U.S. patent application number 10/549286 was filed with the patent office on 2006-10-19 for tube blank correcting member for use in temporarily assembling heat exchanger, and apparatus for and method of temporaily assembling heat exchanger.
This patent application is currently assigned to SHOWA DENKO K.K. Invention is credited to Akira Sekine, Takashi Tamura.
Application Number | 20060231244 10/549286 |
Document ID | / |
Family ID | 37107362 |
Filed Date | 2006-10-19 |
United States Patent
Application |
20060231244 |
Kind Code |
A1 |
Sekine; Akira ; et
al. |
October 19, 2006 |
Tube blank correcting member for use in temporarily assembling heat
exchanger, and apparatus for and method of temporaily assembling
heat exchanger
Abstract
A temporarily assembling apparatus comprises a support member 2
for supporting thereon heat exchange tube blanks P having their
lengthwise direction positioned laterally, with their widthwise
direction positioned vertically, and arranged from front rearward
in parallel with opposite left and right ends thereof aligned
respectively, and the fins F arranged between the respective pairs
of adjacent tube blanks. Two header supports 3 are arranged
respectively at the left and right sides of the support member 2
and movable leftward or rightward. A pair of left and right tube
blank correcting members 19 are each in the form of a plate
extending from the front rearward and having a plurality of blank
fitting slits 23 formed in a side edge thereof and arranged from
the front rearward at the same spacing as the heat exchange tubes
to be produced of the heat exchanger. Each of the blank correcting
members is movable between a correcting position wherein the
corresponding ends of all the tube blanks P as supported on the
support member 2 are fitted into the respective slits 23 and a
noncorrecting position wherein the tube blanks P are not fitted
into the slits 23. In temporarily assembling components, the
opposie ends of the heat exchange blanks P can be reliably placed
into insertion holes of respective headers.
Inventors: |
Sekine; Akira; (Tochigi,
JP) ; Tamura; Takashi; (Tochigi, JP) |
Correspondence
Address: |
C. IRVIN MCCLELLAND;OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Assignee: |
SHOWA DENKO K.K
13-9, Shiba Daimon 1-chome
Minato-ku, Tokyo
JP
105-8518
|
Family ID: |
37107362 |
Appl. No.: |
10/549286 |
Filed: |
March 18, 2004 |
PCT Filed: |
March 18, 2004 |
PCT NO: |
PCT/JP04/03697 |
371 Date: |
June 19, 2006 |
Current U.S.
Class: |
165/173 ;
165/905; 165/906 |
Current CPC
Class: |
Y10T 29/49378 20150115;
Y10T 29/53113 20150115; F28F 9/0243 20130101; B23K 3/087 20130101;
Y10T 29/4935 20150115; F28D 1/0391 20130101; Y10T 29/53117
20150115; F28F 9/182 20130101; B23K 2101/14 20180801; B23P 15/26
20130101; Y10T 29/49359 20150115 |
Class at
Publication: |
165/173 ;
165/905; 165/906 |
International
Class: |
F28F 9/02 20060101
F28F009/02 |
Claims
1. A tube blank correcting member for use in fabricating a heat
exchanger comprising a pair of headers arranged in parallel and
spaced apart from each other, a plurality of flat heat exchange
tubes arranged in parallel between the headers and brazed at
opposite ends to the respective headers with the tube ends placed
into respective insertion holes formed in the headers, and fins
each arranged between and brazed to each pair of adjacent heat
exchange tubes, the blank correcting member being adapted for use
in temporarily assembling the headers, flat heat exchange tube
blanks and the fins into a unit to be brazed, the blank correcting
member extending from front rearward and having a plurality of
blank fitting slits formed in a side edge thereof and arranged from
the front rearward at the same spacing as the heat exchange tubes
to be produced of the heat exchanger.
2. A tube blank correcting member for use in temporarily assembling
a heat exchanger according to claim 1 wherein each of the blank
fitting slits has an opening with a width larger than the maximum
thickness of the flat heat exchange tube blank, and an open end
portion of the slit flares toward the opening with a gradually
increasing width.
3. A tube blank correcting member for use in temporarily assembling
a heat exchanger according to claim 1 wherein an open end portion
of each of the blank fitting slits flares toward an opening with a
gradually increasing width to provide a tapering portion, and the
tapering portion has a taper angle of 10 to 20 deg.
4. A tube blank correcting member for use in temporarily assembling
a heat exchanger according to claim 3 wherein the blank fitting
slit has a portion other than the tapering portion and having a
depth not smaller than the width of the tube blank.
5. A heat exchanger temporarily assembling apparatus for use in
fabricating a heat exchanger comprising a pair of headers arranged
in parallel and spaced apart from each other, a plurality of flat
heat exchange tubes arranged in parallel between the headers and
brazed at opposite ends to the respective headers with the tube
ends placed into respective insertion holes formed in the headers,
and fins each arranged between and brazed to each pair of adjacent
heat exchange tubes, the apparatus being adapted for use in
temporarily assembling the headers, flat heat exchange tube blanks
and the fins into a unit to be brazed, the heat exchanger
temporarily assembling apparatus comprising a support member for
supporting thereon the heat exchanger tube blanks arranged from
front rearward in parallel with their lengthwise direction
positioned laterally, with their widthwise direction positioned
vertically, and with opposite left and right ends thereof aligned
respectively, and the fins arranged between the respective pairs of
adjacent tube blanks, two header supports arranged respectively at
left and right sides of the support member and movable leftward or
rightward, and a pair of left and right tube blank correcting
members each extending from the front rearward and having a
plurality of blank fitting slits formed in a side edge thereof and
arranged from the front rearward at the same spacing as the heat
exchange tubes to be produced of the heat exchanger, each of the
tube blank correcting members being movable between a correcting
position wherein the corresponding ends of all the tube blanks as
supported on the support member are fitted into the respective
slits and a noncorrecting position wherein the tube blanks are not
fitted into the slits.
6. A heat exchanger temporarily assembling apparatus according to
claim 5 wherein each of the blank fitting slits has an opening with
a width larger than the maximum thickness of the flat heat exchange
tube blank, and an open end portion of the slit flares toward the
opening with a gradually increasing width.
7. A heat exchanger temporarily assembling apparatus according to
claim 5 wherein an open end portion of each of the blank fitting
slits flares toward an opening with a gradually increasing width to
provide a tapering portion, and the tapering portion has a taper
angle of 10 to 20 deg.
8. A heat exchanger temporarily assembling apparatus according to
claim 7 wherein the blank fitting slit has a portion other than the
tapering portion and having a depth not smaller than the width of
the tube blank.
9. A heat exchanger temporarily assembling apparatus according to
claim 5 wherein when in the correcting position, the tube blank
correcting member is movable laterally.
10. A heat exchanger temporarily assembling apparatus according to
claim 5 wherein when in the correcting position, the tube blank
correcting member is biased laterally outward by a biasing
member.
