U.S. patent application number 10/490108 was filed with the patent office on 2004-10-28 for heat exchanger, heat exchanger header tank and manufacturing method thereof.
Invention is credited to Furukawa, Yuichi, Hoshino, Ryoichi, Ohashi, Hideo, Shinmura, Etsuo.
Application Number | 20040211551 10/490108 |
Document ID | / |
Family ID | 27347827 |
Filed Date | 2004-10-28 |
United States Patent
Application |
20040211551 |
Kind Code |
A1 |
Shinmura, Etsuo ; et
al. |
October 28, 2004 |
Heat exchanger, heat exchanger header tank and manufacturing method
thereof
Abstract
In the present invention, a header tank 10 includes a header
tank main body 11 and a cover plate 20. The header tank main body
11 is provided with a refrigerant inlet passage 12a and a
refrigerant outlet passage 12b arranged in parallel, connecting
apertures 14a and 14b formed on a tube connecting side 13 and
communicating with the passages 12a and 12b, and a communicating
aperture communicating with the passages 12a and 12b. The cover
plate 20 has insertion apertures 24a and 24b corresponding to the
connecting apertures 14a and 14b. The tubes 1a and 1b, the cover
plate 20 and the header tank main body 11 are integrally joined in
a state in which each end of the tube 1a and 1b is inserted into
the insertion aperture 24a and 24b of the cover plate 20 disposed
on the tube connecting side 13a of the header tank main body 11 and
connected to the connecting apertures 14a and 14b of the header
tank main body 11. Thus, a heat exchanger using CO.sub.2
refrigerant capable of decreasing refrigerant flow resistance and
enough strength against the inner pressure can be obtained.
Inventors: |
Shinmura, Etsuo; (Tochigi,
JP) ; Hoshino, Ryoichi; (Tochigi, JP) ;
Ohashi, Hideo; (Tochigi, JP) ; Furukawa, Yuichi;
(Tochigi, JP) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Family ID: |
27347827 |
Appl. No.: |
10/490108 |
Filed: |
March 25, 2004 |
PCT Filed: |
November 15, 2002 |
PCT NO: |
PCT/JP02/11915 |
Current U.S.
Class: |
165/175 ;
165/173 |
Current CPC
Class: |
F28D 2021/0073 20130101;
F28F 9/0202 20130101; F25B 9/002 20130101; F25B 39/00 20130101;
F28D 1/05391 20130101; F28D 1/0535 20130101; F28F 2225/08 20130101;
F28F 9/0214 20130101 |
Class at
Publication: |
165/175 ;
165/173 |
International
Class: |
F28F 009/02 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 15, 2001 |
JP |
2001350573 |
Nov 27, 2001 |
US |
60333170 |
Jun 7, 2002 |
JP |
2002166686 |
Claims
1. A heat exchanger, comprising: a pair of header tanks; and a
plurality of heat exchanging tubes disposed between said pair of
header tanks in parallel in a longitudinal direction of said header
tanks with opposite ends thereof connected to said pair of header
tanks in fluid communication, wherein each of said 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 said plate connecting surface, wherein said header tank
main body is provided with a refrigerant passage continuously
extending along a longitudinal direction of said header tank main
body and a plurality of tube connecting apertures formed in said
plate connecting surface at predetermined intervals in a
longitudinal direction of said refrigerant passages and
communicated with said refrigerant passage, wherein said cover
plate is provided with a plurality of tube insertion apertures
corresponding to said plurality of tube connecting apertures, and
wherein said plurality of heat exchanging tubes, said cover plate
and said header tank main body are secured with each other in a
state in which an end portion of each of said plurality of heat
exchanging tubes is inserted into a corresponding one of said
plurality of tube insertion apertures formed in said cover plate
disposed on said plate connecting surface and connected to a
corresponding one of said plurality of tube connecting aperture of
said header tank main body in a fluid communication.
2. A heat exchanger, comprising: a pair of header tanks; and a
plurality of heat exchanging tubes disposed between said pair of
header tanks in parallel in a longitudinal direction of said header
tanks with opposite ends thereof connected to said pair of header
tanks in fluid communication, said plurality of heat exchanging
tubes being arranged in plural rows in a widthwise direction of
said header tank, wherein each of said 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 said plate connecting surface, wherein said header tank main
body is provided with a refrigerant inlet passage continuously
extending along a longitudinal direction of said header tank main
body at a front side of said header tank main body, a refrigerant
outlet passage continuously extending along a longitudinal
direction of said header tank main body at a rear side of said
header tank main body, and a plurality of tube connecting apertures
formed in front and rear sides of said plate connecting surface at
predetermined intervals in a longitudinal direction of said
refrigerant inlet passages and said refrigerant outlet passages and
communicated with said refrigerant inlet passages and said
refrigerant outlet passages respectively, wherein said cover plate
is provided with a plurality of tube insertion apertures
corresponding to said plurality of tube connecting apertures,
wherein one of said pair of header tanks is provided with a
communication aperture communicating with said refrigerant inlet
passage and said refrigerant outlet passage, and wherein each of
said plurality of heat exchanging tubes, said cover plate and said
header tank main body are secured with each other in a state in
which an end portion of each of said plurality of heat exchanging
tubes is inserted into a corresponding one of said plurality of
tube insertion apertures formed in said cover plate disposed on
said plate connecting surface and connected to a corresponding one
of said plurality of tube connecting aperture of said header tank
main body in a fluid communication.
3. The heat exchanger as recited in claim 2, wherein said
refrigerant inlet passage and said refrigerant outlet passage
formed in said header tank main body include plural passages
arranged in parallel, respectively.
4. The heat exchanger as recited in claim 2, wherein said header
tank main body has a cut portion formed from an outside surface of
an end portion of said header tank main body and extending to said
refrigeration inlet passage and said refrigeration outlet passage,
and wherein end portions of said refrigerant inlet passage and said
refrigerant outlet passage are closed by a blocking plate inserted
in and secured to said cut portion.
5. A heat exchanger, comprising: a pair of header tanks; and a
plurality of heat exchanging tubes disposed between said pair of
header tanks in parallel in a longitudinal direction of said header
tanks with opposite ends thereof connected to said pair of header
tanks in fluid communication, wherein each of said 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 said plate connecting surface, wherein said header tank
main body is provided with a refrigerant passage continuously
extending along a longitudinal direction of said header tank main
body and a plurality of tube connecting apertures formed in said
plate connecting surface at predetermined intervals in a
longitudinal direction of said refrigerant passages and
communicated with said refrigerant passage, wherein said cover
plate is provided with a plurality of tube insertion apertures
corresponding to said plurality of tube connecting apertures,
wherein said refrigerant passage in said header tank main body is
provided with engaging stepped portions each engaging an end
portion of each of said plurality of heat exchanging tubes, and
wherein said plurality of heat exchanging tubes, said cover plate
and said header tank main body are secured with each other in a
state in which said end portion of each of said plurality of heat
exchanging tubes is inserted into a corresponding one of said
plurality of tube insertion apertures formed in said cover plate
disposed on said plate connecting surface and connected to a
corresponding one of said plurality of tube connecting aperture of
said header tank main body in a fluid communication with said end
portion of each of said plurality of heat exchanging tubes engaged
with said engaging stepped portion.
6. A heat exchanger, comprising: a pair of header tanks; and a
plurality of heat exchanging tubes disposed between said pair of
header tanks in parallel in a longitudinal direction of said header
tanks with opposite ends thereof connected to said pair of header
tanks in fluid communication, wherein each of said 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 said plate connecting surface, wherein said header tank
main body is provided with a plurality of refrigerant passages
continuously extending along a longitudinal direction of said
header tank main body and arranged in a widthwise direction of said
header tank main body, and a plurality of tube connecting apertures
formed in said plate connecting surface so as to bride said
plurality of refrigerant passages at predetermined intervals in a
longitudinal direction of said refrigerant passage and communicated
with said plurality of refrigerant passages, wherein said cover
plate is provided with a plurality of tube insertion apertures
corresponding to said plurality of tube connecting apertures,
wherein a partitioning wall partitioning said plurality of
refrigerant passages in said header tank main body is provided with
engaging dented stepped portions corresponding to said plurality of
tube connecting apertures and engaged with end portions of said
plurality of heat exchanging tubes, and wherein said plurality of
heat exchanging tubes, said cover plate and said header tank main
body are secured with each other in a state in which an end portion
of each of said plurality of heat exchanging tubes is inserted into
a corresponding one of said plurality of tube insertion apertures
formed in said cover plate disposed on said plate connecting
surface and connected to a corresponding one of said plurality of
tube connecting aperture of said header tank main body in a fluid
communication with said end portion of each of said plurality of
heat exchanging tubes engaged with said engaging dented stepped
portion.
