U.S. patent application number 12/097436 was filed with the patent office on 2010-02-04 for heat exchanger with receiver tank.
This patent application is currently assigned to Calsonic Kansei Corporation. Invention is credited to Masayoshi Shinhama, Masakazu Takizawa.
Application Number | 20100025028 12/097436 |
Document ID | / |
Family ID | 38162974 |
Filed Date | 2010-02-04 |
United States Patent
Application |
20100025028 |
Kind Code |
A1 |
Shinhama; Masayoshi ; et
al. |
February 4, 2010 |
HEAT EXCHANGER WITH RECEIVER TANK
Abstract
In a heat exchanger with a receiver tank, a coupling member and
an adapter member constitute a connecting member that connects the
receiver tank and the heat exchanger, where the connecting member
has header connecting portions respectively connected with a
concentrating part and a supercooling part of one of headers and
the adapter member is connected with the connecting member and the
receiver tank and is detachably attached to the receiver tank. The
coupling member is assembled with a first divided member and a
second divided member, where the first divided member is formed
with header connecting portions to be connected with the second
divided member.
Inventors: |
Shinhama; Masayoshi; (Tokyo,
JP) ; Takizawa; Masakazu; (Tokyo, JP) |
Correspondence
Address: |
FOLEY AND LARDNER LLP;SUITE 500
3000 K STREET NW
WASHINGTON
DC
20007
US
|
Assignee: |
Calsonic Kansei Corporation
|
Family ID: |
38162974 |
Appl. No.: |
12/097436 |
Filed: |
December 14, 2006 |
PCT Filed: |
December 14, 2006 |
PCT NO: |
PCT/JP2006/324904 |
371 Date: |
June 10, 2009 |
Current U.S.
Class: |
165/174 ;
165/175; 62/509; 62/513 |
Current CPC
Class: |
F28F 9/0246 20130101;
F28F 9/0224 20130101; F25B 39/04 20130101; F25B 40/02 20130101;
F25B 2339/0446 20130101; F28F 9/0212 20130101 |
Class at
Publication: |
165/174 ;
165/175; 62/509; 62/513 |
International
Class: |
F28F 9/02 20060101
F28F009/02; F25B 39/04 20060101 F25B039/04; F25B 41/00 20060101
F25B041/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 15, 2005 |
JP |
2005-361465 |
Claims
1. A heat exchanger with a receiver tank comprising: a heat
exchanging part having a pair of headers which is divided into a
concentrating part and a supercooling part by a plurality of
partition plates, and a plurality of tubes which is arranged
between the headers and has both end portions fluidically connected
with the headers, respectively; and a receiver tank that is
fluidically connected with the concentrating part and the
supercooling part of one of the headers through a connecting
member, wherein the connecting member has a coupling member and an
adapter member, the coupling member having header connecting
portions that are fluidically connected with the concentrating part
and the supercooling part of the one of the headers, respectively,
and the adapter member being fluidically connected with the
coupling member and the receiver tank and detachably attached to
the receiver tank, and wherein the coupling member has a first
divided member and a second divided member coupled with the first
divided member.
2. The heat exchanger according to claim 1, wherein at least the
first divided member of the first and second divided members is a
press formed product made of a metal plate.
3. The heat exchanger according to claim 2, wherein the first
divided member and the second divided member are formed like
semi-circular cylinders with bottom portions and are coupled with
each other to form the coupling member having the bottom portions
and shaped like a circular cylinder, wherein the coupling member is
formed at an opening end portion thereof with an adapter-member
connecting portion for receiving the adapter member.
4. The heat exchanger according to claim 2, wherein the
concentrating part and the supercooling part of the one of the
headers are formed with communicating holes, respectively, and the
header connecting portions are formed like cylinders projecting
toward the one of the headers, the header connecting portions being
formed with stepped portions having vertical surfaces at
intermediate portions thereof, and wherein the header connecting
portions are fixed to the one of the headers, being inserted into
the communicating holes, and the stepped portions contacting with
an outer surface of the one of the headers.
5. The heat exchanger according to claim 2, wherein the header
connecting portions are formed to have cross sections shaped in
ellipses.
6. The heat exchanger according to claim 2, wherein a space is
formed between the header connecting portions and an outer surface
of the one of the headers.
7. The heat exchanger according to claim 2, wherein a connecting
portion of the first divided member and the second divided member
is provided with a positioning means for positioning the first and
second divided members relative to each other.
8. The heat exchanger according to claim 1, wherein the first
divided member and the second divided member are formed like
semi-circular cylinders with bottom portions and are coupled with
each other to form the coupling member having the bottom portions
and shaped like a circular cylinder, wherein the coupling member is
formed at an opening end portion thereof with an adapter-member
connecting portion for receiving the adapter member.