11. A heat exchanger temporarily assembling apparatus according to
claim 5 wherein each of the tube blank correcting members is
provided on a tube blank holding member extending from the front
rearward, and the tube blank holding member is movable between a
first position wherein the holding member is placed on
corresponding left or right end portions of all the heat exchange
tube blanks supported on the support member and a second position
where the holding member is away from all the heat exchange tube
blanks, the tube blank correcting member being movable upward or
downward relative to the holding member when the holding member is
in the first position, the blank correcting member assuming the
correcting position when moved downward or assuming the
noncorrecting position when moved upward.
12. A heat exchanger temporarily assembling apparatus according to
claim 11 wherein the tube blank holding member is disposed
laterally outwardly of the corresponding header support and fixed
to a free end of an arm attached to a horizontal rod extending from
the front rearward and pivotally movable about an axis of the rod,
and the holding member is movable between the first position and
the second position by the pivotal movement of the arm.
13. In fabricating a heat exchanger comprising a pair of headers
arranged in parallel and spaced apart from each other, a plurality
of flat heat exchange tubes arranged in parallel between the
headers and brazed at opposite ends to the respective headers with
the tube ends placed into respective insertion holes formed in the
headers, and fins each arranged between and brazed to each pair of
adjacent heat exchange tubes, each of the heat exchange tubes
having a pair of flat walls opposed to each other and two side
walls interconnecting the two flat walls respectively at opposite
side edges thereof, a heat exchanger temporarily assembling method
for use in temporarily assembling the headers, flat heat exchange
tube blanks and the fins into a unit to be brazed, the heat
exchanger temporarily assembling method using an apparatus
according to any one of claims 5 to 12 and including: causing the
support member to support thereon the heat exchange tube blanks
arranged from front rearward in parallel with their lengthwise
direction positioned laterally, with their widthwise direction
positioned vertically, and with opposite left and right ends
thereof aligned respectively, and the fins arranged between the
respective pairs of adjacent tube blanks, placing the headers on
the respective header supports as spaced apart from each other,
moving each of the tube blank correcting members to the correcting
position to place corresponding left or right ends of all the tube
blanks on the support member into the respective blank fitting
slits, and moving the two header supports laterally inward to place
the opposite ends of the tube blanks into the respective insertion
holes of the headers.
14. A heat exchanger temporarily assembling method according to
claim 13 wherein each of the heat exchange tube blanks is produced
from a metal plate having two first portions for making the flat
walls, a second portion interconnecting the first portions for
forming one of the side walls, and two third portions projecting
from the respective first portions integrally therewith each at a
side edge thereof opposite to the second portion for making the
other side wall, by bending the metal plate to the shape of a
hairpin at the second portion to place the third portions end to
end.
15. A heat exchanger temporarily assembling method according to
claim 14 wherein the metal plate is formed from an aluminum brazing
sheet having a brazing material layer providing opposite surfaces
thereof by rolling the sheet.
16. A process for fabricating a heat exchanger characterized in
that the headers, the heat exchange tube blanks and the fins
temporarily assembled by a method according to any one of claims 13
to 15 are brazed.
17. A heat exchanger fabricated by brazing the headers, the heat
exchange tube blanks and the fins temporarily assembled by a method
according to any one of claims 13 to 15.
18. A vehicle comprising a refrigeration cycle having a compressor,
a condenser and an evaporator, the condenser being a heat exchanger
according to claim 17.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] 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 Provisional Application No.
60/465,788 filed Apr. 28, 2003 pursuant to 35 U.S.C.
.sctn.111(b).
TECHNICAL FIELD
[0002] The present invention relates to tube blank correcting
members for use in temporarily assembling heat exchangers, and an
apparatus for and a method of temporarily assembling heat
exchangers. More particularly, the invention relates to a tube
blank correcting member, and temporarily assembling apparatus and
method for use in fabricating heat exchangers which comprise a pair
of headers arranged in parallel and spaced apart from each other, a
plurality of flat heat exchanger tubes arranged in parallel between
the headers and brazed at opposite ends to the respective headers
with the tube ends placed into respective insertion holes formed in
the headers, and fins each arranged between and brazed to each pair
of adjacent heat exchange tubes, and which are useful, for example,
as condensers or evaporators for motor vehicle air conditioners,
motor vehicle oil coolers and motor vehicle radiators, the tube
blank correcting member and the temporarily assembling apparatus
and method being adapted for use in temporarily assembling the
headers, flat heat exchange tube blanks and the fins into a unit to
be brazed.
[0003] The term "aluminum" as used herein and in the appended
claims includes aluminum alloys in addition to pure aluminum. The
upper, lower, left and right sides of FIG. 2 will be herein
referred to respectively as "upper," "lower," "left" and "right,"
and the lower and upper sides of FIG. 1 as "front" and "rear."
BACKGROUND ART
[0004] Widely used, for example, in motor vehicle air conditioners
in place of conventional serpentine condensers are condensers which
comprise, as shown in FIG. 13, a pair of headers 50, 51 arranged in
parallel and spaced apart from each other, parallel flat heat
exchange tubes 52 made of aluminum and each joined at its opposite
ends to the two headers 50, 51, corrugated aluminum fins 53 each
disposed in an air flow clearance between the adjacent heat
exchange tubes 52 and brazed to the adjacent tubes 52, an inlet
pipe 54 connected to the upper end of peripheral wall of the first
50 of the headers, an outlet pipe 55 connected to the lower end of
peripheral wall of the second 51 of the headers, a first partition
56 provided inside the first header 50 and positioned above the
midportion thereof, and a second partition 57 provided inside the
second header 51 and positioned below the midportion thereof, the
number of heat exchange tubes 52 between the inlet pipe 54 and the
first partition 56, the number of heat exchange tubes 52 between
the first partition 56 and the second partition 57 and the number
of heat exchange tubes 52 between the second partition 57 and the
outlet pipe 55 decreasing from above downward to provide groups of
channels. A refrigerant flowing into the inlet pipe 54 in a vapor
phase flows zigzag through the channel groups as units within the
condenser before flowing out from the outlet pipe 55 in a liquid
phase. The condensers of the construction described are called
multiflow condensers, and realize high efficiencies, lower pressure
losses and supercompactness (see, for example, the publication of
JP-A No. 1994-281373).
[0005] It is required that the heat exchange tube 52 of the
condenser described be excellent in heat exchange efficiency and
have pressure resistance against the high-pressure gaseous
refrigerant to be introduced thereinto. Moreover, the tube needs to
be small in wall thickness and low in height so as to make the
condenser compact.
[0006] As disclosed in the above publication, the heat exchange
tube 52 which is excellent in heat exchange efficiency for use in
such condensers comprises two flat walls which are parallel to each
other, opposite side walls interconnecting the two flat walls at
the respective opposite side edges thereof, and a plurality of
reinforcing walls interconnecting the two flat walls, extending
longitudinally of the tube and spaced apart from one another as
positioned between the opposite side walls, the tube having
parallel fluid channels formed inside thereof, each of the
reinforcing walls being formed from a ridge projecting inward from
one of the flat walls integrally therewith and a ridge projecting
inward from the other flat wall integrally therewith by brazing the
two ridges to each other as positioned end-to-end.