7. The heat exchanger as recited in claim 6, wherein a
communication groove communicating with end openings of tube
apertures of said plurality of heat exchanging tubes and said
plurality of refrigerant passages is formed at a bottom surface of
said engaging dented stepped portion.
8. A heat exchanger, comprising: a pair of header tanks; and a
plurality of heat exchanging tubes disposed between said pair of
header tanks in parallel in a longitudinal direction of said header
tank with opposite ends of each of said plurality of heat
exchanging tubes connected to said pair of header tanks in fluid
communication, said plurality of heat exchanging tubes being
arranged in plural rows in a widthwise direction of said header
tank, wherein each of said 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 said plate
connecting surface, wherein said header tank main body is provided
with a plurality of refrigerant inlet passages continuously
extending along a longitudinal direction of said header tank main
body at a front side of said header tank main body and disposed in
parallel in a widthwise direction of said header tank main body, a
plurality of refrigerant outlet passages continuously extending
along a longitudinal direction of said header tank main body at a
rear side of said header tank main body and disposed in parallel in
a widthwise direction of said header tank main body, a plurality of
tube connecting apertures formed in a front side of said plate
connecting surface so as to bride said plurality of refrigerant
inlet passages at predetermined intervals in a longitudinal
direction of said refrigerant inlet passage and communicated with
said plurality of refrigerant inlet passages, and a plurality of
tube connecting apertures formed in a rear side of said plate
connecting surface so as to bride said plurality of refrigerant
outlet passages at predetermined intervals in a longitudinal
direction of said refrigerant outlet passage and communicated with
said plurality of refrigerant outlet passages, wherein said cover
plate is provided with a plurality of tube insertion apertures
corresponding to said plurality of tube connecting apertures,
wherein one of said pair of header tanks is provided with a
communication aperture communicating with said plurality of
refrigerant inlet passages and said plurality of refrigerant outlet
passages, wherein a partitioning wall partitioning said plurality
of refrigerant inlet passages and a partitioning wall partitioning
said plurality of refrigerant outlet passages in said header tank
main body are provided with engaging dented stepped portions
corresponding to said plurality of tube connecting apertures
respectively, and wherein said plurality of heat exchanging tubes,
said cover plate and said header tank main body are secured with
each other in a state in which an end portion of each of said
plurality of heat exchanging tubes is inserted into a corresponding
one of said plurality of tube insertion apertures formed in said
cover plate disposed on said plate connecting surface and connected
to a corresponding one of said plurality of tube connecting
aperture of said header tank main body in a fluid communication
with said end portion of each of said plurality of heat exchanging
tubes engaged with said engaging dented stepped portion.
9. The heat exchanger as recited in claim 8, wherein a
communication groove communicating with end openings of tube
apertures of said plurality of heat exchanging tubes and said
plurality of refrigerant inlet passages and a communication groove
communicating with end openings of tube apertures of said plurality
of heat exchanging tubes and said plurality of refrigerant outlet
passages are formed at a bottom surface of said engaging dented
stepped portion respectively.
10. The heat exchanger as recited in claim 9, wherein said
communication groove is formed into a generally V-shape.
11. The heat exchanger as recited in claim 9, wherein said
communication groove is formed into a generally U-shape.
12. The heat exchanger as recited in claim 1, wherein said
refrigerant is carbon dioxide refrigerant.
13. A method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between said pair of header tanks and arranged in parallel in a
longitudinal direction of said header tank with opposite ends
thereof connected to said pair of header tanks in fluid
communication, said method, comprising: 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 said intermediate; obtaining a header tank main body
by forming a plurality of tube connecting apertures communicating
with said refrigerant passage in said plate connecting surface of
said intermediate at predetermined intervals in a longitudinal
direction of said intermediate; preparing a cover plate to be
fitted to said plate connecting surface, said cover plate having a
plurality of tube insertion apertures corresponding to said
plurality of tube connecting apertures; and integrally joining said
header tank main body, said cover plate and said plurality of heat
exchanging tubes in a state in which an end portion of each of said
plurality of heat exchanging tubes is inserted into a corresponding
one of said plurality of tube insertion apertures formed in said
cover plate disposed on said plate connecting surface and connected
to a corresponding one of said plurality of tube connecting
aperture of said header tank main body in a fluid
communication.
14. A method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between said pair of header tanks and arranged in parallel in a
longitudinal direction of said header tank with opposite ends
thereof connected to said pair of header tanks in fluid
communication, said plurality of heat exchanging tubes being
arranged in plural rows in a widthwise direction of said header
tank, said method, comprising: preparing an intermediate having a
flat plate connecting surface at a tube connecting side, a
refrigerant inlet passage extending in a longitudinal direction of
said intermediate at a front side of said intermediate, and a
refrigerant outlet passage extending in a longitudinal direction of
said intermediate at a rear side of said intermediate; obtaining a
header tank main body by forming a plurality of tube connecting
apertures communicating with said refrigerant inlet passage in a
front side of said plate connecting surface of said intermediate at
predetermined intervals in a longitudinal direction of said
intermediate and a plurality of tube connecting apertures
communicating with said refrigerant outlet passage in a rear side
of said plate connecting surface of said intermediate at
predetermined intervals in a longitudinal direction of said
intermediate; forming a communication aperture communicating with
said refrigerant inlet passage and said refrigerant outlet passage
in said plate connecting surface of said header tank main body
corresponding to one of said pair of header tanks; preparing a
cover plate to be fitted to said plate connecting surface, said
cover plate having a plurality of tube insertion apertures
corresponding to said plurality of tube connecting apertures; and
integrally joining said header tank main body, said cover plate and
said plurality of heat exchanging tubes in a state in which an end
portion of each of said plurality of heat exchanging tubes is
inserted into a corresponding one of said plurality of tube
insertion apertures formed in said cover plate disposed on said
plate connecting surface and connected to a corresponding one of
said plurality of tube connecting aperture of said header tank main
body in a fluid communication.
15. The method for manufacturing a heat exchanger as recited in
claim 14, wherein said refrigerant inlet passage and said
refrigerant outlet passage are formed to have plural rows arranged
in parallel, respectively.
16. The method for manufacturing a heat exchanger as recited in
claim 14, wherein said intermediate having said refrigerant inlet
passage and said refrigerant outlet passage is formed by extrusion
molding or drawing molding.
17. The method for manufacturing a heat exchanger as recited in
claim 14, wherein said plate connecting surface is formed by
milling.
18. The method for manufacturing a heat exchanger as recited in
claim 14, wherein said tube connecting apertures are formed by
cutting.
19. The method for manufacturing a heat exchanger as recited in
claim 14, wherein said communication apertures are formed by
cutting.
20. The method for manufacturing a heat exchanger as recited in
claim 14, wherein said tube connecting apertures and said
communication apertures are formed simultaneously.
21. A method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between said pair of header tanks and arranged in parallel in a
longitudinal direction of said header tank with opposite ends
thereof connected to said pair of header tanks in fluid
communication, said method, comprising: 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 said intermediate; obtaining a header tank main body
by forming a plurality of tube connecting apertures communicating
with said refrigerant passage in said plate connecting surface of
said intermediate at predetermined intervals in a longitudinal
direction of said intermediate and engaging stepped portions each
capable of engaging with an end portion of said heat exchanging
tube at a portion corresponding to each of said plurality of tube
connecting apertures; preparing a cover plate to be fitted to said
plate connecting surface, said cover plate having a plurality of
tube insertion apertures corresponding to said plurality of tube
connecting apertures; and integrally joining said header tank main
body, said cover plate and said plurality of heat exchanging tubes
in a state in which an end portion of each of said plurality of
heat exchanging tubes is inserted into a corresponding one of said
plurality of tube insertion apertures formed in said cover plate
disposed on said plate connecting surface and connected to a
corresponding one of said plurality of tube connecting aperture of
said header tank main body in a fluid communication with said end
portion of each of said plurality of heat exchanging tubes engaged
with said engaging stepped portion.