9. The heat exchanger according to claim 8, wherein the
concentrating part and the supercooling part of the one of the
headers are formed with communicating holes, respectively, and the
header connecting portions are formed like cylinders projecting
toward the one of the headers, the header connecting portions being
formed with stepped portions having vertical surfaces at
intermediate portions thereof, and wherein the header connecting
portions are fixed to the one of the headers, being inserted into
the communicating holes, and the stepped portions contacting with
an outer surface of the one of the headers.
10. The heat exchanger according to claim 3, wherein the header
connecting portions are formed to have cross sections shaped in
ellipses.
11. The heat exchanger according to claim 3, wherein a space is
formed between the header connecting portions and an outer surface
of the one of the headers.
12. The heat exchanger according to claim 3, wherein a connecting
portion of the first divided member and the second divided member
is provided with a positioning means for positioning the first and
second divided members relative to each other.
13. The heat exchanger according to claim 1, wherein the
concentrating part and the supercooling part of the one of the
headers are formed with communicating holes, respectively, and the
header connecting portions are formed like cylinders projecting
toward the one of the headers, the header connecting portions being
formed with stepped portions having vertical surfaces at
intermediate portions thereof, and wherein the header connecting
portions are fixed to the one of the headers, being inserted into
the communicating holes, and the stepped portions contacting with
an outer surface of the one of the headers.
14. The heat exchanger according to claim 13, wherein the header
connecting portions are formed to have cross sections shaped in
ellipses.
15. The heat exchanger according to claim 12, wherein a space is
formed between the header connecting portions and an outer surface
of the one of the headers.
16. The heat exchanger according to claim 12, wherein a connecting
portion of the first divided member and the second divided member
is provided with a positioning means for positioning the first and
second divided members relative to each other.
17. The heat exchanger according to claim 2, wherein the header
connecting portions are formed to have cross sections shaped in
ellipses.
18. The heat exchanger according to claim 17, wherein a connecting
portion of the first divided member and the second divided member
is provided with a positioning means for positioning the first and
second divided members relative to each other.
19. The heat exchanger according to claim 1, wherein a space is
formed between the header connecting portions and an outer surface
of the one of the headers.
20. The heat exchanger according to claim 1, wherein a connecting
portion of the first divided member and the second divided member
is provided with a positioning means for positioning the first and
second divided members relative to each other.
Description
TECHNICAL FIELD
[0001] The present invention relates to a heat exchanger with a
receiver tank.
BACKGROUND OF THE INVENTION
[0002] Conventional heat exchangers with a receiver tank are
disclosed in Japanese patent applications Laid-open publication No.
2003-240386 and No. 11-2475. They have a pair of headers, a
plurality of tubes which is arranged between the headers and is
fluidically connected with the headers at its both end portions,
respectively, a heat exchanging main part, and a receiver tank
fluidically connected with a concentrating part and a supercooling
part of one of the headers of the heat exchanger through a
connecting member.
DISCLOSURE OF THE INVENTION
Problem(s) to be Solved by the Invention
[0003] The conventional heat exchangers with the receiver tanks,
however, have problems increasing a manufacturing cost and weight
of the connecting member because the connecting member is formed of
metal material to be shaped like a block as one unit, by using an
extrusion process and a machining process, and consequently leaving
unavoidable residual material on a portion thereof unnecessary for
its function.
[0004] In addition, the connecting member and the header are
normally fixed to each other by brazing, which causes bad or poor
brazing because of delay in temperature rise and fall thereof in a
heating furnace due to increase in mass of the connecting
member.
[0005] The present invention is made to solve the problems, and its
object is to provide a heat exchanger with a receive tank that can
decrease a manufacturing cost and weight of a connecting member for
connecting the receiver tank and a heat exchanging main part with
each other, the connecting member allowing the receiver tank to be
detachably attached to the heat exchanging main part.
Means for Solving the Problems
[0006] According to an aspect of the present invention, there is
provided a heat exchanger with a receiver tank including a pair of
headers, a plurality of tubes and a receiver tank. Each of the pair
of headers is divided into a concentrating part and a supercooling
part by a plurality of partition plates, and the plurality of tubes
is arranged between the headers and has both end portions
fluidically connected with the headers, respectively. The receiver
tank is fluidically connected with the concentrating part and the
supercooling part of one of the headers through a connecting
member. The connecting member has a coupling member and an adapter
member, where the coupling member has header connecting portions
that are fluidically connected with the concentrating part and the
supercooling part of the one of the headers, respectively, and the
adapter member is fluidically connected with the coupling member
and the receiver tank and is detachably attached to the receiver
tank. The coupling member has a first divided member having the
header connecting portions and a second divided member coupled with
the first divided member.
[0007] Preferably, at least the first divided member of the first
and second divided members is a press formed product made of a
metal plate.