[0007] Such a flat heat exchange tube is fabricated from a metal
plate having two first portions 60 for making the flat walls, a
second portion 61 interconnecting the first portions 60 for forming
one of the side walls, two third portions 62 projecting from the
respective first portions 60 integrally therewith each at a side
edge thereof opposite to the second portion 61 for making the other
side wall, and a plurality of ridges 63 formed on each first
portion 60 integrally therewith, arranged at a spacing widthwise
thereof and projecting in the same direction as the third portion
62, by bending the metal plate to the shape of a hairpin at the
second portion 61 to place the third portions 62, as well as the
opposed ridges 63 in each pair, end to end and obtain a heat
exchange tube blank P (see FIG. 14), and brazing the third portions
62 of the blank P to each other and the opposed ridges 63 thereof
in each pair to each other. To prevent the third portions 62 from
separating from each other in the heat exchange tube blank P, a
ridge 64 formed in the end face of one of the third portions 62 is
forced into a furrow 65 formed in the end face of the other third
portion 62 by a press fit. Before the metal plate is bent to form
the tube blank P, each ridge 63 on one of the first portions 60 and
the corresponding ridge 63 on the other first portion 60 are
positioned symmetrically about the widthwise center line of the
metal plate.
[0008] For example, the publication of JP-A No. 1993-7958 discloses
an apparatus for use in temporarily assembling headers, flat heat
exchange tube blanks and fins into a unit which is to be brazed to
fabricate such a condenser as described above. This apparatus
comprises a guide fixedly mounted on a work table and provided in
its upper side with a plurality of blank grooves extending
laterally of the table and having a width corresponding to the
thickness of the tube blanks, and a pair of header supports
provided on the work table respectively at the left and right sides
of the guide and movable toward or away from each other.
[0009] The headers, heat exchange tube blanks and fins are
temporarily assembled in the following manner using this apparatus.
One end of one of the tube blanks is placed into an insertion hole
of one of the headers, and the other end of another one of the tube
blanks is placed into an insertion hole of the other header. All
the remaining tube blanks are fitted into respective blank grooves
of the guide. The headers are then arranged on the respective
header supports. The header supports are subsequently moved toward
each other, whereby opposite ends of the tube blanks are placed
into respective insertion holes of the headers. The headers and the
heat exchange tube blanks are thereafter removed from the header
supports and the guide, and corrugated fins are arranged between
the adjacent tube blanks. In this way, the headers, heat exchange
tube blanks and fins are temporarily assembled into a unit.
[0010] However when the heat exchange tube blank P shown in FIG. 14
is used as the tube blank, we have found that the following problem
is encountered with the conventional temporarily assembling
apparatus.
[0011] Such heat exchange tube blanks P are produced by cutting an
elongated heat exchange tube blank into predetermined lengths while
continuously forming the elongated tube blank, so that the cutting
force is likely to cause the ridge 64 to slip off from the furrow
65 at the cut end portion, permitting the third portions 62 of the
tube blank P to separate from each other and form an opening. This
gives the end portion of the tube blank P a thickness T which is
greater than the width S of the insertion hole H1 formed in the
header H, with the result that the end portion of the tube blank P
can not be placed into the insertion hole H1 of the header H.
[0012] An object of the present invention is to overcome the above
problem and to provide a tube blank correcting member for use in
temporarily assembling heat exchangers which makes it possible to
reliably insert the corresponding ends of heat exchange tube blanks
into respective insertion holes of a header, and a temporarily
assembling apparatus and method for heat exchangers.
DISCLOSURE OF THE INVENTION
[0013] The present invention provides a tube blank correcting
member for use in fabricating a heat exchanger comprising a pair of
headers arranged in parallel and spaced apart from each other, a
plurality of flat heat exchange tubes arranged in parallel between
the headers and brazed at opposite ends to the respective headers
with the tube ends placed into respective insertion holes formed in
the headers, and fins each arranged between and brazed to each pair
of adjacent heat exchange tubes. The blank correcting member for
temporarily assembling the heat exchanger, i.e., for use in
temporarily assembling the headers, flat heat exchange tube blanks
and the fins into a unit to be brazed, extends from front rearward
and has a plurality of blank fitting slits formed in a side edge
thereof and arranged from the front rearward at the same spacing as
the heat exchange tubes to be produced of the heat exchanger.
[0014] The heat exchange tube blank is made from a metal plate
which has, for example, two first portions for making flat walls, a
second portion interconnecting the first portions for forming one
of side walls, and two third portions projecting from the
respective first portions integrally therewith each at a side edge
thereof opposite to the second portion for making the other side
wall, by bending the metal plate to the shape of a hairpin at the
second portion to place the third portions end to end. Even if the
third portions open relative to each other at opposite end portions
to give each end of the tube blank a thickness greater than the
width of the insertion hole of the header, the third portions can
be butted against each other and closed to give the blank end a
thickness permitting the blank end to be placed into the insertion
hole, by arranging such tube blanks from front rearward in
parallel, with their lengthwise direction positioned laterally and
their widthwise direction positioned vertically, while aligning
opposite left and right ends thereof respectively, and fitting the
opposite ends of the tube blanks into the slits of respective blank
correcting members. Further in the case where the tube blank has a
bulging widthwise intermediate portion, the bulging portion can be
corrected by fitting the blank into the slit of the correcting
member.
[0015] With the tube blank correcting member of the invention, each
of the blank fitting slits has an opening with a width larger than
the maximum thickness of the flat heat exchange tube blank, and an
open end portion of the slit flares toward the opening with a
gradually increasing width. The slit open end portion flaring
toward the opening with a gradually increasing width provides a
tapering portion, and the tapering portion preferably has a taper
angle of 10 to 20 deg. Even if each of the left and right ends of
the tube blank then has a thickness larger than the insertion hole
of the header, the blank end can be fitted smoothly into the blank
fitting slit of the corresponding correcting member in this case.
Moreover, the blank end can be smoothly fitted into the slit
regardless of whether the third portions are positioned down or up.
Further in the case where the tube blank has a bulging widthwise
intermediate portion, the bulging portion can be corrected by
fitting the blank into the slit of the correcting member.
[0016] With the tube blank correcting member wherein the slit open
end portion is in the form of a tapering portion, the slit may have
a portion other than the tapering portion and having a depth not
smaller than the width of the tube blank. Each of left and right
ends of the tube blank can then be made to have a thickness
permitting the blank end to be placed into the insertion hole of
the header regardless of whether the third portions are positioned
down or up.
[0017] The present invention provides a heat exchanger temporarily
assembling apparatus for use in fabricating a heat exchanger
comprising a pair of headers arranged in parallel and spaced apart
from each other, a plurality of flat heat exchange tubes arranged
in parallel between the headers and brazed at opposite ends to the
respective headers with the tube ends placed into respective
insertion holes formed in the headers, and fins each arranged
between and brazed to each pair of adjacent heat exchange tubes.