22. A method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between said pair of header tanks and arranged in parallel in a
longitudinal direction of said header tank with opposite ends
thereof connected to said pair of header tanks in fluid
communication, said method, comprising: 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 said intermediate and disposed in a
widthwise direction of said intermediate; obtaining a header tank
main body by forming a plurality of tube connecting apertures
communicating with said plurality of refrigerant passages so as to
bridge said plurality of refrigerant passages in said plate
connecting surface of said intermediate at predetermined intervals
in a longitudinal direction of said intermediate and engaging
dented stepped portions each capable of engaging with an end
portion of said heat exchanging tube at a partitioning walls
partitioning said plurality of refrigerant passages portion
corresponding to each of said plurality of tube connecting
apertures; preparing a cover plate to be fitted to said plate
connecting surface, said cover plate having a plurality of tube
insertion apertures corresponding to said plurality of tube
connecting apertures; and integrally joining said header tank main
body, said cover plate and said plurality of heat exchanging tubes
in a state in which an end portion of each of said plurality of
heat exchanging tubes is inserted into a corresponding one of said
plurality of tube insertion apertures formed in said cover plate
disposed on said plate connecting surface and connected to a
corresponding one of said plurality of tube connecting aperture of
said header tank main body in a fluid communication with said end
portion of each of said plurality of heat exchanging tubes engaged
with said engaging dented stepped portion.
23. The method for manufacturing a heat exchanger as recited in
claim 22, wherein, at a step of obtaining said header tank main
body, a communication groove communicating with end openings of
tube apertures of said heat exchanging tube and said plurality of
refrigerant passages is formed at a bottom surface of each of said
engaging dented stepped portions.
24. A method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between said pair of header tanks and arranged in parallel in a
longitudinal direction of said header tank with opposite ends
thereof connected to said pair of header tanks in fluid
communication, said plurality of heat exchanging tubes being
arranged in plural rows in a widthwise direction of said header
tank, said method, comprising: preparing an intermediate having a
flat plate connecting surface at a tube connecting side thereof,
refrigerant inlet passages extending in a longitudinal direction of
said intermediate at a front side of said intermediate and arranged
in a widthwise direction of said intermediate, and refrigerant
outlet passages extending in a longitudinal direction of said
intermediate at a rear side of said intermediate and arranged in a
widthwise direction of said intermediate; obtaining a header tank
main body by forming a plurality of front side tube connecting
apertures communicating with said plurality of refrigerant inlet
passages so as to bridge said plurality of refrigerant inlet
passages in said plate connecting surface of said intermediate at
predetermined intervals in a longitudinal direction of said
intermediate, a plurality of rear side tube connecting apertures
communicating with said plurality of refrigerant outlet passages so
as to bridge said plurality of refrigerant outlet passages in said
plate connecting surface of said intermediate at predetermined
intervals in a longitudinal direction of said intermediate,
engaging dented stepped portions each capable of engaging with an
end portion of said front side heat exchanging tube at partitioning
walls partitioning said plurality of refrigerant inlet passages
corresponding to each of said plurality of tube connecting
apertures, and engaging dented stepped portions each capable of
engaging with an end portion of said rear side heat exchanging tube
at partitioning walls partitioning said plurality of refrigerant
outlet passages corresponding to each of said plurality of tube
connecting apertures; preparing a cover plate to be fitted to said
plate connecting surface, said cover plate having a plurality of
tube insertion apertures corresponding to said plurality of tube
connecting apertures; and integrally joining said header tank main
body, said cover plate and said plurality of heat exchanging tubes
in a state in which an end portion of each of said plurality of
heat exchanging tubes is inserted into a corresponding one of said
plurality of tube insertion apertures formed in said cover plate
disposed on said plate connecting surface and connected to a
corresponding one of said plurality of tube connecting aperture of
said header tank main body in a fluid communication with said end
portion of each of said plurality of heat exchanging tubes engaged
with said engaging dented stepped portion.
25. The method for manufacturing a heat exchanger as recited in
claim 24, wherein, at a step of obtaining said header tank main
body, a communication groove communicating with end openings of
tube apertures of said heat exchanging tube and said plurality of
refrigerant inlet passages and a communication groove communicating
with end openings of tube apertures of said heat exchanging tube
and said plurality of refrigerant outlet passages are formed at a
bottom surface of each of said engaging dented stepped
portions.
26. A heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, said heat exchanger header tank, comprising: a
header tank main body having a plate connecting surface located at
a tube connecting side thereof; and a cover plate secured to said
plate connecting surface, wherein said header tank main body is
provided with a refrigerant passage continuously extending along a
longitudinal direction of said header tank main body and a
plurality of tube connecting apertures formed in said plate
connecting surface at predetermined intervals in a longitudinal
direction of said refrigerant passages and communicated with said
refrigerant passage, and wherein said cover plate is provided with
a plurality of tube insertion apertures corresponding to said
plurality of tube connecting apertures, whereby each of said
plurality of heat exchanging tubes and said cover plate are secured
with each other in a state in which an end portion of each of said
plurality of heat exchanging tubes is inserted into a corresponding
one of said plurality of tube insertion apertures formed in said
cover plate disposed on said plate connecting surface and connected
to a corresponding one of said plurality of tube connecting
aperture of said header tank main body in a fluid
communication.
27. A heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, said heat exchanger header tank, comprising: a
header tank main body having a plate connecting surface located at
a tube connecting side thereof; and a cover plate secured to said
plate connecting surface, wherein said header tank main body is
provided with a refrigerant inlet passage continuously extending
along a longitudinal direction of said header tank main body at a
widthwise front side of said header tank main body, a refrigerant
outlet passage continuously extending along a longitudinal
direction of said header tank main body at a widthwise rear side of
said header tank main body, and a plurality of tube connecting
apertures formed in front and rear sides of said plate connecting
surface at predetermined intervals in a longitudinal direction of
said refrigerant inlet passages and said refrigerant outlet
passages and communicated with said refrigerant inlet passages and
said refrigerant outlet passages respectively, and wherein said
cover plate is provided with a plurality of tube insertion
apertures corresponding to said plurality of tube connecting
apertures, whereby an end portion of each of said plurality of heat
exchanging tubes is inserted into a corresponding one of said
plurality of tube insertion apertures formed in said cover plate
and connected to a corresponding one of said plurality of tube
connecting aperture of said header tank main body in a fluid
communication.
28. The heat exchanger header tank as recited in claim 27, wherein
said refrigerant inlet passage and said refrigerant outlet passage
formed in said header tank main body include plural passages
arranged in parallel, respectively.
29. The heat exchanger header tank as recited in claim 27, wherein
said header tank main body has a cut portion formed from an outside
surface of an end portion of said header tank main body and
extending to said refrigeration inlet passage and said
refrigeration outlet passage, and wherein end portions of said
refrigerant inlet passage and said refrigerant outlet passage are
closed by a blocking plate inserted in and secured to said cut
portion.
30. The heat exchanger header tank as recited in claim 27, wherein
said header tank main body has a communication aperture
communicating with said refrigerant inlet passage and said
refrigerant outlet passage.
31. A heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, said heat exchanger header tank, comprising: a
header tank main body having a plate connecting surface located at
a tube connecting side thereof; and a cover plate secured to said
plate connecting surface, wherein said header tank main body is
provided with a refrigerant passage continuously extending along a
longitudinal direction of said header tank main body and a
plurality of tube connecting apertures formed in said plate
connecting surface at predetermined intervals in a longitudinal
direction of said refrigerant passage and communicated with said
refrigerant passage, wherein said cover plate is provided with a
plurality of tube insertion apertures corresponding to said
plurality of tube connecting apertures, and wherein said
refrigerant passage in said header tank main body is provided with
engaging stepped portions for engaging end portions of said
plurality of heat exchanging tubes, whereby said end portion of
each of said plurality of heat exchanging tubes is inserted into a
corresponding one of said plurality of tube insertion apertures
formed in said cover plate disposed on said plate connecting
surface and connected to a corresponding one of said plurality of
tube connecting aperture of said header tank main body in a fluid
communication with said end portions of said plurality of heat
exchanging tubes engaged with said engaging stepped portions.