[0008] Preferably, the first divided member and the second divided
member are formed like semi-circular cylinders with bottom portions
and are coupled with each other to form the coupling member having
the bottom portions and shaped like a circular cylinder. The
coupling member is formed at an opening end portion thereof with an
adapter-member connecting portion for receiving the adapter
member.
[0009] Preferably, the concentrating part and the supercooling part
of the one of the headers are formed with communicating holes,
respectively, and the header connecting portions are formed like
cylinders projecting toward the one of the headers, and the header
connecting portions are formed with stepped portions having
vertical surfaces at intermediate portions thereof. The header
connecting portions are fixed to the one of the headers, being
inserted into the communicating holes, and the stepped portions
contacting with an outer surface of the one of the headers.
[0010] Preferably, the header connecting portions are formed to
have cross sections shaped in ellipses.
[0011] Preferably, a space is formed between the header connecting
portions and the outer surface of the one of the headers.
[0012] Preferably, a connecting portion of the first divided member
and the second divided member is provided with a positioning means
for positioning the first and second divided members relative to
each other.
EFFECT OF THE INVENTION
[0013] The heat exchanger with the receiver tank of the present
invention includes the heat exchanging main part, which is divided
into the concentrating part and the supercooling part, and the
receiver tank which is fluidically connected through the connecting
member with the concentrating part and the supercooling part of the
one of the headers of the heat exchanging main part. The heat
exchanging main part has the plurality of tubes that is arranged
between the headers so that the both end portions thereof are
fluidically connected with the headers, respectively. The
connecting member has the coupling member and the adapter member,
where the coupling member has the header connecting portions
fluidically connected with the concentrating part and the
supercooling part of the one of the headers, and the adapter member
is fluidically connected with the coupling member and is detachably
attached to the receiver tank. The coupling member has the first
divided member formed with the header connecting portions, and the
second divided member coupled with the first divided member.
[0014] Therefore, in the embodiment, the receiver tank can be
detachably attached to the heat exchanging main part. In addition,
the connecting member, connecting the receiver tank and the heat
exchanging main part with each other, can be decreased in its
manufacturing cost and weight because of removal of an unavoidable
residual material on portions thereof unnecessary for its
function.
[0015] At least the first divided member of the first and second
divide members is made of the metal plate by using the press
forming process. This enables the connecting member to be
manufactured easily and at a low cost.
[0016] The first divided member and the second divided member are
formed like the semi-circular cylinders having the bottom portions,
and are coupled with each other to form the coupling member 11 that
has the bottom and is formed like the cylinder shape, and the
coupling member is formed with the adapter-member connecting
portion for receiving the adapter member.
[0017] Therefore, the adapter-member connecting portion can be
formed easily and at a low cost by using the first and second
divided members coupled with each other.
[0018] In addition, the bottom of the coupling member does not need
to be closed by using an additional lid part. Therefore, its
manufacturing cost can be also decreased because the number of
parts thereof can be decreased.
[0019] The concentrating part and the supercooling part of the one
of the headers are formed with the communicating holes,
respectively. The header connecting portions are projected toward
the one of the headers to be inserted into the communicating holes
of the tank plate, respectively, and they are formed at their
intermediate portions with the stepped portions that have the
vertical surfaces and are contacted with the outer surface of the
one of the headers.
[0020] Therefore, the header connecting portions can be fixed to
the one of the headers, being positioned relative to the one of the
headers. In addition, they can be firmly fixed due to increase in
contact area thereof, and accordingly the receiver tank can be
stably fixed and supported.
[0021] The header connecting portions are formed to have cross
sections shaped in ellipses. This enables the coupling member and
the adapter member to be stably fixed to each other, relative to
those having cross sections shaped in circles, in and after a
brazing process.
[0022] The space is formed between the header connecting portions
and the outer surface of the one of the headers. This decrease heat
influence on the one of the headers in the brazing process, and
accordingly they can be stably brazed with each other.
[0023] The positioning means is provided at the connecting portion
of the first divided member and the second divided member in order
to position them relative to each other.