The apparatus is adapted for use in temporarily assembling the heat
exchanger, i.e., for use in temporarily assembling the headers,
flat heat exchange tube blanks and the fins into a unit to be
brazed, comprises a support member for supporting thereon the heat
exchange tube blanks arranged from front rearward in parallel with
their lengthwise direction positioned laterally, with their
widthwise direction positioned vertically, and with opposite left
and right ends thereof aligned respectively, and the fins arranged
between the respective pairs of adjacent tube blanks, two header
supports arranged respectively at left and right sides of the
support member and movable leftward or rightward, and a pair of
left and right tube blank correcting members each extending from
the front rearward and having a plurality of blank fitting slits
formed in a side edge thereof and arranged from the front rearward
at the same spacing as the heat exchange tubes to be produced of
the heat exchanger, each of the tube blank correcting members being
movable between a correcting position wherein the corresponding
ends of all the tube blanks as supported on the support member are
fitted into the respective slits and a noncorrecting position
wherein the tube blanks are not fitted into the slits.
[0018] The heat exchange tube blank is made from a metal plate
which has, for example, two first portions for making flat walls, a
second portion interconnecting the first portions for forming one
of side walls, and two third portions projecting from the
respective first portions integrally therewith each at a side edge
thereof opposite to the second portion for making the other side
wall, by bending the metal plate to the shape of a hairpin at the
second portion to place the third portions end to end. Even if the
third portions open relative to each other at opposite end portions
to give each end of the tube blank a thickness greater than the
width of the insertion hole of the header, the third portions can
be butted against each other and closed to give the blank end a
thickness permitting the blank end to be placed into the insertion
hole, by causing the support member to support thereon such tube
blanks from front rearward in parallel, with their lengthwise
direction positioned laterally, with their widthwise direction
positioned vertically, and with opposite left and right ends
thereof aligned respectively, and fins as arranged between the
respective pairs of adjacent tube blanks, moving the blank
correcting members from their noncorrecting position to the
correcting position and thereby fitting the opposite ends of the
tube blanks into the slits of respective blank correcting members.
Further in the case where the tube blank has a bulging widthwise
intermediate portion, the bulging portion can be corrected by
fitting the blank into the slit of the correcting member.
[0019] With the heat exchanger temporarily assembling apparatus of
the invention, each of the blank fitting slits has an opening with
a width larger than the maximum thickness of the flat heat exchange
tube blank, and an open end portion of the slit flares toward the
opening with a gradually increasing width. The slit open end
portion flaring toward the opening with a gradually increasing
width provides a tapering portion, and the tapering portion
preferably has a taper angle of 10 to 20 deg. Even if each of the
left and right ends of the tube blank then has a thickness larger
than the insertion hole of the header, the blank end can be fitted
smoothly into the blank fitting slit of the corresponding
correcting member in this case. Moreover, the blank end can be
smoothly fitted into the slit regardless of whether the third
portions are positioned down or up. Further in the case where the
tube blank has a bulging widthwise intermediate portion, the
bulging portion can be corrected by fitting the blank into the slit
of the correcting member.
[0020] With the temporarily assembling apparatus wherein the slit
open end portion of the tube blank correcting member is in the form
of a tapering portion, the slit may have a portion other than the
tapering portion and having a depth not smaller than the width of
the tube blank. When the opposite ends of tube blanks are placed
into the insertion holes of the respective headers in this case,
the tube blank correcting members having the opposite ends of the
tube blanks fitted into their slits are moved laterally inward by
being pushed by the respective headers, so that the blank ends can
be placed into the insertion holes free of trouble.
[0021] With the heat exchanger temporarily assembling apparatus of
the invention, each tube blank correcting member is movable
laterally when in the correcting position. When the opposite ends
of the tube blanks are placed into the insertion holes of the
respective headers in this case, the tube blank correcting members
having the opposite ends of the tube blanks fitted into their slits
are moved laterally inward by being pushed by the respective
headers, so that the blank ends can be placed into the insertion
holes free of trouble.
[0022] With the heat exchanger temporarily assembling apparatus of
the invention, each tube blank correcting member is biased
laterally outward by a biasing member when in the correcting
position. When the blank correcting members are moved to their
noncorrecting position after the opposite ends of the tube blanks
are placed into the insertion holes of the respective headers, the
correcting members are moved laterally outward to the original
position by being moved laterally outward with the biasing force of
the biasing members.
[0023] With the heat exchanger temporarily assembling apparatus of
the invention, each of the tube blank correcting members is
provided on a tube blank holding member extending from the front
rearward, and the tube blank holding member is movable between a
first position wherein the holding member is placed on
corresponding left or right end portions of all the heat exchange
tube blanks supported on the support member and a second position
where the holding member is away from all the heat exchange tube
blanks, the tube blank correcting member being movable upward or
downward relative to the holding member when the holding member is
in the first position, the blank correcting member assuming the
correcting position when moved downward or assuming the
noncorrecting position when moved upward. Preferably, the tube
blank holding member is disposed laterally outwardly of the
corresponding header support and fixed to a free end of an arm
attached to a horizontal rod extending from the front rearward and
pivotally movable about an axis of the rod, and the holding member
is movable between the first position and the second position by
the pivotal movement of the arm. When the tube blank correcting
member is to be moved from the noncorrecting position to the
correcting position, the blank holding member is in the first
position, holding the corresponding ends of the tube blanks in this
case, so that the tube blanks can be reliably fitted into the slits
of the correcting member and reliably placed into the insertion
holes of the corresponding header.
[0024] The temporarily assembling apparatus of the invention
further includes the following constructions.
[0025] The support member comprises a pair of support tables spaced
apart laterally of the apparatus, and a blank guide is provided
between the support tables and movable upward or downward. When in
a raised position, the blank guide has its upper surface positioned
above the upper surface of the support member. The blank guide is
provided in its upper surface with a plurality of fitting grooves
extending laterally of the apparatus and arranged from the front
rearward at a spacing larger than the spacing between the heat
exchange tubes of the heat exchanger to be fabricated for placing
respective heat exchange tube blanks thereinto. Preferably, the
blank guide is fixedly provided with a receiving member at one of
the front and rear ends thereof and has a pressure member disposed
at the other end thereof and movable forward or rearward.