32. A heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, said heat exchanger header tank, comprising: a
header tank main body having a plate connecting surface located at
a tube connecting side thereof; and a cover plate secured to said
plate connecting surface, wherein said header tank main body is
provided with a plurality of refrigerant passages continuously
extending along a longitudinal direction of said header tank main
body and arranged in a widthwise direction of said header tank main
body, and a plurality of tube connecting apertures formed in said
plate connecting surface so as to bride said plurality of
refrigerant passages at predetermined intervals in a longitudinal
direction of said refrigerant passage and communicated with said
plurality of refrigerant passages, wherein said cover plate is
provided with a plurality of tube insertion apertures corresponding
to said plurality of tube connecting apertures, and wherein a
partitioning wall partitioning said plurality of refrigerant
passages in said header tank main body is provided with an engaging
dented stepped portion corresponding to said tube connecting
aperture and engaging with an end portion of each of said plurality
of heat exchanging tubes, whereby an end portion of each of said
plurality of heat exchanging tubes is inserted into a corresponding
one of said plurality of tube insertion apertures formed in said
cover plate disposed on said plate connecting surface and connected
to a corresponding one of said plurality of tube connecting
aperture of said header tank main body in a fluid communication
with said end portion of each of said plurality of heat exchanging
tubes engaged with said engaging dented stepped portion.
33. The heat exchanger header tank as recited in claim 32, wherein
a communication groove communicating with end openings of tube
apertures of said plurality of heat exchanging tubes and said
plurality of refrigerant passages is formed at a bottom surface of
said engaging dented stepped portion.
34. A heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, said heat exchanger header tank, comprising: a
header tank main body having a plate connecting surface located at
a tube connecting side; and a cover plate secured to said plate
connecting surface, wherein said header tank main body is provided
with a plurality of refrigerant inlet passages continuously
extending along a longitudinal direction of said header tank main
body at a front side of said header tank main body and disposed in
parallel in a widthwise direction of said header tank main body, a
plurality of refrigerant outlet passage continuously extending
along a longitudinal direction of said header tank main body at a
rear side of said header tank main body and disposed in parallel in
a widthwise direction of said header tank main body, a plurality of
tube connecting apertures formed in a front side of said plate
connecting surface so as to bride said plurality of refrigerant
inlet passages at predetermined intervals in a longitudinal
direction of said refrigerant inlet passage and communicated with
said plurality of refrigerant inlet passages, and a plurality of
tube connecting apertures formed in a rear side of said plate
connecting surface so as to bride said plurality of refrigerant
outlet passages at predetermined intervals in a longitudinal
direction of said refrigerant outlet passage and communicated with
said plurality of refrigerant outlet passages, wherein said cover
plate is provided with a plurality of tube insertion apertures
corresponding to said plurality of tube connecting apertures, and
wherein a partitioning wall partitioning said plurality of
refrigerant inlet passages and a partitioning wall partitioning
said plurality of refrigerant outlet passages in said header tank
main body are provided with an engaging dented stepped portion
corresponding to said tube connecting aperture respectively,
whereby an end portion of each of said plurality of heat exchanging
tubes is inserted into a corresponding one of said plurality of
tube insertion apertures formed in said cover plate disposed on
said plate connecting surface and connected to a corresponding one
of said plurality of tube connecting aperture of said header tank
main body in a fluid communication with said end portion of each of
said plurality of heat exchanging tubes engaged with said engaging
dented stepped portion.
35. The heat exchanger as recited in claim 34, wherein a
communication groove communicating with end openings of tube
apertures of said plurality of heat exchanging tubes and said
plurality of refrigerant inlet passages and a communication groove
communicating with end openings of tube apertures of said plurality
of heat exchanging tubes and said plurality of refrigerant outlet
passages are formed at a bottom surface of said engaging dented
stepped portion respectively.
36. A method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, said method, comprising: 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
said intermediate; obtaining a header tank main body by forming a
plurality of tube connecting apertures communicating with said
refrigerant passage in said plate connecting surface of said
intermediate at predetermined intervals in a longitudinal direction
of said intermediate; preparing a cover plate to be fitted to said
plate connecting surface, said cover plate having a plurality of
tube insertion apertures corresponding to said plurality of tube
connecting apertures; and joining said cover plate to said plate
connecting surface of said header tank main body in a state in
which said plurality of heat exchanging tubes are fitted in said
plurality of tube insertion apertures.
37. A method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, said method, comprising: preparing an intermediate having
a fiat plate connecting surface at a tube connecting side, a
refrigerant inlet passage extending in a longitudinal direction of
said intermediate at a front side of said intermediate, and a
refrigerant outlet passage extending in a longitudinal direction of
said intermediate at a rear side of said intermediate; obtaining a
header tank main body by forming a plurality of tube connecting
apertures communicating with said refrigerant inlet passage in a
front side of said plate connecting surface of said intermediate at
predetermined intervals in a longitudinal direction of said
intermediate and a plurality of tube connecting apertures
communicating with said refrigerant outlet passage in a rear side
of said plate connecting surface of said intermediate at
predetermined intervals in a longitudinal direction of said
intermediate; preparing a cover plate to be fitted to said plate
connecting surface, said cover plate having a plurality of tube
insertion apertures corresponding to said plurality of tube
connecting apertures; and joining said cover plate to said plate
connecting surface of said header tank main body in a state in
which said plurality of heat exchanging tubes are fitted in said
plurality of tube insertion apertures.
38. The method for manufacturing a heat exchanger header tank as
recited in claim 37, wherein said refrigerant inlet passage and
said refrigerant outlet passage are formed to have plural rows
arranged in parallel, respectively.
39. A method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, said method, comprising: preparing an intermediate having
a flat plate connecting surface at a tube connecting side and a
refrigerant passage extending in a longitudinal direction of said
intermediate; obtaining a header tank main body by forming a
plurality of tube connecting apertures communicating with said
refrigerant passage in said plate connecting surface of said
intermediate at predetermined intervals in a longitudinal direction
of said intermediate and engaging stepped portions each capable of
engaging with an end portion of said heat exchanging tube at a
portion corresponding to each of said plurality of tube connecting
apertures; preparing a cover plate to be fitted to said plate
connecting surface, said cover plate having a plurality of tube
insertion apertures corresponding to said plurality of tube
connecting apertures; and joining said cover plate to said plate
connecting surface of said header tank main body in a state in
which said plurality of heat exchanging tubes are fitted in said
plurality of tube insertion apertures.
40. A method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, said method, comprising: 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 said intermediate and arranged in a widthwise
direction of said intermediate; obtaining a header tank main body
by forming a plurality of tube connecting apertures communicating
with said plurality of refrigerant passages so as to bridge said
plurality of refrigerant passages in said plate connecting surface
of said intermediate at predetermined intervals in a longitudinal
direction of said intermediate and engaging dented stepped portions
each capable of engaging with an end portion of said heat
exchanging tube at partitioning walls partitioning said plurality
of refrigerant passages at a portion corresponding to each of said
plurality of tube connecting apertures; preparing a cover plate to
be fitted to said plate connecting surface, said cover plate having
a plurality of tube insertion apertures corresponding to said
plurality of tube connecting apertures; and joining said cover
plate to said plate connecting surface of said header tank main
body in a state in which said plurality of heat exchanging tubes
are fitted in said plurality of tube insertion apertures.
41. The method for manufacturing a heat exchanger header tank as
recited in claim 40, wherein, at a step of obtaining said header
tank main body, a communication groove communicating with end
openings of tube apertures of said heat exchanging tube and said
plurality of refrigerant passages is formed at a bottom surface of
said engaging dented stepped portion.
42. A method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, said method, comprising: preparing an intermediate having
a flat plate connecting surface at a tube connecting side,
refrigerant inlet passages extending in a longitudinal direction of
said intermediate at a front side of said intermediate and arranged
in a widthwise direction of said intermediate, and refrigerant
outlet passages extending in a longitudinal direction of said
intermediate at a rear side of said intermediate and arranged in a
widthwise direction of said intermediate; obtaining a header tank
main body by forming a plurality of front side tube connecting
apertures communicating with said plurality of refrigerant inlet
passages so as to bridge said plurality of refrigerant inlet
passages in said plate connecting surface of said intermediate at
predetermined intervals in a longitudinal direction of said
intermediate, a plurality of rear side tube connecting apertures
communicating with said plurality of refrigerant outlet passages so
as to bridge said plurality of refrigerant outlet passages in said
plate connecting surface of said intermediate at predetermined
intervals in a longitudinal direction of said intermediate,
engaging dented stepped portions each capable of engaging with an
end portion of said front side heat exchanging tube at partitioning
walls partitioning said plurality of refrigerant inlet passages
corresponding to each of said plurality of tube connecting
apertures, and engaging dented stepped portions each capable of
engaging with an end portion of said rear side heat exchanging tube
at partitioning walls partitioning said plurality of refrigerant
outlet passages corresponding to each of said plurality of tube
connecting apertures; preparing a cover plate to be fitted to said
plate connecting surface, said cover plate having a plurality of
tube insertion apertures corresponding to said plurality of tube
connecting apertures; and joining said cover plate to said plate
connecting surface of said header tank main body in a state in
which said plurality of heat exchanging tubes are fitted in said
plurality of tube insertion apertures.