[0024] Therefore, the first divided member and the second divided
member can be fixed to each other, being positioned properly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The objects, features and advantages of the present
invention will become apparent as the description proceeds when
taken in conjunction with the accompanying drawings, in which:
[0026] FIG. 1 is a front view showing a heat exchanger with a
receiver tank of an embodiment according to the present
invention;
[0027] FIG. 2 is an exploded perspective view showing an upper
portion of a header of the heat exchanger with the receiver tank of
the embodiment;
[0028] FIG. 3 is an exploded perspective view showing a lower
portion of the header of the heat exchanger with the receiver tank
of the embodiment;
[0029] FIG. 4 is a perspective view showing the upper portion of
the header of the heat exchanger with the receiver tank of the
embodiment;
[0030] FIG. 5 is a perspective view showing the lower portion of
the header of the heat exchanger with the receiver tank of the
embodiment;
[0031] FIG. 6 is an exploded view showing an adapter member and a
connecting member that connects the header and the receiver tank of
the heat exchanger of the embodiment;
[0032] FIG. 7 is a perspective view showing the connecting member
and the adapter member of the heat exchanger of the embodiment;
[0033] FIG. 8 is an exploded perspective view showing the
connecting member shown in FIG. 6;
[0034] FIG. 9 is a perspective view showing the connecting member
shown in FIG. 6;
[0035] FIG. 10 is a side cross-sectional view showing the receiver
tank of the heat exchanger of the embodiment;
[0036] FIG. 11 is an enlarged cross-sectional view showing a main
portion of a connecting portion of the receiver tank and the header
of the heat exchanger of the embodiment;
[0037] FIG. 12 is a cross-sectional view showing a state where a
first separated member and a tank plate, of the heat exchanger of
the embodiment, are to be fixed to each other immediately before
two jigs are inserted into the first separated member; and
[0038] FIG. 13 is a cross-sectional view showing a state where the
first separated member and the tank plate are to be fixed with each
other when the jig is inserted into the first separated member.
DESCRIPTION OF REFERENCE NUMBERS
[0039] D1, D2, D3, D4, D5, D6, D7, D8 first to eighth partition
plate, respectively [0040] E1 concentrating part [0041] E2
supercooling part [0042] O space [0043] P1 first connector [0044]
P2 second connector [0045] R1, R2, R3, R4, R5, R6 first to sixth
room, respectively [0046] 1 heat exchanging main part [0047] 2
receiver tank [0048] 2a main body [0049] 2b lid part [0050] 3
connecting member [0051] 4 first header [0052] 5 second header
[0053] 6 core part [0054] 7 tube plate [0055] 7a cut-off portion
[0056] 7b projecting portion [0057] 7c tube-plate hole [0058] 7d
reinforcement hole [0059] 7e supporting portion [0060] 7f cut-off
portion [0061] 7g holding portion [0062] 8 tank plate [0063] 8a
opening portion [0064] 8b, 8c communicating hole [0065] 9 locking
portion [0066] 10 reinforcement [0067] 11 coupling member [0068]
11a adaptor-member connecting part [0069] 11b bottom portion [0070]
12 adaptor member [0071] 12a seal groove [0072] 12b groove [0073]
12c stepped portion [0074] 12d reduced diameter portion [0075] 13
first divided member [0076] 13a side portion [0077] 13b, 13c header
connecting portion [0078] 13d stepped portion [0079] 13e fitting
portion [0080] 13f bottom portion [0081] 14 second divided member
[0082] 14a edge portion [0083] 14b bottom portion [0084] 15
connecting tube [0085] 15a flange portion [0086] 15b groove [0087]
15c, 15d, 15e seal groove [0088] 16a, 16b connecting hole [0089]
20a stepped portion
BEST MODE FOR CARRYING OUT THE INVETION
[0090] An embodiment of the present invention will be described
with reference to the accompanying drawings.
Embodiment
[0091] A heat exchanger with a receiver tank of the embodiment will
be described below.
[0092] FIG. 1 is a front view of the heat exchanger with the
receiver tank of the embodiment according to the present invention,
FIG. 2 is an exploded perspective view of an upper portion of a
header, FIG. 3 is an exploded perspective view of a lower portion
of the header, FIG. 5 is a perspective view of the upper portion of
the header, FIG. 6 is an exploded perspective view of a connecting
member, FIG. 7 is a perspective view of the connecting member, FIG.
8 is an exploded perspective view of a coupling member, FIG. 9 is a
perspective view of the coupling member, FIG. 10 is a side
cross-sectional view of a portion of the receiver tank, FIG. 11 is
an enlarged cross-sectional view of a main portion of the
embodiment, and FIGS. 12 and 13 are views explaining connecting
state of a tank plate and a first separated member.
[0093] First an entire construction of the heat exchanger with the
receiver tank of the embodiment will be described.
[0094] As shown in FIG. 1, the heat exchanger HA of the embodiment
includes a heat exchanging main part 1, the receiver tank 2 and a
connecting member 3.
[0095] The heat exchanging main part 1 includes a pair of headers,
namely a first header 4 and a second header 5, and a core part 6,
where the first and second headers 4 and 5 are apart from each
other in a lateral direction thereof (namely, a lateral direction
of a motor vehicle when the heat exchanger HA is mounted on the
motor vehicle), and the core part 6 is arranged between the first
and second headers 4 and 5.
[0096] As shown in FIG. 2 and FIG. 3, the first header 4 has a tube
plate 7 having a cross section shaped like a U-letter, a tank plate
8 having a cross section shaped like a U-letter, and first to
fourth partition plates D1, D2, D3 and D4 (The second partition
plate D2 is shown in FIG. 1).