[0026] In fabricating a heat exchanger comprising a pair of headers
arranged in parallel and spaced apart from each other, a plurality
of flat heat exchange tubes arranged in parallel between the
headers and brazed at opposite ends to the respective headers with
the tube ends placed into respective insertion holes formed in the
headers, and fins each arranged between and brazed to each pair of
adjacent heat exchange tubes, each of the heat exchange tubes
having a pair of flat walls opposed to each other and two side
walls interconnecting the two flat walls respectively at opposite
side edges thereof, the present invention provides a heat exchanger
temporarily assembling method for use in temporarily assembling the
headers, flat heat exchange tube blanks and the fins into a unit to
be brazed, the heat exchanger temporarily assembling method using
the apparatus described above and including: causing the support
member to support thereon the heat exchange tube blanks arranged
from front rearward in parallel with their lengthwise direction
positioned laterally, with their widthwise direction positioned
vertically, and with opposite left and right ends thereof aligned
respectively, and the fins arranged between the respective pairs of
adjacent tube blanks, placing the headers on the respective header
supports as spaced apart from each other, moving each of the tube
blank correcting members to the correcting position to place
corresponding left or right ends of all the tube blanks on the
support member into the respective blank fitting slits, and moving
the two header supports laterally inward to place the opposite ends
of the tube blanks into the respective insertion holes of the
headers.
[0027] The heat exchange tube blank is made from a metal plate
which has, for example, two first portions for making flat walls, a
second portion interconnecting the first portions for forming one
of side walls, and two third portions projecting from the
respective first portions integrally therewith each at a side edge
thereof opposite to the second portion for making the other side
wall, by bending the metal plate to the shape of a hairpin at the
second portion to place the third portions end to end. Even if the
third portions open relative to each other at opposite end portions
to give each end of the tube blank a thickness greater than the
width of the insertion hole of the header, the third portions can
be butted against each other and closed to give the blank end a
thickness permitting the blank end to be placed into the insertion
hole, by causing the support member to support thereon such tube
blanks from front rearward in parallel, with their lengthwise
direction positioned laterally, with their widthwise direction
positioned vertically, and with opposite left and right ends
thereof aligned respectively, and fins as arranged between the
respective pairs of adjacent tube blanks, moving the blank
correcting members from their noncorrecting position to the
correcting position and thereby fitting the opposite ends of the
tube blanks into the slits of respective blank correcting
members.
[0028] With the heat exchanger temporarily assembling method of the
invention, each of the heat exchange tube blanks is produced from a
metal plate having two first portions for making the flat walls, a
second portion interconnecting the first portions for forming one
of the side walls, and two third portions projecting from the
respective first portions integrally therewith each at a side edge
thereof opposite to the second portion for making the other side
wall, by bending the metal plate to the shape of a hairpin at the
second portion to place the third portions end to end. The third
portions of the metal plate are each made by forming this portion
as projected from the first portion integrally therewith, or by
bending a side edge portion of the first portion. The metal plate
comprises, for example, an aluminum brazing sheet having a brazing
material layer providing opposite surfaces thereof. In the case
where the third portions are each formed as a projection on the
first portion integral therewith, the metal plate is made by
rolling the aluminum brazing sheet.
[0029] The present invention provides a process for fabricating a
heat exchanger which process is characterized in that the headers,
the heat exchange tube blanks and the fins temporarily assembled by
the method described above are brazed.
[0030] The present invention provides a heat exchanger fabricated
by brazing the headers, the heat exchange tube blanks and the fins
temporarily assembled by the method described above.
[0031] The present invention provides a vehicle comprising a
refrigeration cycle having a compressor, a condenser and an
evaporator, the condenser comprising the heat exchanger described
above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a plan view partly broken away and showing the
overall construction of an apparatus of the invention for
temporarily assembling a heat exchanger.
[0033] FIG. 2 is a view in vertical section showing the overall
construction of the assembling apparatus of the invention as it is
seen from the front.
[0034] FIG. 3 is an enlarged view in section taken along the line
A-A in FIG. 2.
[0035] FIG. 4 is an enlarged fragmentary front view partly broken
away and showing a blank position adjusting device as raised after
heat exchange tube blanks are arranged on a blank guide.
[0036] FIG. 5 is a plan view showing corrugated fins as arranged
between the heat exchange tube blanks supported on support
tables.
[0037] FIG. 6 is a plan view showing the heat exchange tube blanks
as held at their opposite ends by blank holding members and moved
forward.
[0038] FIG. 7 is an enlarged fragmentary perspective view showing a
blank correcting member immediate before it is lowered.
[0039] FIG. 8 is an enlarged fragmentary side elevation showing
heat exchange tube blanks immediately before ends thereof are
fitted into blank fitting slits.
[0040] FIG. 9 is an enlarged fragmentary front view partly broken
away and showing the end of heat exchange tube blank fitted in the
blank fitting slit, with the blank correcting member lowered.
[0041] FIG. 10 is an enlarged fragmentary front view partly broken
away and showing the end of heat exchange tube blank placed in
insertion holes of a header.
[0042] FIG. 11 is an enlarged front view partly broken away and
showing the tube blank correcting member as raised and a header
support as moved laterally outward.
[0043] FIG. 12 is a plan view showing headers, heat exchange tube
blanks and corrugated fins as temporarily assembled on a support
member.
[0044] FIG. 13 is a perspective view showing a motor vehicle
condenser.
[0045] FIG. 14 is a perspective view showing the heat exchange tube
blank.
[0046] FIG. 15 is a fragmentary plan view showing the problem
encountered when a conventional temporarily assembling apparatus is
used.
[0047] FIG. 16 is a perspective view showing a modified heat
exchange tube blank.
[0048] FIG. 17 is a perspective view showing another modification
of heat exchange tube blank.
[0049] FIG. 18 is an enlarged fragmentary view in vertical section
showing a modification of header.
[0050] FIG. 19 is a view in section taken along the line B-B in
FIG. 18.
BEST MODE OF CARRYING OUT THE INVENTION
[0051] Embodiments of the present invention will be described below
with reference to the drawings.
[0052] FIGS. 1 and 2 show the overall construction of an apparatus
of the invention for temporarily assembling a heat exchanger, and
FIGS. 3 to 12 show the constructions of main parts of the
apparatus.
[0053] With reference to FIGS. 1 to 3, the heat exchanger
temporarily assembling apparatus comprises a support member 2
provided on a base 1 for supporting a plurality of flat heat
exchange tube blanks P as arranged in parallel from the front
rearward with their lengthwise direction positioned laterally and
their widthwise direction positioned vertically, and corrugated
fins each arranged between each pair of adjacent tube blanks P,
header supports 3 extending from the front rearward, arranged
respectively at the left and right sides of the support member 2
and movable leftward and rightward or laterally, holding-correcting
devices 4 arranged respectively on the left and right sides of the
support member 2 for holding the tube blanks P from above each at
respective portions thereof away from the lengthwise midportion
thereof closer to the left and right ends thereof and correcting
the thickness of the tube blanks P each at the left and right ends
thereof, and blank position adjusting devices 5 arranged
respectively at the left and right sides of the support member 2
for adjusting the positions of opposite ends of each of the tube
blanks P supported by the support member 2.
[0054] The support member 2 comprises a pair of left and right
support tables 6 extending from the front rearward, spaced apart
laterally of the apparatus and having respective flat upper
surfaces which are positioned on the same horizontal plane. A
pressure receiving plate 40 which is elongated laterally is fixedly
connected between the front ends of the two support tables 6.