43. The method for manufacturing a heat exchanger header tank as
recited in claim 42, wherein, at a step of obtaining said header
tank main body, a communication groove communicating with end
openings of tube apertures of said heat exchanging tube and said
plurality of refrigerant inlet passages and a communication groove
communicating with end openings of tube apertures of said heat
exchanging tube and said plurality of refrigerant outlet passages
are formed at a bottom surface of said engaging dented stepped
portion.
Description
[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.
CROSS REFERENCE TO RELATED APPLICATIONS
[0002] This application is an application filed under 35 U.S.C.
.sctn.111(a) claiming the benefit pursuant to 35 U.S.C.
.sctn.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.
.sctn.111(b).
TECHNICAL FIELD
[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.sub.2. It also
relates to a header tank for such heat exchangers and methods for
manufacturing them.
BACKGROUND ART
[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.sub.2) as refrigerant has been proposed.
CO.sub.2 is one of natural refrigerants found in nature, and hardly
affects the global environment as compared with Freon.
[0006] However, in cases where CO.sub.2 is used as refrigerant in a
refrigeration cycle, the refrigerant working pressure at a higher
pressure side becomes high about 10 times as compared with Freon
family refrigerant since the thermodynamic property peculiar to
CO.sub.2 causes a supercritical cycle. Accordingly, in cases where
a structure of a refrigeration cycle apparatus such as a heat
exchanger using conventional Freon family refrigerant is applied to
a structure of a refrigeration cycle apparatus using CO.sub.2 as
refrigerant, it is required to improve the pressure resistance by,
for example, increasing the wall thickness of various parts
constituting the apparatus. This causes increased weight of the
apparatus, and therefore it is difficult to achieve the practical
use of such apparatus.
[0007] Under such a technical background, a high pressure
resistance heat exchanger using CO.sub.2 refrigerant is known
(e.g., Japanese Unexamined Laid-open Patent Publication No. JP
2000-81294 A). In this heat exchanger, the header tank includes a
header plate having a number of tube connection apertures into
which end portions of heat exchanging tubes are connected and a
plate cover covering one side of the header plate.
[0008] However, in the aforementioned conventional heat exchanger
using CO.sub.2 refrigerant, since the peripheral wall of the header
tank is constituted by two members, the header plate and the plate
cover, enough joining strength therebetween cannot be obtained.
Therefore, there has been difficult to secure predetermined
pressure resistance. If the cross-sectional area of the refrigerant
passage in the header tank is increased in order to reduce the flow
resistance, the joining area between the header plate and the cover
plate decreases, resulting in decreased joining strength, which in
turn further deteriorates the pressure resistance.
[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.sub.2
refrigerant. Another object of the present invention is to provide
a header tank for such a heat exchanger, a method for manufacturing
the heat exchanger and a method for manufacturing the header
tank.
[0010] Other objects of the present invention will become apparent
from the following explanations.
DISCLOSURE OF INVENTION
[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.sup.nd aspect of the present invention, a
heat exchanger, comprises:
[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.sup.nd aspect of the present invention, it is
preferable that the refrigerant inlet passage and the refrigerant
outlet passage formed in the header tank main body include plural
passages arranged in parallel, respectively.
[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.sup.nd aspect of the present invention, it is
preferable that the header tank main body has a cut portion formed
from an outside surface of an end portion of the header tank main
body and extending to the refrigeration inlet passage and the
refrigeration outlet passage, and wherein end portions of the
refrigerant inlet passage and the refrigerant outlet passage are
closed by a blocking plate inserted in and secured to the cut
portion.
[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.sup.rd aspect of the present invention, a
heat exchanger, comprises:
[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.sup.st aspect of the present invention, enough strength
against the inner pressure can be secured, and the refrigerant flow
resistance can be decreased.
[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.sup.th aspect of the present invention, a
heat exchanger, comprises:
[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.sup.rd aspect of the present invention, enough strength
against the inner pressure can be secured, and the refrigerant flow
resistance can be decreased. Furthermore, 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.
[0053] Like the 4.sup.th aspect of the present invention, in cases
where the refrigerant passages are arranged in parallel, it is
possible to form an engaging dented stepped portion as an engaging
stepped portion at the partitioning wall partitioning the
passages.
[0054] In this 4.sup.th aspect of the present invention, it is
preferable that a communication groove communicating with end
openings of tube apertures of the plurality of heat exchanging
tubes and the plurality of refrigerant passages is formed at a
bottom surface of the engaging dented stepped portion.
[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.sup.th aspect of the present invention, a
heat exchanger, comprises:
[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.sup.th aspect of
the present invention, like the 4.sup.th aspect of the present
invention, enough strength against the inner pressure can be
secured, and the refrigerant flow resistance can be decreased.
Furthermore, when inserting the heat exchanging tube into the
connecting aperture of the header tank main body, the heat
exchanging tube can be positioned in the insertion direction
thereof.
[0066] In the 5.sup.th aspect of the present invention, it is
preferable that a communication groove communicating with end
openings of tube apertures of the plurality of heat exchanging
tubes and the plurality of refrigerant inlet passages and a
communication groove communicating with end openings of tube
apertures of the plurality of heat exchanging tubes and the
plurality of refrigerant outlet passages are formed at a bottom
surface of the engaging dented stepped portion respectively.
[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.sup.th aspect of the present invention, the
communication groove may be formed into a generally V-shape, and
the communication groove may be formed into a generally
U-shape.
[0070] In the heat exchanger according to the 1.sup.st to 5.sup.th
aspect of the present invention, since the heat exchanger has
enough strength against the inner pressure, the heat exchanger can
be preferably applied to a heat exchanger for use in a vapor
compression type refrigeration cycle using CO.sub.2
refrigerant.
[0071] That is, in the heat exchanger according to the 1.sup.st to
5.sup.th aspect of the present invention, it is preferable that
carbon dioxide refrigerant (CO.sub.2 refrigerant) is used as the
refrigerant.
[0072] The 6.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger according to the
1.sup.st aspect of the present invention.
[0073] According to the 6.sup.th aspect of the present invention, a
method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between the pair of header tanks and arranged in parallel in a
longitudinal direction of the header tank with opposite ends
thereof connected to the pair of header tanks in fluid
communication, the method, comprises:
[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.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger according to the
2.sup.nd aspect of the present invention.
[0079] According to the 7.sup.th aspect of the present invention, a
method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between the pair of header tanks and arranged in parallel in a
longitudinal direction of the header tank 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, the method, comprises:
[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.sup.th aspect of the present invention, it is
preferable that the refrigerant inlet passage and the refrigerant
outlet passage are formed to have plural rows arranged in parallel,
respectively.
[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.sup.th aspect of the present invention, it is
preferable that the intermediate having the refrigerant inlet
passage and the refrigerant outlet passage is formed by extrusion
molding or drawing molding.
[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.sup.th aspect of the present invention, it is
preferable that the plate connecting surface is formed by
milling.
[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.sup.th aspect of the present invention, it is
preferable to employ the tube connecting apertures formed by
cutting, and the communication apertures formed by cutting.
[0092] In this case, the tube connecting apertures and the
communication apertures can be formed in high accuracy.
[0093] In the 7.sup.th aspect of the present invention, it is
preferable that the tube connecting apertures and the communication
apertures are formed simultaneously.
[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.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger according to the
3.sup.rd aspect of the present invention.
[0096] According to the 8.sup.th aspect of the present invention, a
method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between the pair of header tanks and arranged in parallel in a
longitudinal direction of the header tank with opposite ends
thereof connected to the pair of header tanks in fluid
communication, the method, comprises:
[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.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger according to the
4.sup.th aspect of the present invention.
[0102] According to the 9.sup.th aspect of the present invention, a
method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between the pair of header tanks and arranged in parallel in a
longitudinal direction of the header tank with opposite ends
thereof connected to the pair of header tanks in fluid
communication, the method, comprises:
[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.sup.th aspect of the present invention, it is
preferable that, at a step of obtaining the header tank main body,
a communication groove communicating with end openings of tube
apertures of the heat exchanging tube and the plurality of
refrigerant passages is formed at a bottom surface of each of the
engaging dented stepped portions.