[0097] The tube plate 7 is formed longer in a longitudinal
directional length than the tank plate 8, and it is formed with a
pair of projecting portions 7a and 7b, each having cut-off portions
7a, at its both end portions in the longitudinal direction.
[0098] The tube plate 7 is also formed with a plurality of tube
holes 7c for receiving end portions of tubes 6a of the core part 6
and also with two reinforcement holes 7d for receiving end portions
of upper and lower reinforcements 10a and 10b.
[0099] On an inner surface of the tube plate 7, there is provided
four pairs of supporting portions 7e, which are formed like a
semi-circular cylinder projecting inward from the inner surface
thereof for holding end portions of the first to fourth partition
plates D1 to D4, respectively, by each sandwiching a part of an
upper surface and a part of a lower surface of each partition plate
D1, D2, D3, D4. The tank plate 8 is formed with four opening
portions 8, which faces the supporting portions 7e of the tube
plate 7, for respectively receiving four projecting locking
portions 9 of the first to forth partition plates D1 to D4.
[0100] In addition, the tube plate 7 is formed with a plurality of
pairs of holding portions 7g, which are arranged apart from its
adjacent ones at a certain distance. Each holding portion 7g has a
pair of cut-off portions 7f at its upper side and its lower side,
respectively, projecting from both side portions of the tube plate
7. The tank plate 8 is formed, at its lower portion, with first and
second communicating holes 8b and 8c which are fluidically
connected with the receiver tank 2 through a coupling member 11.
The first and second communicating holes 8b and 8c have an elliptic
shape that is slightly long in a vertical direction.
[0101] As shown in FIG. 4, the tube plate 7 and the tank plate 8
are faced to and contacted with each other, containing the first to
fourth partition plates D1 to D4, and then they are coupled with
each other by the holding portions 7g of the tube plate 7 being
bent inward to hold an outer surface of the tank plate 8 as shown
in FIG. 5.
[0102] Consequently, the first to fourth partition plates D1 to D4
define three rooms, namely a second room R2, a fourth room R4 and a
fifth room R5 in the tube plate 7 and the tank plate 8.
[0103] The second header 5 is formed bilaterally symmetrically to
the first header 4, where an inside of the second header 5 is
defined by the fifth to eighth partition plates D5 to D8 into three
rooms, namely a first room R1, a third room R3 and a sixth room R6.
A first connector P1 is provided to fluidically communicate with
the first room R1, while a second connector P2 is provided to
fluidically communicate with the sixth room R6.
[0104] The core part 6 has the plurality of tubes 6a and a
plurality of fins 6b, where they are arranged alternately to each
other and the both end portions of the tubes 6a are inserted into
the corresponding tube-plate holes 7c to be fixed to the tube plate
7. A pair of reinforcements 10a and 10b are arranged at an upper
side and a lower side of the core part 6 to connect the upper and
lower end portions of the first and second headers 4 and 5, which
are inserted into the reinforcement holes 7d, thereby reinforcing
the core part 6.
[0105] As shown in FIG. 6 and FIG. 7, the connecting member 3
consists of the coupling member 11 and the adapter member 12,
functioning to support the receiver tank 2 and also to fluidically
communicate the forth room R4 and the fifth room 5 with an inside
of the receiver tank 2.
[0106] As shown in FIG. 8, the coupling member 11 consists of a
first divided member 13 and a second divided member 14, and they
are coupled with each other to form like a circular cylinder with a
bottom portion as shown in FIG. 9.
[0107] An opening end portion of the coupling member 11 is formed
with an adapter-member connecting portion 11a for receiving a
reduced diameter portion 12 of the adapter member 12, and a bottom
portion 11b of the coupling member 11 is formed to have a gentle
curve like an R-letter shape. Each of the first and second divided
members 13 and 14 has a bottom portion and is formed like a
semi-circular cylinder. The first divided member 13 is provided on
its side portion 13a with two header connecting portions 13b and
13c which are apart from each other in the vertical direction and
have cross sections shaped like an ellipse, projecting from the
side portion 13a, so as to be insertable into the first and second
communicating holes 8b and 8c of the tank plate 8,
respectively.
[0108] The header connecting portions 13b and 13c are also formed
to have cross sections shaped like an ellipse, and they are formed
at their intermediate portions with a stepped portion 13d having a
vertical surface.
