portion of each of the plurality of heat exchanging tubes engaged with the engaging dented stepped portion.
[0107] In the 9
[0108] In this case, in the similar manner as mentioned above, all of the tube apertures can be communicated with the refrigerant passage, resulting in enough refrigerant flow amount.
[0109] The 10
[0110] According to the 10
[0111] preparing an intermediate having a flat plate connecting surface at a tube connecting side thereof, refrigerant inlet passages extending in a longitudinal direction of the intermediate at a front side of the intermediate and arranged in a widthwise direction of the intermediate, and refrigerant outlet passages extending in a longitudinal direction of the intermediate at a rear side of the intermediate and arranged in a widthwise direction of the intermediate;
[0112] obtaining a header tank main body by forming a plurality of front side tube connecting apertures communicating with the plurality of refrigerant inlet passages so as to bridge the plurality of refrigerant inlet passages in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate, a plurality of rear side tube connecting apertures communicating with the plurality of refrigerant outlet passages so as to bridge the plurality of refrigerant outlet passages in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate, engaging dented stepped portions each capable of engaging with an end portion of the front side heat exchanging tube at partitioning walls partitioning the plurality of refrigerant inlet passages corresponding to each of the plurality of tube connecting apertures, and engaging dented stepped portions each capable of engaging with an end portion of the rear side heat exchanging tube at partitioning walls partitioning the plurality of refrigerant outlet passages corresponding to each of the plurality of tube connecting apertures;
[0113] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0114] integrally joining the header tank main body, the cover plate and the plurality of heat exchanging tubes in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication with the end portion of each of the plurality of heat exchanging tubes engaged with the engaging dented stepped portion.
[0115] In the 10
[0116] The 11
[0117] According to the 11
[0118] a header tank main body having a plate connecting surface located at a tube connecting side thereof; and
[0119] a cover plate secured to the plate connecting surface,
[0120] wherein the header tank main body is provided with a refrigerant passage continuously extending along a longitudinal direction of the header tank main body and a plurality of tube connecting apertures formed in the plate connecting surface at predetermined intervals in a longitudinal direction of the refrigerant passages and communicated with the refrigerant passage, and
[0121] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures,
[0122] whereby each of the plurality of heat exchanging tubes and the cover plate are secured with each other in a state in which an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication.
[0123] The 12
[0124] According to the 12
[0125] a header tank main body having a plate connecting surface located at a tube connecting side thereof; and
[0126] a cover plate secured to the plate connecting surface,
[0127] wherein the header tank main body is provided with a refrigerant inlet passage continuously extending along a longitudinal direction of the header tank main body at a widthwise front side of the header tank main body, a refrigerant outlet passage continuously extending along a longitudinal direction of the header tank main body at a widthwise rear side of the header tank main body, and a plurality of tube connecting apertures formed in front and rear sides of the plate connecting surface at predetermined intervals in a longitudinal direction of the refrigerant inlet passages and the refrigerant outlet passages and communicated with the refrigerant inlet passages and the refrigerant outlet passages respectively, and
[0128] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures,
[0129] whereby an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication.
[0130] In the 12
[0131] That is, in the 12
[0132] The 13
[0133] According to the 13
[0134] a header tank main body having a plate connecting surface located at a tube connecting side thereof; and
[0135] a cover plate secured to the plate connecting surface,
[0136] wherein the header tank main body is provided with a refrigerant passage continuously extending along a longitudinal direction of the header tank main body and a plurality of tube connecting apertures formed in the plate connecting surface at predetermined intervals in a longitudinal direction of the refrigerant passage and communicated with the refrigerant passage,
[0137] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures, and
[0138] wherein the refrigerant passage in the header tank main body is provided with engaging stepped portions for engaging end portions of the plurality of heat exchanging tubes,
[0139] whereby the end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication with the end portions of the plurality of heat exchanging tubes engaged with the engaging stepped portions.
[0140] The 14
[0141] According to the 14
[0142] a header tank main body having a plate connecting surface located at a tube connecting side thereof; and
[0143] a cover plate secured to the plate connecting surface,
[0144] wherein the header tank main body is provided with a plurality of refrigerant passages continuously extending along a longitudinal direction of the header tank main body and arranged in a widthwise direction of the header tank main body, and a plurality of tube connecting apertures formed in the plate connecting surface so as to bride the plurality of refrigerant passages at predetermined intervals in a longitudinal direction of the refrigerant passage and communicated with the plurality of refrigerant passages,
[0145] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures, and
[0146] wherein a partitioning wall partitioning the plurality of refrigerant passages in the header tank main body is provided with an engaging dented stepped portion corresponding to the tube connecting aperture and engaging with an end portion of each of the plurality of heat exchanging tubes,
[0147] whereby an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication with the end portion of each of the plurality of heat exchanging tubes engaged with the engaging dented stepped portion.