Similarly, a pressure plate 41 which is elongated laterally is
connected between the rear ends of the support plates 6 and movable
forward or rearward. The pressure plate 41 is fixed to the forward
end of the piston rod 42a of a hydraulic cylinder 42 facing forward
and mounted by a suitable support member (not shown) on the base 1,
and is moved forward or rearward by the advance or retraction of
the piston rod 42a. A blank guide 7 extending from the front
rearward is disposed between the two support tables 6 and movable
upward or downward. The blank guide 7 is fixed to the upper end of
the piston rod 8a of a hydraulic cylinder 8 facing upward and
mounted on the base 1, and is movable upward or downward by the
advance or retraction of the piston rod 8a. When the blank guide 7
is positioned as raised, the upper surface of the blank guide 7 is
positioned above the upper surface of the support table 6, while
conversely when the guide 7 is positioned as lowered, the upper
surface of the guide 7 is positioned below that of the support
table 6. The blank guide 7 is provided in its supper surface with a
plurality of fitting grooves 9 for heat exchange tube blanks P
extending laterally and having their widthwise direction positioned
vertically to fit in, the grooves 9 being arranged from the front
rearward at a spacing larger than the spacing between the heat
exchange tubes of the heat exchanger to be fabricated. When the
guide 7 is in its raised position, the bottom faces of the fitting
grooves 9 are positioned at the same level as the upper surfaces of
the support tables 6.
[0055] Each of the header supports 3 serves to support a header H
with insertions holes H1 facing toward the tube blanks P at a level
corresponding to the blanks P supported by the support member 2.
The header support 3 is fixed to the forward end of the piston rod
12a of a hydraulic cylinder 12 facing laterally inward and attached
to a pair of opposite cylinder brackets 11 fixed to the base 1 and
projecting upward. The header support 3 is movable leftward or
rightward by the advance or retraction of the piston rod 12a. Fixed
to the front end of the header support 3 is a receiving plate 13
for the front end of the header H to bear on. The header support 23
is provided at its rear end with a pushing plate 14 movable forward
or rearward for pushing the header H forward in contact with the
rear end face of the header H. The pushing plate 14 is fixed to the
free end of the piston rod 15a of a hydraulic cylinder 15 facing
rearward and attached to the header support 3, and is movable
forward or rearward by the retraction or advance of the piston rod
15a.
[0056] Each of the holding-correcting devices 4 comprises a
horizontal rod 16 extending from the front rearward and disposed
laterally outwardly of the header support 3 below the support 3, a
pair of front and rear generally L-shaped arms 17 each attached at
a portion close to abase end thereof to the horizontal rod 16 and
rotatable about the axis of the rod 16, a blank holding member 18
extending from the front rearward, rectangular in cross section and
fixedly connected between the free ends of the two arms 17, and a
blank correcting member 19 attached to the blank holding member
18.
[0057] The horizontal rod 16 extends between and is fixed to a pair
of front and rear rod brackets 21 fixed to and projecting upward
from the base 1 and positioned respectively at the front and rear
sides of the header support 3. The arms 17 are attached to the
horizontal rod 16 at portions thereof projecting forward and
rearward beyond the respective rod brackets 21, and are pivotally
moved in the following manner. A hydraulic cylinder 22 facing
laterally inward is supported at a laterally outer end thereof on a
portion of the base 1 rearwardly of the rear arm bracket 21 so as
to be pivotally movable about an axis extending from the front
rearward. The free end of the piston rod 22a of the cylinder 22 is
pivoted to the base end of the rear arm 17 so as to be pivotally
movable about an axis extending from the front rearward. The arms
17 are pivotally moved about the axis of the horizontal rod 16 by
the advance and retraction of the piston rod 22a.
[0058] The blank holding member 18 is movable by the pivotal
movement of the arms 17 between a first position (as indicated by a
chain line in FIG. 2) where the member 18 is placed on all the tube
blanks P supported by the support member 2 at the portions thereof
each slightly closer to the midportion of the blank than the
corresponding left or right end and a second position (as indicated
in a solid line in FIG. 2) away from all the blanks P.
[0059] The terms "upward," "downward," "left" and "right" as used
hereinafter in connection with the blank holding member 18, the
blank correcting member 19, and the portions and members relating
to these members are used based on the case wherein the blank
holding member 18 is in the first position.
[0060] The blank correcting member 19 is in the form of a plate
extending from the front rearward and having blank fitting slits 23
formed in its lower edge at the same spacing as the heat exchange
tubes of the heat exchanger to be fabricated. As shown in FIG. 8,
the slits 23 have a width W which is preferably equal to the
thickness of the tube blanks P but which may be about 0.1 mm larger
than the thickness in view of ease of fitting the blanks P into the
respective slits 23. If the slits are still larger, the left or
right end of the tube plank P can not be dimensionally corrected in
the direction of its thickness by being inserted into the slit 23,
and it is likely that the end of the blank P can not be placed into
the insertion hole H1 of the header H. The opening at the lower end
of the blank fitting slit 23 has a width larger than the maximum
thickness of the tube blank P. For example when the left or right
end of the tube blank P is open, the width is larger than the
thickness of the open end portion (see FIG. 15, T). The slit 23 has
a lower end portion (open end portion) flaring downward (toward the
opening) with a gradually increasing width, i.e. tapering upward.
This tapering portion 23a preferably has a taper angle X of 10 to
20 deg. If this taper angle X is less than 10 deg, the left or
right end of the tube blank P will not always fit into the slit 23
smoothly when the end is open. If the angle is in excess of 20 deg,
the left or right end portion of the tube blank P is likely to
become caught by the tapering portion 23a when the end portion is
open. The blank end portion then fails to close and will be
deformed. Preferably, the taper angle X is 16 to 18 deg. In the
drawing, the spacing between the slits 23 is shown as being larger
than actually. The portion of the slit 23 other than the tapering
portion 23a has a depth Y (vertical length) which is not smaller
than the width of the blank P.
[0061] With reference to FIGS. 3 and 7, each blank holding member
18 is fixedly provided with two rod brackets 24 projecting upward
from the laterally inner side edge of its upper surface and spaced
apart in the forward or rearward direction. A rod 25 laterally
extends through each of the rod brackets 24 laterally movably. The
rod 25 has a stopper 26 at the laterally inner end thereof. A
cylinder mount plate 27 extending from the front rearward has its
front and rear end portions fixed to the laterally outer ends of
the front and rear rods 25. A compression coil spring 28 (biasing
member) is provided around each rod 25 between the rod bracket 24
and the cylinder mount plate 27. A hydraulic cylinder 29 facing
upward is attached to each of the front and rear end portions of
the mount plate 27 on the laterally outer surface thereof. The
piston rod 29a of the cylinder 29 is provided with an inverted
generally L-shaped bracket 31 comprising a lateral portion 31a and
a downward portion 31b extending downward from the laterally outer
end of the lateral portion 31a. The lateral portion 31a of the
bracket 31 is fixed to the upper end of the piston rod 29a. The
blank correcting member 19 is fixed to the lower end of the
downward portion 31b of each bracket 31 so that the blank fitting
slits 23 face downward. When the blank holding member 18 is brought
to the first position, the advance or retraction of the piston rods
29a of the hydraulic cylinders 29 causes the brackets 31 to move
the blank correcting member 19 upward or downward to a
noncorrecting position wherein the blanks P are not fitted into the
slits 23 or to a correcting position wherein the corresponding ends
of all the tube blanks P on the support member 2 are fitted into
the respective slits 23.