[0109] In the heat exchanger HB with the receiver tank of the
embodiment, the second divided member 14 is partially fitted in the
first divided member 14, where the first divided member 13 has
fitting portions 13e corresponding to an positioning means, and a
bottom portion 13f corresponding to a part of the bottom portion of
the coupling member 11. The both side edge portions of the first
divided member 13 are bent outwardly like an L-letter to form the
fitting portions 13e. On the other hand, the second divided member
14 has the both side edge portions 14a corresponding to the
positioning means, and a bottom portion 14b corresponding to the
rest of the bottom portion of the coupling member 11, where the
side edge portions 14a of the second divided member 13 are coupled
with the fitting portions 13e, respectively. In the embodiment, the
side edge portions 14a of the second divided member 14 are formed
to be partially in no-contact with the fitting portions 13e of the
first divided member 13, while they are not limited to the above
structure in the present invention.
[0110] The first and second divided members 13 and 14 are
press-formed products, which are formed from aluminum plate with a
thickness of approximately 1 to 2 mm that is press-formed by using
a not-shown die.
[0111] The end portions of the header connecting portions 13b are
punched out to be opened in the press forming process, accurately a
punching press forming process. Material, the thickness and others
of the first and second divided members 13 and 14 may be set
appropriately, for example, the first divided member 13 may be
larger in thickness than the second divided member 14.
[0112] Therefore, although the first divided member 13 has a
complicated configuration because of its header connecting portions
13b and 13c, it can be manufactured in a short time, easily and at
a low cost, and accordingly manufacturing costs of the coupling
member 11 can be held down.
[0113] In addition, it does not need an extrusion process or a
machining process, thereby being compact and light in weight
because of removal of an unavoidable residual material on portions
thereof unnecessary for its function.
[0114] The first divided member 13 and the second divided member 14
may be manufactured by using a casting process or a forging
process.
[0115] The adapter member 12 is formed like a circular cylinder as
one unit, and it is formed with a first circular seal groove 12a,
in which a first seal member S1 is fitted, on an upper inner
surface of the adapter member 12. On the inner surface thereof, a
groove 12b of an internal thread is also formed near and under the
seal groove 12a.
[0116] The adapter member 12 is formed with a reduced diameter
portion 12c at a lower end portion thereof.
[0117] Material and a thickness of the adapter member 12 may be set
appropriately, and the positions and lengths of the grooves 12a and
12b may be also set appropriately.
[0118] In this embodiment, the adapter member 12 is obtained by a
process in which an aluminum circular cylinder is machined by using
a lathe or the like to a thickness of approximately 1 to 2 mm and
then it is cut to form the grooves 12a and 12b thereon.
[0119] Since the adapter member 12 has a simple configuration, it
can be easily manufactured with a relatively simple work.
[0120] As shown in FIG. 1, the receiver tank 2 consists of a
circular-cylindrical main body 2a, a lid part 2b shaped like a disc
for covering an upper portion of the main body 2a, and a connecting
pipe 15 shaped like a circular-cylinder and attached to a lower end
portion of the main body 2a. The main body 2a contains inner
structural parts such as a not-shown drying agent and a not-shown
filter.
[0121] As shown in FIG. 10, the connecting pipe 15, which is
attached to the lower end portion of the main body 2a of the
receiver tank 2, is formed on its outer surface with a flange
portion 15a projecting radially outwardly to contact with the lower
end portion of the main body 2a. It is also formed with a groove
15b of an external thread for a certain length under the flange
portion 15b.
[0122] An upper portion of the connecting pipe 15 is provided at an
upper side of the flange portion 15a with a second circular seal
groove 15c, in which a second seal member S2 is fitted, and also
with third and forth circular seal grooves 15d and 15e, in which a
third seal member S3 and a fourth seal member S4 are respectively
fitted, where the seal groove 15d and the seal groove 15e are set
apart from each other in the vertical direction under the groove
15b.
[0123] As shown in FIG. 11, the coupling member 11 is fixed with
the first header 4 by the header connecting portions 13b and 13c of
the coupling member 11 being inserted into the first and second
communicating holes 8b and 8c of the tank plate 8 of the first
header 4, respectively. The coupling member 11 is fixed with the
adapter member 12 by the stepped portion 12d of the adapter member
12 being inserted into the adapter-member connecting portion 11a of
the coupling member 11.
[0124] The receiver tank 2 is fixed with the coupling member 11 by
using the groove 12b of the adapter member 12 and the groove 15b of
the connecting pipe 15 connected with the receiver tank 2 which are
screwed together. The first, third and fourth seal members S1, S3
and S4 ensure liquid-tight fitting between the connecting pipe 15
and the adapter member 12.
[0125] As understood from the above description, the receiver tank
2 is detachably attached to the adapter member 12 and is
fluidically communicated with the fourth room R4 and the fifth room
R5 of the first header 4 through the adapter member 12 and the
header connecting portions 13b and 13c of the coupling member 11,
respectively.
[0126] The heat exchanger HA with the receiver tank 2 of the
embodiment is entirely made of aluminum, where at least ones of
contacting portions of the members are provided with a clad layer,
namely a brazing sheet.