[0148] In the 14
[0149] The 15
[0150] According to the 15
[0151] a header tank main body having a plate connecting surface located at a tube connecting side; and
[0152] a cover plate secured to the plate connecting surface,
[0153] wherein the header tank main body is provided with a plurality of refrigerant inlet passages continuously extending along a longitudinal direction of the header tank main body at a front side of the header tank main body and disposed in parallel in a widthwise direction of the header tank main body, a plurality of refrigerant outlet passage continuously extending along a longitudinal direction of the header tank main body at a rear side of the header tank main body and disposed in parallel in a widthwise direction of the header tank main body, a plurality of tube connecting apertures formed in a front side of the plate connecting surface so as to bride the plurality of refrigerant inlet passages at predetermined intervals in a longitudinal direction of the refrigerant inlet passage and communicated with the plurality of refrigerant inlet passages, and a plurality of tube connecting apertures formed in a rear side of the plate connecting surface so as to bride the plurality of refrigerant outlet passages at predetermined intervals in a longitudinal direction of the refrigerant outlet passage and communicated with the plurality of refrigerant outlet passages,
[0154] wherein the cover plate is provided with a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures, and
[0155] wherein a partitioning wall partitioning the plurality of refrigerant inlet passages and a partitioning wall partitioning the plurality of refrigerant outlet passages in the header tank main body are provided with an engaging dented stepped portion corresponding to the tube connecting aperture respectively,
[0156] whereby an end portion of each of the plurality of heat exchanging tubes is inserted into a corresponding one of the plurality of tube insertion apertures formed in the cover plate disposed on the plate connecting surface and connected to a corresponding one of the plurality of tube connecting aperture of the header tank main body in a fluid communication with the end portion of each of the plurality of heat exchanging tubes engaged with the engaging dented stepped portion.
[0157] In the 15
[0158] The 16
[0159] According to the 16
[0160] preparing an intermediate having a flat plate connecting surface at a tube connecting side thereof and a refrigerant passage extending in a longitudinal direction of the intermediate;
[0161] obtaining a header tank main body by forming a plurality of tube connecting apertures communicating with the refrigerant passage in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate;
[0162] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0163] joining the cover plate to the plate connecting surface of the header tank main body in a state in which the plurality of heat exchanging tubes are fitted in the plurality of tube insertion apertures.
[0164] The 17
[0165] According to the 17
[0166] preparing an intermediate having a flat plate connecting surface at a tube connecting side, a refrigerant inlet passage extending in a longitudinal direction of the intermediate at a front side of the intermediate, and a refrigerant outlet passage extending in a longitudinal direction of the intermediate at a rear side of the intermediate;
[0167] obtaining a header tank main body by forming a plurality of tube connecting apertures communicating with the refrigerant inlet passage in a front side of the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate and a plurality of tube connecting apertures communicating with the refrigerant outlet passage in a rear side of the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate;
[0168] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0169] joining the cover plate to the plate connecting surface of the header tank main body in a state in which the plurality of heat exchanging tubes are fitted in the plurality of tube insertion apertures.
[0170] In the 17
[0171] The 18
[0172] According to the 18
[0173] preparing an intermediate having a flat plate connecting surface at a tube connecting side and a refrigerant passage extending in a longitudinal direction of the;
[0174] obtaining a header tank main body by forming a plurality of tube connecting apertures communicating with the refrigerant passage in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate and engaging stepped portions each capable of engaging with an end portion of the heat exchanging tube at a portion corresponding to each of the plurality of tube connecting apertures;
[0175] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0176] joining the cover plate to the plate connecting surface of the header tank main body in a state in which the plurality of heat exchanging tubes are fitted in the plurality of tube insertion apertures.
[0177] The 19
[0178] According to the 19
[0179] preparing an intermediate having a flat plate connecting surface at a tube connecting side and a plurality of refrigerant passages extending in a longitudinal direction of the intermediate and arranged in a widthwise direction of the intermediate;
[0180] obtaining a header tank main body by forming a plurality of tube connecting apertures communicating with the plurality of refrigerant passages so as to bridge the plurality of refrigerant passages in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate and engaging dented stepped portions each capable of engaging with an end portion of the heat exchanging tube at partitioning walls partitioning the plurality of refrigerant passages at a portion corresponding to each of the plurality of tube connecting apertures;
[0181] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0182] joining the cover plate to the plate connecting surface of the header tank main body in a state in which the plurality of heat exchanging tubes are fitted in the plurality of tube insertion apertures.