[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.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger according to the
5.sup.th aspect of the present invention.
[0110] According to the 10.sup.th aspect of the present invention,
a method for manufacturing a heat exchanger including a pair of
header tanks and a plurality of heat exchanging tubes disposed
between the pair of header tanks and arranged in parallel in a
longitudinal direction of the header tank 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, the method, comprises:
[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.sup.th aspect of the present invention, like the
5.sup.th aspect of the present invention, it is preferable that, at
a step of obtaining the header tank main body, a communication
groove communicating with end openings of tube apertures of the
heat exchanging tube and the plurality of refrigerant inlet
passages and a communication groove communicating with end openings
of tube apertures of the heat exchanging tube and the plurality of
refrigerant outlet passages are formed at a bottom surface of each
of the engaging dented stepped portions.
[0116] The 11.sup.th aspect of the present invention specifies the
header tank as a main component of the heat exchanger according to
the 1.sup.st aspect of the present invention.
[0117] According to the 11.sup.th aspect of the present invention,
a heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, the heat exchanger header tank, comprises:
[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.sup.th aspect of the present invention specifies the
header tank as a main component of the heat exchanger according to
the 2.sup.nd aspect of the present invention.
[0124] According to the 12.sup.th aspect of the present invention,
a heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, the heat exchanger header tank, comprises:
[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.sup.th aspect of the present invention, like the
2.sup.nd aspect of the present invention, it is preferable to
employ the flowing structure.
[0131] That is, in the 12.sup.th aspect of the present invention,
1) it is preferable that the refrigerant inlet passage and the
refrigerant outlet passage formed in the header tank main body
include plural passages arranged in parallel, respectively; 2) it
is preferable that the header tank main body has a cut portion
formed from an outside surface of an end portion of the header tank
main body and extending to the refrigeration inlet passage and the
refrigeration outlet passage, and wherein end portions of the
refrigerant inlet passage and the refrigerant outlet passage are
closed by a blocking plate inserted in and secured to the cut
portion; 3) it is preferable that the header tank main body has a
communication aperture communicating with the refrigerant inlet
passage and the refrigerant outlet passage.
[0132] The 13.sup.th aspect of the present invention specifies the
header tank as a main component of the heat exchanger according to
the 3rd aspect of the present invention.
[0133] According to the 13.sup.th aspect of the present invention,
a heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, the heat exchanger header tank, comprises:
[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.sup.th aspect of the present invention specifies the
header tank as a main component of the heat exchanger according to
the 4.sup.th aspect of the present invention.
[0141] According to the 14.sup.th aspect of the present invention,
a heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, the heat exchanger header tank, comprises:
[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.sup.th aspect of the present invention, like the
4.sup.th aspect of the present invention, it is preferable that a
communication groove communicating with end openings of tube
apertures of the plurality of heat exchanging tubes and the
plurality of refrigerant passages is formed at a bottom surface of
the engaging dented stepped portion.
[0149] The 15.sup.th aspect of the present invention specifies the
header tank as a main component of the heat exchanger according to
the 5.sup.th aspect of the present invention.
[0150] According to the 15.sup.th aspect of the present invention,
a heat exchanger header tank for connecting end portions of a
plurality of heat exchanging tubes disposed in parallel in fluid
communication, the heat exchanger header tank, comprising:
[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.sup.th aspect of the present invention, like the
5th aspect of the present invention, it is preferable that a
communication groove communicating with end openings of tube
apertures of the plurality of heat exchanging tubes and the
plurality of refrigerant inlet passages and a communication groove
communicating with end openings of tube apertures of the plurality
of heat exchanging tubes and the plurality of refrigerant outlet
passages are formed at a bottom surface of the engaging dented
stepped portion respectively.
[0158] The 16.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger header tank
according to the 6.sup.th aspect of the present invention.
[0159] According to the 16.sup.th aspect of the present invention,
a method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, the method, comprises:
[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.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger header tank
according to the 7.sup.th aspect of the present invention.
[0165] According to the 17.sup.th aspect of the present invention,
a method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, the method, comprises:
[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.sup.th aspect of the present invention, it is
preferable that the refrigerant inlet passage and the refrigerant
outlet passage are formed to have plural rows arranged in parallel,
respectively.
[0171] The 18.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger header tank
according to the 8.sup.th aspect of the present invention.
[0172] According to the 18.sup.th aspect of the present invention,
a method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, the method, comprises:
[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.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger header tank
according to the 9.sup.th aspect of the present invention.
[0178] According to the 19.sup.th aspect of the present invention,
a method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, the method, comprises:
[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.sup.th aspect of the present invention, like the
9.sup.th aspect of the present invention, it is preferable that, at
a step of obtaining the header tank main body, a communication
groove communicating with end openings of tube apertures of the
heat exchanging tube and the plurality of refrigerant passages is
formed at a bottom surface of the engaging dented stepped
portion.
[0184] The 20.sup.th aspect of the present invention specifies one
of manufacturing processes of the heat exchanger header tank
according to the 10.sup.th aspect of the present invention.
[0185] According to the 20.sup.th aspect of the present invention,
a method for manufacturing a heat exchanger header tank for
connecting a plurality of heat exchanging tubes arranged in
parallel, the method, comprises:
[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.sup.th aspect of the present invention, like the
10.sup.th aspect of the present invention, it is preferable that,
at a step of obtaining the header tank main body, a communication
groove communicating with end openings of tube apertures of the
heat exchanging tube and the plurality of refrigerant inlet
passages and a communication groove communicating with end openings
of tube apertures of the heat exchanging tube and the plurality of
refrigerant outlet passages are formed at a bottom surface of the
engaging dented stepped portion.
[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.
BRIEF DESCRIPTION OF DRAWINGS
[0192] The accompanying figures are provided by way of example,
without limiting the broad scope of the invention or various other
embodiments, wherein:
[0193] FIG. 1 is a perspective view showing an embodiment of a
exchanger according to the present invention;
[0194] FIG. 2 is a perspective view showing a lower header tank of
the heat exchanger and therearound;
[0195] FIG. 3 is an exploded perspective view showing the lower
header tank of the heat exchanger and therearound;
[0196] FIG. 4 is a cross-sectional view showing tube connecting
portions of the upper and lower header tanks of the heat exchanger
and therearound;
[0197] FIG. 5 is a cross-sectional view showing a communication
aperture of the lower header tank of the heat exchanger and
therearound;
[0198] FIG. 6 is a perspective view showing the lower header tank
main body applied to the heat exchanger and therearound;
[0199] FIG. 7 is a perspective view showing the upper header tank
of the heat exchanger and therearound;
[0200] FIG. 8 is an exploded perspective view showing the upper
header tank of the heat exchanger and therearound;
[0201] FIG. 9 is a cross-sectional view taken along the line X-X in
FIG. 4;
[0202] FIG. 10 is a cross-sectional view showing tube connecting
portions of a lower header tank of a heat exchanger according to a
first modification of the present invention;
[0203] FIG. 11A is a cross-sectional view taken along the line Y-Y
in FIG. 10;
[0204] FIG. 11B is an exploded cross-sectional view of FIG.
11A;
[0205] FIG. 12A is a cross-sectional view corresponding to the
cross-sectional view taken along the line Y-Y in FIG. 10, and shows
the tube connecting portion of the lower header of a heat exchanger
according to a second embodiment of the present invention; and
[0206] FIG. 12B is an exploded cross-sectional view of the tube
connecting portion of the lower header and the tube shown in FIG.
11A.
BEST MODE FOR CARRYING OUT THE INVENTION
[0207] FIG. 1 is a perspective view showing a heat exchanger
according to an embodiment of the present invention. This is a heat
exchanger to be used in a vapor compression refrigeration cycle
using CO.sub.2 as refrigerant. As shown in this figure, this heat
exchanger is provided with, as fundamental components, a pair of
lower and upper flat header tanks 10 and 30, flat heat exchanging
tubes 1a and 1b disposed in parallel with each other along the
longitudinal direction of the header tanks (right and left
direction) between the pair of header tanks 10 and 30 with opposite
ends communicated with the pair of header tanks 10 and 30, the
tubes forming two rows in the widthwise direction of the header
tank (front and rear direction) and corrugated fins 5 disposed
between the adjacent tubes 1a and 1b arranged in the right and left
direction.