[0062] With reference to FIGS. 4 to 6, each blank position
adjusting device 5 comprises a horizontal base plate 32 extending
from the front rearward and movable upward or downward, two upright
walls 33 provided respectively at the front and rear ends of the
base plate 32, a pair of left and right guide bars 34 extending
from the front rearward and connected between the two upright walls
33, a plurality of movable members 35 mounted on the guide bars 34
thereacross and movable forward or rearward along the guide bars
34, and a blank end positioning bar 36 having a circular cross
section, positioned above the movable members 35 slightly laterally
inwardly of the lateral midportion of the base plate 32 and
connected between the upright walls 33. A pair of front and rear
hydraulic cylinders 37 each having a piston rod 37a projecting
upward beyond the base 1 are attached to the lower side of the base
1 to face upward. The horizontal base plate 32 is fixed to the
upper ends of the piston rods 37a. The base plate 32 is moved
upward or downward by the advance or retraction of the piston rods
37a of the hydraulic cylinders 37. Each of the movable members 35
is integrally provided with a blank spacing adjusting member 38
upwardly projecting from its upper side and positioned laterally
inwardly of the positioning bar 36. The front-to-rear width of the
spacing adjusting member 38 is equal to the spacing between each
pair of insertion holes H1 of the header H which are adjacent to
each other in the forward or rearward direction. When the movable
members 35 which are forwardly or rearwardly adjacent to one
another are brought into contact with one another, the spacing
between forwardly or rearwardly adjacent blank spacing adjusting
members 38 is equal to the thickness of the tube blanks P. Although
not shown, the blank position adjusting device 5 is provided with a
device for moving the movable members 35 as positioned in contact
with one another away from one another. When the movable members 35
are separated from one another by this device, the blank spacing
adjusting members 38 are each positioned between the adjacent
fitting grooves 9 of the blank guide 7 and are spaced apart from
one another by a distance larger than the thickness of the tube
blanks P.
[0063] Using the temporarily assembling apparatus of the
construction described above, the headers H, heat exchange tube
blanks P and corrugated fins F for a heat exchanger are temporarily
assembled in the following manner.
[0064] First, the headers H, flat heat exchange tube blanks P and
corrugated fins F are prepared. The headers H are tubular and each
have a plurality of vertically elongated insertion holes H1
arranged from the front rearward at a spacing for placing the tube
blanks P thereinto. The tube blank P has the construction shown in
FIG. 14 as already described, and is made from an aluminum brazing
sheet having a cladding of brazing material over opposite surfaces
of a core by rolling the sheet. The tube blank P is produced by
bending the aluminum brazing sheet into the form of a hairpin to
obtain a continuous body while paying off the sheet from a roll and
cutting the bent continuous body into predetermined lengths. As
previously described with reference to the prior art, it is likely
that the third portions 62 of the tube blank P will open slightly
relative to each other with the ridge 64 slipping out of the furrow
65 at each end of the blank, i.e., the cut end, to give the blank
end a thickness T which is larger than the width of the insertion
hole H1 of the header H (see FIG. 15).
[0065] The present apparatus is in the following state for
assembling. The blank guide 7 is in its raised position, with the
respective header supports 3 positioned as moved laterally outward.
The arms 17 of the blank holding-correcting device 4 at the left
are positioned as pivotally moved counterclockwise and the arms 17
of the device 4 at the right are positioned as moved clockwise to
bring the blank holding members 18 in their second position. At
this time, each blank correcting member 19 is raised relative to
the holding member 18 to the noncorrecting position. The blank
position adjusting devices 5 are in their lowered position. As this
time, the movable members 35 are positioned as separated from one
another, and the spacing between the adjacent spacing adjusting
members 38 is larger than the thickness of tube blanks P.
[0066] In this state, the midportions of flat heat exchange tube
blanks P are fitted respectively into all fitting grooves 9 of the
blank guide 7, and the headers H are placed on the respective
header supports 3 with their insertion holes H1 facing laterally
inward (see FIGS. 1 and 2). The tube blanks P have their opposite
ends projected laterally outward beyond the respective left and
right support tables 6. The blank position adjusting devices 5 are
then raised to position the opposite ends of the tube blanks P
between the adjacent spacing adjusting members 38, and the opposite
ends of all the tube blanks P are positioned in place by the blank
end positioning bars 36. The blank guide 7 is then lowered (see
FIG. 4), permitting the respective support tables 6 to support the
opposite ends of the tube blanks P, and the corrugated fins F are
arranged between the respective pairs of adjacent tube blanks P
(see FIG. 5). Subsequently, the arms 17 of the holding-correcting
device 4 at the left and the arms 17 of the device 4 at the right
are moved clockwise and counterclockwise, respectively, to move the
blank holding members 18 to their first position and hold all the
tube blanks P and corrugated fins F at their opposite ends.
Subsequently, the pressure plate 41 is advanced to move the tube
blanks P forward until the adjacent movable members 35 come into
contact with one another (see FIG. 6). This makes the spacing
between the adjacent tube blanks P equal to the spacing between the
insertion holes H1 of the headers H. Each pushing plate 14 is then
advanced to clamp the header H between the pushing plate 14 and the
receiving plate 13. The blank position adjusting devices 5 are
thereafter lowered to cause the left and right support tables 6 to
support thereon the tube blanks P as arranged from the front
rearward in parallel, with their lengthwise direction positioned
laterally, with their widthwise direction positioned vertically,
and with their opposite ends aligned respectively, and the fins F
arranged between the respective pairs of adjacent tube blanks
P.
[0067] Next as shown in FIGS. 7 and 8, the blank correcting members
19 are lowered to fit the opposite ends of all the tube blanks P
into the slits 23 (see FIG. 9). Even if the third portions 62 are
slightly open relative to each other at each end of the blank P,
the blank fitting slit 23 serves to butt the ends of the third
portions 62 against each other. Since the open end portion of the
slit 23 has the tapering portion 23a, each end of the tube blank P
can be smoothly fitted into the slit 23 when the blank P is
supported on the tables 6 regardless of whether the third portions
62 are positioned down or up (see FIG. 8).
[0068] The header supports 3 are then moved laterally inward to fit
the opposite ends of the tube blanks P into the insertion holes H1.
At this time, the blank correcting member 19, hydraulic cylinder 29
and cylinder mount plate 27 are moved laterally inward by being
pushed by each header H against the force of the spring 28, so that
the ends of the tube blanks P can be placed into the insertion
holes H1 free of trouble. (see FIG. 10).