[0127] The heat exchanger HA with the receiver tank 2 of the
embodiment is manufactured as follows.
[0128] First the heat exchanging main part 1 is temporally
assembled, and then the header connecting portions 13b and 13c of
the first divided member 13 are inserted into the first and second
communicating holes 8b and 8c of the tank plate 8, respectively, so
that the stepped portions 13d of the header connecting portions 13b
and 13c contact with the outer surface of the tank plate 8.
[0129] Next, as shown in shown in FIG. 12, two jigs 20 are
prepared. The jigs 20 are formed like an elliptic cylinder and have
stepped portions 20a with diameters larger than inner diameters of
the first and second header connecting portions 13b and 13c,
respectively. The jigs 20 are respectively inserted into the header
connecting portions 13b and 13c from an opening side of the first
divided member 13 to fix the header connecting portions 13b and 13c
and the tank plate 8 with each other at its communicating holes 8b
and 8c by radially-outwardly expanding the diameters of the header
connecting portions 13b and 13c to caulk them together as shown in
FIG. 13.
[0130] In this caulking process, the stepped portions 20a of the
jigs 20 contact with the inner surfaces of the stepped portions 13d
of the header connecting portions 13b and 13c to be pressed
thereon, thereby the header connecting portions 13b and 13c being
caulked with the tank plate 8 at its communicating holes 8b and 8c,
so that the stepped portions 13d of the header connecting portions
13b and 13c attached firmly to the outer surface of the tank plate
8.
[0131] The header connecting portions 13b and 13c may be caulked so
that they are increasingly expanded in diameter to be
plastic-deformed toward their end portions.
[0132] Accordingly, it provides a good workability, since the jig
20 can be easily inserted from the opening side of the first
divided member 13 to expand the diameters of the header connecting
portions 13b and 13c, and there is no need for another jig to fix
the header connecting portions 13b and 13c to the tank plate 8 in
the embodiment.
[0133] The stepped portions 13d of the header connecting portions
13b and 13c are contacted to the outer surface of the tank plate 8,
which can provide easy setting of the insertion lengths of the
header connecting portions 13b and 13c into the first and second
communicating holes 8a and 8b, with easily positioning them.
[0134] Incidentally, the first divided member 13 may be fixed to
the tank plate 8 by means described above before the tank plate 8
is temporally assembled with the heat exchanging main part 1. In
this case, the jig 20 may be inserted from the inner side of the
tank plate 8 to caulk the header connecting portions 13b and 13c
with the tank plate 8 at its communicating holes 8b and 8c.
[0135] Next the second divided member 14 is partially inserted into
and is contacted with the first divided member 13 so that they are
temporally assembled with each other to form the coupling member
11, and then the reduced diameter portion 12d of the adapter member
12 is inserted into the upper opening of the adapter-member
connecting portion 11a of the coupling member 11.
[0136] In this stage, the side edge portions 14a of the second
divided member 14 are fitted into the fitting portions 13e of the
first divided portion 13, thereby the first and second divided
members 13 and 14 being positioned to each other.
[0137] Next the heat exchanging main part 1 is temporally assembled
with the adapter member 12 and the first and second divided members
13 and 14, and then it is conveyed into a not-shown heat furnace,
in which the heat exchanging main part 1 is heat-treated to be
brazed at the connecting portions thereof.
[0138] In this brazing process, brazing material is placed on the
inner surfaces of the first divided member 13 and the second
divided member 14 to braze the first and second divided members 13
and 14 and the adapter member 12 with each other, thereby the
connecting portions of these three members 12, 13 and 14 being
firmly fixed together by using less amount of brazing material.
[0139] The brazing material may be placed on appropriate portions,
for example on the adapter member 12.
[0140] The both divided members 13 and 14, particularly the first
divided member 13 which directly contacts with the tank plate 8,
are manufactured by using a press forming process, thereby being
light in weight and low in heat mass. This decreases heat influence
on the tank plate 8 in the brazing process to ensure stable fixing
thereof.
[0141] As shown in FIG. 11, a space O is produced between the outer
surface of the first header 4 and the header connecting portions
13b and 13c because of the existence of the cylindrical header
connecting portions 13b and 13c projecting from the outer surface
of the coupling member 11. This decreases contact area
therebetween, thereby providing smooth rise and fall in temperature
of the first header 4 in the brazing process.
[0142] The stepped portions 13d of the header connecting portions
13b and 13c of the coupling member 11 contact with the outer
surface of the tank plate 8, and they have cross sections in
elliptic shapes, which enables the coupling member 11 and the
adapter member 12 to be more stably fixed to each other, relative
to those with cross sections shaped in a circle, in and after the
brazing process.