[0208] As shown in FIGS. 1 to 6, the lower refrigerant turn-side
header tank 10 includes a header tank main body 11 and a cover
plate 20.
[0209] The header tank main body 11 has four refrigerant passages
12a and 12b disposed in parallel with each other in the widthwise
direction of the header tank main body 11 and each extending in the
longitudinal direction of the header tank main body 11. Among four
refrigerant passages 12a and 12b, two front side refrigerant
passages are constituted as refrigerant inlet flow passage 12a and
12a, and two rear side refrigerant passages are constituted as
refrigerant discharging passages 12b and 12b.
[0210] The inner side surface (upper surface) of the header tank
main body 11 is formed into a plate connecting surface 13. The
front half portion and the rear half portion of this plate
connecting surface 13 is provided with a plurality of tube
connecting apertures 14a and 14b disposed at predetermined
intervals respectively. Each front side tube connecting aperture
14a is formed into an elongated aperture corresponding to the
cross-sectional configuration of the heat exchanging tube 1a and
disposed in the header tank main body 11 so as to bridge the two
front side refrigerant inlet flow passages 12a and 12a and
communicate with them. Like the front side tube connecting aperture
14a, each rear side tube connecting aperture 14b is formed into an
elongated aperture corresponding to the cross-sectional
configuration of the heat exchanging tube 1b and disposed in the
header tank main body 11 so as to bridge the two rear side
refrigerant inlet flow passages 12b and 12b and communicate with
them.
[0211] The aforementioned tube connecting apertures 14a (14b) are
formed by cutting operation which will be explained below. By this
cutting operation, an engaging dented portion 19a and 19b as an
engaging stepped portion is formed at the partitioning wall 18a
between the two front side refrigerant inlet passages 12a and 12a
and the partitioning wall 18b between the two rear side refrigerant
outlet passages 12b and 12b, respectively.
[0212] In the plate connecting surface 13 of the header tank main
body 11, a plurality of elongated communication apertures 15 each
extending in the widthwise direction of the header tank main body
11 are formed at predetermined positions between the tube
connecting apertures 14a and 14b. Each communication aperture 15 is
disposed so as to cross the four refrigerant passages 12a and 12b
and communicate with these passages in the header tank main body
11. Thereby, the refrigerant inlet passages 12a and the refrigerant
outlet passages 12b are communicated with each other.
[0213] In the outside surface (lower surface) at both end portions
of the header tank main body 11, a cut portions 16 is formed from
the front side surface of the header tank main body 11 to the rear
side surface thereof so as to cross the four refrigerant passages
12a and 12b.
[0214] In each of these cut portions 16 and 16, a blocking plate 17
is fitted and fixed therein, thereby hermetically closing the end
portions of each refrigerant passage 12a(12b).
[0215] The cover plate 20 has a dimension corresponding to the
plate connecting surface 13 of the header tank main body 11. In
this cover plate 20, a plurality of elongated tube insertion
apertures 24a and 24b forming two rows are formed at predetermined
intervals in the longitudinal direction of the header tank main
body 11.
[0216] This cover plate 20 is joined to the plate connecting
surface 13 of the header tank main body 11 in a laminated state. In
this state, the communication apertures 15 of the header tank main
body 11 is sealed by the cover plate 20, while each of the tube
connecting apertures 14a and 14b is disposed so as to coincide with
each of the tube insertion apertures 24a and 24b.
[0217] As shown in FIGS. 5, 7 and 8, the upper header tank 30 for
introducing and discharging refrigerant has a header tank main body
31 and the cover plate 40 like the aforementioned lower header
tank.
[0218] Like the lower header tank 10, the upper header tank 31 is
provided with refrigerant inlet passages 32a and 32a, refrigerant
outlet passages 32b and 32b, a plate connecting surface 33, tube
connecting apertures 34a and 34b, cut portions 36 and 36,
partitioning walls 38a and 38b and engaging dented portions 39a and
39b. Furthermore, the header tank main body 31 is provided with a
plurality of communication apertures 60 disposed at predetermined
intervals for allowing the communication of the adjacent
refrigerant inlet passages 32a and 32a and the communication of the
adjacent refrigerant outlet passages 32b and 32b. In this header
tank main body 31, no communication passage for allowing the
communication between the refrigerant inlet passages 32a and the
refrigerant outlet passages 32b is provided.
[0219] Furthermore, like the lower cover plate 20, this cover plate
40 is provided with tube insertion apertures 44a and 44b.
[0220] Furthermore, like the lower header tank main body 11, a
blocking plate 37 is inserted in a cut portion 36 formed in one end
of the header tank main body 31, thereby closing each one end
portion of the refrigerant inlet passages 32a and the refrigerant
outlet passages 32b.
[0221] Furthermore, into the other cut portion 36, a refrigerant
inlet/outlet plate 50 are inserted. This refrigerant inlet/outlet
plate 50 is provided with a refrigerant flow inlet 51a and a
refrigerant flow outlet 51b. The refrigerant flow inlet 51a
communicates with the end portions of the two front side
refrigerant inlet flow passages 32a and 32a in the header tank main
body 31, and the refrigerant flow outlet 51b communicates with the
end portions of the two rear side refrigerant inlet flow passages
32b and 32b in the header tank main body 31.
[0222] Furthermore, a refrigerant inlet pipe 52a and a refrigerant
outlet pipe 52b are inserted into the end portion of the header
tank main body 3 respectively. The insertion end portion of the
refrigerant inlet pipe 52a is connected to the refrigerant flow
inlet 51a of the plate 50, while the insertion end portion of the
refrigerant outlet pipe 52b is connected to the refrigerant flow
outlet 51b of the plate 50. Thereby, the refrigerant inlet pipe 52a
is connected to the refrigerant inlet passages 32a of the upper
header tank 30 in fluid communication, while the refrigerant outlet
pipe 52b is connected to the refrigerant outlet passages 32b of the
upper header tank 30 in fluid communication.
[0223] In this embodiment, the header tanks 10 and 30 are formed by
an extrusion method or a drawing method.
[0224] In detail, an intermediate having refrigerant passages 12a
and 12b (32a and 32b) is formed by an extrusion method or a drawing
method. Thereafter, the intermediate is subjected to cutting
processing for forming tube connecting apertures 14a and 14b (34a,
34b), communication apertures 15 and cut portions 16(36) to thereby
obtain the aforementioned header tank main body 11 (31).
[0225] In cases where communication apertures 15 are formed, like
the refrigerant-turn side header tank main body 11, the processing
for cutting the communication apertures 15 and the tube connecting
apertures 14a and 14b may be performed simultaneously, which can
reduce the number of processing steps. This in turn can improve the
productivity.
[0226] In this embodiment, after the aforementioned cutting
processing, it is preferable to conduct milling processing to the
plate connecting surface 13 (33) of the header tank main body 11
(31) to obtain a flat and smooth surface with no uneven portion.
That is, by forming the connecting surface 13 (33) into a flat and
smooth surface, the joining area of the connecting surface 13 (33)
to which the cover plate 20(40) is integrally connected can be
increased, resulting in improved joining (adhering) strength, which
can improve the joining strength. As a result, the pressure
resistance can be further improved.
[0227] The cover plate 20(40) can be made by, for example, a
calendar forming method, a extrusion method and a drawing method.
That is, after manufacturing a plate-shaped intermediate by the
aforementioned method, the intermediate is subjected to cutting
processing or drilling processing to form tube insertion aperture
24a and 24b (44a and 44b). Thus, a cover plate 20(40) can be
obtained.
[0228] As shown in, for example, FIGS. 2 and 3, the heat exchanging
tube 1a and 1b is constituted by an extruded article or a drawn
article, and has a flat cross-sectional configuration. The heat
exchanging tube 1a and 1b has a plurality of circular passages
extending in the longitudinal direction thereof and disposed in
parallel with each other in the widthwise direction of the
tube.
[0229] The lower and upper end portions of each heat exchanging
tube 1a (1b) are inserted in the tube insertion apertures 24a and
44a (24b and 44b) of the cover plates 20 and 40 of the
aforementioned header tanks 10 and 30, and inserted into and
secured to the tube connecting apertures 14a and 34a (14b and 34b)
of the header tank main bodies 11 and 31 respectively. At this
time, as shown in FIGS. 4 and 9, the end portions of the heat
exchanging tube 1a(1b) is engaged with the engaging dented portion
19a ad 39a (19b and 39b) formed in the partitioning wall 18a and
38a (18b and 38b) to thereby be positioned in the insertion
direction of the heat exchanging tube 1a and 1b.