[0069] The pushing plates 14 are then retracted, the header
supports 3 are moved laterally outward, and the blank correcting
members 19 are thereafter raised (see FIG. 11). At this time, the
force of each compression coil spring 28 returns the blank
correcting member 19, hydraulic cylinder 29 and cylinder mount
plate 27 to their original positions. The pressure plates 41 are
thereafter retracted, the arms 17 of the holding-correcting device
4 at the left and the arms 17 of the device 4 at the right are
moved counterclockwise and clockwise, respectively to move the
blank holding members 18 to their second position. In this way, the
headers H, tube blanks P and corrugated fins F are temporarily
assembled (see FIG. 12).
[0070] The motor vehicle air conditioner condenser shown in FIG. 13
is fabricated by temporarily assembling the components as described
above, thereafter inserting partitions 56, 57 into partition
inserting holes formed in the headers H, and collectively brazing
the headers H to the tube blanks P, the headers H to the partition
56 or 57, the third portions 62 of each of the tube blanks P to
each other, the opposed ridges 63 in each pair of the blanks P to
each other and each pair of adjacent tube blanks P to the fin
therebetween. The heat exchange tube blanks P provide respective
flat heat exchange tubes 52.
[0071] The condenser thus fabricated provides a refrigeration cycle
along with a compressor and an evaporator, and the cycle is
installed in a motor vehicle as a vehicle air conditioner.
[0072] In the foregoing embodiments, other fluid pressure
cylinders, such as air cylinders, can be used in place of all the
hydraulic cylinders.
[0073] The temporarily assembling apparatus of the present
invention is usable also when the flat heat exchange tube blank
shown in FIG. 16 is used.
[0074] With reference to FIG. 16, the flat heat exchange tube blank
P1 is made from a metal plate which has two first portions 70 for
making flat walls, a second portion 71 interconnecting the two
first portions 70 for making one of two side walls, two third
portions 72 formed by folding the respective first portions 70 each
at a side edge portion opposite to the second portion 71 for making
the other side wall, and a plurality of ridges 73 formed by bending
each first portion 70 at positions spaced apart along the widthwise
direction thereof and projecting in the same direction as the third
portion 72 provided by the same first portion, by bending the metal
plate to the shape of a hairpin at the second portion 71 to place
the third portions 72 end to end and to bring the ridges 73 of each
of the first portions 70 into contact with the other first portion
70. Before the metal plate is bent into the tube blank P1, the
ridges 73 of one of the first portions 70 and the ridges 73 of the
other first portion 70 are positioned asymmetric about the center
line with respect to the direction of width of the metal plate.
[0075] The temporarily assembling apparatus of the present
invention is further usable also when the flat heat exchange tube
blank shown in FIG. 17 is used.
[0076] With reference to FIG. 17, the flat heat exchange tube blank
P2 is made from a metal plate which has a single first portion 80
for making one of two flat walls, two second portions 81
approximately one-half of the first portion 80 in width for making
the other flat wall, two third portions 82 for connecting the first
portion 80 to the respective second portions 81 for making two side
walls, and two fourth portions 83 upstanding from the respective
second portions 81 each at a side edge thereof opposite to the
third portion 82, by bending the metal plate at the two third
portions 82 to butt the fourth portion providing side edges of the
second portions 81 against each other and to fit the fourth
portions 83 to each other.
[0077] The metal plates for making the tube blanks P1, P2 shown in
FIGS. 16 and 17 are made of an aluminum brazing sheet having a
cladding of brazing material on opposite sides.
[0078] The flat heat exchange tube blanks for which the assembling
apparatus of the invention is usable are not limited to those
described above; the apparatus is usable also when flat heat
exchange tube blanks are used which are made of an extrudate, i.e.,
by cutting an elongated extrudate into predetermined lengths. The
tube blank thus produced is likely to be deformed at the cut end by
cutting and can not always be placed into the insertion hole of the
header. The temporarily assembling apparatus of the invention is
usable also when flat heat exchange tube blanks are used each of
which comprises two platelike components in combination as
disclosed in the publication of JP-A No. 1994-281373, Para. 0045 to
0054 and FIGS. 13 and 14. These tube blanks are produced by cutting
an elongated combination of two platelike components into
predetermined lengths. The tube blank is likely to be deformed at
the cut end by cutting and can not always be placed into the
insertion hole of the header. Furthermore, the temporarily
assembling apparatus of the invention is usable also when flat heat
exchange tube blanks are used which are made of an
electro-resistance welded tube or which are made by bending a
plate. These tube blanks are likely to have a bulging widthwise
intermediate portion, or to be deformed at cut ends by cutting
since they are produced by cutting an elongated tubular body into
predetermined lengths. In either case, such tube blanks are not
always placeable into insertion holes of headers.
[0079] The tube blank correcting member of the invention is usable
also in the temporarily assembling apparatus disclosed in the
publication of JP-A No. 1993-7958. In this case, the correcting
member is provided at a level above the guide, as positioned
laterally outwardly of the guide and made movable upward or
downward.
[0080] FIGS. 18 and 19 show a heat exchanger header which can be
temporarily assembled by the apparatus of the invention.
[0081] With reference to FIGS. 18 and 19, two side edges defining
an insertion hole H1 in the header HA and extending widthwise of
the hole are each inclined inwardly of the header HA toward the
other side edge to provide two tapering portions H2 integrally with
the header, and the inner end of each tapering portion H2 is
integrally provided with a guide H3. The opposed faces H4 of the
two guides H3 are each positioned on a plane orthogonal to the
center line of the header HA. The header HA is covered with a
brazing material layer over the inner and outer peripheral surfaces
thereof. In the case of this header HA, a heat exchange tube blank
P, P1 or P2 can be placed into the insertion hole H1 smoothly. When
the header HA is brazed to the tube blank P, P1 or P2 after
temporary assembling, a melt of brazing material collects in a
clearance H5 between the tapering portion H2 and the blank P, P1,
or P2, consequently forming a fillet H6 in the clearance as
indicating by hatching in FIG. 18. The heat exchange tube 52
produced can therefore be brazed to the header HA with an improved
strength.
INDUSTRIAL APPLICABILITY
[0082] The present invention provides a temporarily assembling
apparatus for use in fabricating heat exchangers which comprise a
pair of headers arranged in parallel and spaced apart from each
other, a plurality of flat heat exchanger tubes arranged in
parallel between the headers and brazed at opposite ends to the
respective headers with the tube ends placed into respective
insertion holes formed in the headers, and fins each arranged
between and brazed to each pair of adjacent heat exchange tubes,
and which are useful, for example, as condensers or evaporators for
motor vehicle air conditioners, motor vehicle oil coolers and motor
vehicle radiators. The apparatus is adapted for use in temporarily
assembling the headers, flat heat exchange tube blanks and the fins
into a unit to be brazed.
* * * * *