[0183] In the 19
[0184] The 20
[0185] According to the 20
[0186] preparing an intermediate having a flat plate connecting surface at a tube connecting side, refrigerant inlet passages extending in a longitudinal direction of the intermediate at a front side of the intermediate and arranged in a widthwise direction of the intermediate, and refrigerant outlet passages extending in a longitudinal direction of the intermediate at a rear side of the intermediate and arranged in a widthwise direction of the intermediate;
[0187] obtaining a header tank main body by forming a plurality of front side tube connecting apertures communicating with the plurality of refrigerant inlet passages so as to bridge the plurality of refrigerant inlet passages in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate, a plurality of rear side tube connecting apertures communicating with the plurality of refrigerant outlet passages so as to bridge the plurality of refrigerant outlet passages in the plate connecting surface of the intermediate at predetermined intervals in a longitudinal direction of the intermediate, engaging dented stepped portions each capable of engaging with an end portion of the front side heat exchanging tube at partitioning walls partitioning the plurality of refrigerant inlet passages corresponding to each of the plurality of tube connecting apertures, and engaging dented stepped portions each capable of engaging with an end portion of the rear side heat exchanging tube at partitioning walls partitioning the plurality of refrigerant outlet passages corresponding to each of the plurality of tube connecting apertures;
[0188] preparing a cover plate to be fitted to the plate connecting surface, the cover plate having a plurality of tube insertion apertures corresponding to the plurality of tube connecting apertures; and
[0189] joining the cover plate to the plate connecting surface of the header tank main body in a state in which the plurality of heat exchanging tubes are fitted in the plurality of tube insertion apertures.
[0190] In the 20
[0191] The above and/or other aspects, features and/or advantages of various embodiments will be further appreciated in view of the following description in conjunction with the accompanying figures. Various embodiments can include and/or exclude different aspects, features and/or advantages where applicable. In addition, various embodiments can combine one or more aspect or feature of other embodiments where applicable. The descriptions of aspects, features and/or advantages of particular embodiments should not be construed as limiting other embodiments or the claims.
[0192] The accompanying figures are provided by way of example, without limiting the broad scope of the invention or various other embodiments, wherein:
[0193]
[0194]
[0195]
[0196]
[0197]
[0198]
[0199]
[0200]
[0201]
[0202]
[0203]
[0204]
[0205]
[0206]
[0207]
[0208] As shown in FIGS.
[0209] The header tank main body
[0210] The inner side surface (upper surface) of the header tank main body
[0211] The aforementioned tube connecting apertures
[0212] In the plate connecting surface
[0213] In the outside surface (lower surface) at both end portions of the header tank main body
[0214] In each of these cut portions
[0215] The cover plate
[0216] This cover plate
[0217] As shown in
[0218] Like the lower header tank
[0219] Furthermore, like the lower cover plate
[0220] Furthermore, like the lower header tank main body
[0221] Furthermore, into the other cut portion
[0222] Furthermore, a refrigerant inlet pipe
[0223] In this embodiment, the header tanks
[0224] In detail, an intermediate having refrigerant passages
[0225] In cases where communication apertures
[0226] In this embodiment, after the aforementioned cutting processing, it is preferable to conduct milling processing to the plate connecting surface
[0227] The cover plate
[0228] As shown in, for example,
[0229] The lower and upper end portions of each heat exchanging tube
[0230] In the state in which the heat exchanging tubes
[0231] In the heat exchanger of this embodiment, each component is made of, for example, aluminum or its alloy, or an aluminum brazing sheet formed by laminating a brazing material layer on at least one surface of an aluminum sheet. These components are assembled into a predetermined configuration of a heat exchanger via brazing material if necessary and temporarily fixed. This temporarily fixed provisional assembly is brazed in a furnace to secure the components.
[0232] In the present invention, when assembling the heat exchanger, any assembling method may be employed. For example, all of the components may be brazed individually, or some of the components may be brazed and then the remaining components may be brazed in a furnace.
[0233] In the aforementioned heat exchanger constituted as mentioned above, the CO
[0234] As explained above, in the heat exchanger according to this embodiment, almost the entire periphery of the external wall of the header tank
[0235] Furthermore, in the heat exchanger of this embodiment, since enough strength against the inner pressure can be secured, the cross-sectional area of the refrigerant passage
[0236] Furthermore, since four refrigerant passages
[0237] Furthermore, the communication apertures
[0238] Furthermore, since the communication apertures
[0239] In cases where the communication aperture
[0240] Furthermore, in this embodiment, cut portions
[0241] Furthermore, in this embodiment, since the header tank main bodies
[0242] Furthermore, in this embodiment, since the plate connecting surface
[0243] Furthermore, in this embodiment, when inserting the heat exchanging tubes
[0244] As shown in
[0245] Accordingly, as shown in
[0246] The aforementioned communication groove
[0247] Needless to say, such a communication groove
[0248] In the aforementioned embodiment, the heat exchanger in which heat exchanging tubes
[0249] Furthermore, in the present invention, the number or the configuration of the refrigerant passage
[0250] As mentioned above, in the heat exchanger according to the 1
[0251] The method for manufacturing the heat exchanger according to the 6
[0252] The header tank for heat exchangers according to the 11
[0253] The header tank for heat exchangers according to the 16
[0254] While illustrative embodiments of the present invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments having modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive and means “preferably, but not limited to.” Means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are not recited.
[0255] The present invention can improve a heat exchange performance of a heat exchanger, and therefore can be preferably applied to a refrigeration cycle for an automobile air conditioner, a household air conditioner, a refrigerator or a cooler for electrical/electric equipments, especially a refrigeration cycle using CO