[0230] In the state in which the heat exchanging tubes 1a and 1b
are inserted in the header tanks 10 and 30 and corrugated fins 5
are disposed between the adjacent heat exchanging tubes 1a and 1b,
these components are integrally joined to form a heat exchanger
according to this embodiment.
[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.sub.2 refrigerant flowed into the
refrigerant inlet passages 32a and 32a of the upper header tank 30
through the refrigerant inlet pipe 52a goes down through a
plurality of heat exchanging tubes 1a located at the front side of
the heat exchanger, and then flows into the refrigerant inlet
passages 12a and 12a of the lower header tank 10. The refrigerant
flowed into the inlet passages 12a and 12a is led to the
refrigerant outlet passages 12b and 12b through the communication
apertures 15, and then goes up through a plurality of heat
exchanging tubes 1b located at the rear side of the heat exchanger,
and flows into the refrigerant outlet passages 32b and 32b of the
upper header tank 30. Thereafter, the refrigerant is sent to the
following portion in a refrigeration cycle through the refrigerant
outlet pipe 52b.
[0234] As explained above, in the heat exchanger according to this
embodiment, almost the entire periphery of the external wall of the
header tank 10(30) is formed by an integrally formed header tank
main body 11(31), and the tube connecting side of the header tank
main body 11(31) is reinforced by the cover plat 20(40) joined to
the tube connecting side. Therefore, enough strength against the
inner pressure can be obtained.
[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 12a, 12b, 32a and
32b can be increased, resulting in decreased flow resistance, which
in turn can further improve the heat exchange performance.
[0236] Furthermore, since four refrigerant passages 12a and 12b
(32a and 32b) are formed in the header tank 10(30), a plurality of
partitioning walls partitioning the passages function as
reinforcing walls, which further increase the strength against the
inner pressure.
[0237] Furthermore, the communication apertures 15 of the
refrigerant-turn side header tank 10 are formed by cutting
processing simultaneously with the tube connecting apertures.
Therefore, the number of processing steps can be reduced as
compared with the case where the communication apertures 15 are
formed separately. Accordingly, the header tank can be manufactured
easily and efficiently.
[0238] Furthermore, since the communication apertures 15 are
hermetically sealed by the cover plate 20, no additional step for
sealing the communication apertures is required, resulting in
further enhanced productivity.
[0239] In cases where the communication aperture 15 is formed to
have a small width, the joining area between the cover plate 20 and
the header tank main body 11 can be increased, which in turn can
further increase the strength against the inner pressure.
[0240] Furthermore, in this embodiment, cut portions 16(36) are
formed in the outer sides of the opposite end portions of the
header tank main body 11(31), and blocking plates 17(37) are
inserted in the cut portions 16(36) to hermetically seal the end
portions of each refrigerant passages 12a and 12b (32a and 32b).
This enables an easy manufacturing of the header tank. For example,
in cases where caps or the like are attached to end portions of a
header tank to close the ends of the refrigeration passages, it is
required to prepare components having a complicate configuration
like a cap, which makes it difficult to manufacture a header. To
the contrary, in this embodiment, since cut portions 16(36) are
formed by cutting the end portions of the header tank main body
11(31) and the plate-shaped blocking plates 17(37) are inserted and
secured therein, the manufacturing of the header tank can be
performed easily.
[0241] Furthermore, in this embodiment, since the header tank main
bodies 11 and 31 are manufactured by an extrusion method or a
drawing method which is suitable for mass production, they can be
manufactured more efficiently.
[0242] Furthermore, in this embodiment, since the plate connecting
surface 11(13) of the header tank main body 11(31) is formed into a
flat and smooth surface by milling, the cover plate 20(40) can be
more assuredly secured to the plate connecting surface 13(33),
which can further enhance the strength against the inner
pressure.
[0243] Furthermore, in this embodiment, when inserting the heat
exchanging tubes 1a and 1b into the tube insertion apertures 14a,
14b, 34a and 34b of the header tank main bodies 11 and 31, since
the end faces of the heat exchanging tubes 1a and 1b engage with
the engaging dented portions 19a, 19b, 39a and 39b formed in the
partitioning walls 18a, 18b, 38a and 38b, the heat exchanging tubes
1a and 1b can be properly positioned with regard to the insertion
direction. Accordingly, the tube insertion can be performed
easily.
[0244] As shown in FIG. 9, in this embodiment, the end face of the
tube 1a(1b) is joined to the bottom surface of the engaging dented
portion 19a(19b). Therefore, a part of the end opening of the
aperture (passages) 2 of the tube is blocked by the bottom surface
of the engaging dented portion 19a(19b). Accordingly, the
refrigerant cannot flow through a part of the aperture 2 of the
tube, causing a decreased flow amount of refrigerant, which may
deteriorate the heat exchange performance.
[0245] Accordingly, as shown in FIGS. 10 and 11, it is recommended
to provide communication grooves 70 communicating with the adjacent
refrigerant inlet (outlet) passages 12a and 12a (12b and 12b) at
the bottom surface of each engaging dented portion 19a(19b). In
this case, the end opening of the aperture 2 of the tube 1a(1b) can
communicate with the refrigerant inlet passage 12a and the
refrigerant outlet passage 12b via the communication groove 70.
This allows the refrigerant to pass through all of the tube
apertures 2, resulting in an increased refrigerant flow amount,
which in turn can enhance the heat exchanging performance.
[0246] The aforementioned communication groove 70 may be formed
into a V-shape as shown in FIG. 11 or a generally U-shape as shown
in FIG. 12. As a method for forming the communication grooves 70,
for example, a method in which the tube connecting apertures 14a
and 14b are formed in the header tank main body 11 by cutting and
then the communication grooves 70 are formed by cutting may be
preferably employed. In this case, the width of the communication
groove 70 formed by the second cutting is preferably set smaller
than the tube-width by 0.4 to 0.5 mm.
[0247] Needless to say, such a communication groove 70 may be
formed in the upper header tank 30 as well as in the refrigerant
outlet passage 12b side.
[0248] In the aforementioned embodiment, the heat exchanger in
which heat exchanging tubes 1a and 1b are arranged in two rows was
exemplified. However, the present invention is not limited to the
above, and may be applied to a heat exchanger in which heat
exchanging tubes 1a and 1b are arranged in one row or three or more
rows.
[0249] Furthermore, in the present invention, the number or the
configuration of the refrigerant passage 12a, 12b 32a and 32b, the
tube connecting aperture 14a, 14b, 34a and 34b and the tube
insertion aperture 24a, 24b, 44a and 44b are not limited to the
aforementioned embodiments.
[0250] As mentioned above, in the heat exchanger according to the
1.sup.th to 5.sup.th aspects of the present invention, the
approximately entire periphery of the external wall of the header
tank is constituted by a header tank main body which can be
integrally formed, and the tube connecting side surface of the
header tank main body is reinforced by joining the cover plate.
Accordingly, sufficient strength against the inner pressure can be
obtained, which enables to secure a larger cross-sectional area of
the refrigerant flow passage. Thus, the flow resistance can be
decreased and the heat exchange performance can be improved.
Especially, in the heat exchanger according to the 3.sup.rd to
5.sup.th aspects of the present invention, the positioning of the
heat exchanging tube with regard to the tube insertion direction
can be attained when inserting the heat exchanging tube into the
header tank, the tube connection work can be performed easily.
[0251] The method for manufacturing the heat exchanger according to
the 6.sup.th to 10.sup.th aspects of the present invention
specifies an embodiment of the manufacture process of the heat
exchanger according to the 1.sup.st to 5.sup.th aspects of the
present invention. Therefore, the heat exchanger having the
aforementioned effects can be manufactured.
[0252] The header tank for heat exchangers according to the
11.sup.th to 15.sup.th aspects of the present invention specifies
an embodiment of the header tank as a main component of the heat
exchanger according to the 1.sup.st to 5.sup.th aspects of the
present invention. Accordingly, the heat exchanger having the
aforementioned effects can be obtained.
[0253] The header tank for heat exchangers according to the
16.sup.th to 20.sup.th aspects of the present invention specifies
the header tank as a main component of the heat exchanger according
to the 1.sup.st to 5.sup.th aspects of the present invention.
Accordingly, the heat exchanger having the aforementioned effects
can be obtained.
[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.
INDUSTRIAL APPLICABILITY
[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.sub.2.
* * * * *