[0143] Next the groove 15b formed on the connecting pipe 15 of the
receiver tank 2 and the groove 12b of the adapter member 12 are
screwed together so that the lower surface of the flange portion
15a contacts with the upper end portion of the adapter member 12,
thereby fixing the receiver tank 2 and the adapter member 12 to
each other. Thus the heat exchanger HA with the receiver tank 2 is
completed.
[0144] In this screwing process, the screwing work can be carried
out by using a not-shown screw wrench, holding the flange portion
15a of the connecting pipe 15 of the receiver tank 2, to be turned.
This can avoid the brazing material placed on a periphery thereof
from being cracked and/or destroyed.
[0145] The lower surface of the flange portion 15 contacts with the
upper end portion of the adapter member 12, which can prevent the
connecting pipe 15 and the adapter member 12 from being
overscrewed. Therefore, the receiver tank 2 can be easily attached
to and detached from the adapter member 12, and the types and sizes
of the receiver tanks can be easily designed and changed according
to a type and a core size of a heat exchanging main part. When the
receiver tank 2 is damaged, it can be easily detached to be changed
or repaired, which can improve its maintenance.
[0146] Next the operation of the heat exchanger HA with the
receiver tank 2 of the embodiment will be described.
[0147] The heat exchanger HA with the receiver tank 2 of the
embodiment is mounted on a not-shown motor vehicle. A circulating
medium at a temperature of approximately 70.degree. C. enters the
first room R1 of the second header 5 through the connecting hole
16a of the first connector P1, which is shown in FIG. 1, from a
not-shown compressor side. Then the circulating medium is cooled
down due to a heat exchange between the fins 6b and a wind
generated during vehicle running and/or a forced wind generated by
a not-shown fan while it flows through the tubes 6a corresponding
to the first room R1 and the second room R2 of the core part 6, and
then it flows into the second room R2 of the first header 4.
[0148] The circulating medium entering the second room R2 flows
into the third room R3 of the second header 5 through the tubes 6a
corresponding to the second room R2 and the third room R3 of the
core part 6. The circulating medium entering the third room R3 is
cooled down due to the heat exchange between the fins 6b and the
wind generated during vehicle running and/or the forced wind
generated by the fan while it flows through the tubes 6a
corresponding to the third room R3 and the fourth room R4 of the
core part 6, and then it flows into the fourth room R4 of the first
header 4.
[0149] The circulating medium entering the fourth room R4 flows
into the inside of the receiver tank 2 through the header
connecting portion 13b of the coupling member 11 to be gas-liquid
separated by the inner structural parts thereof, and then it is
discharged into the fifth room R5 through the header connecting
portion 13c.
[0150] The circulating medium entering the fifth room R5 is cooled
down to a temperature of approximately 45.degree. C. due to the
heat exchange between the fins 6b and the wind generated during
vehicle running and/or the forced wind generated by the fan while
it flows through the tubes 6a corresponding to the fifth room R5
and the sixth room R6 of the core part 6
[0151] The circulating medium entering the sixth room R6 is
discharged to a not-shown evaporator through the connecting hole
16b of the second connector P2. As described above, as shown in
FIG. 1, the heat exchanging main part 1 functions as a condenser
which is divided into a concentrating part E1 and a supercooling
part E2, where the concentrating part E1 corresponds to the first
room R1 to the fourth room R4 and is arranged at its upper side
and, and the supercooling part E2 corresponds to the fifth room R5
and the sixth room R6 and is arranged at the lower side.
[0152] Next the effects of the heat exchanger HA with the receiver
tank 2 of the embodiment will be described.
[0153] The heat exchanger HA with the receiver tank 2 of the
embodiment includes the heat exchanging main part 1, which is
divided into the concentrating part E1 and the supercooling part
E2, and the receiver tank 2 fluidically connected with the
concentrating part E1 and the supercooling part E2 of the first
header 4 through the connecting member 3. The heat exchanging main
part 1 has the plurality of tubes 6a that is arranged between the
first header 4 and the second header 5 so that the both end
portions thereof are fluidically connected with the first and
second headers 4 and 5, respectively. The connecting member 3
consists of the coupling member 11 and the adapter member 12, where
the coupling member 11 has the header connecting portions 13b and
13c fluidically connected with the concentrating part E1 and the
supercooling part E2 of the first header 4. The adapter member 12
is fluidically connected with the coupling member 11 and is
detachably attached with the receiver tank 2. The coupling member
11 consists of the first divided member 13 and the second divided
member 14, where the first divided member 13 is formed with the
header connecting portions 13b and 13c, and the second divided
member 14 is coupled with the first divided member 14.
[0154] Therefore, in the embodiment, the receiver tank 2 can be
detachably attached to the heat exchanging main part 1. In
addition, the connecting member 3, which connects the receiver tank
2 and the heat exchanging main part 1 with each other, can be
decreased in its manufacturing cost and weight because of the
removal of the unavoidable residual material on the portions
thereof unnecessary for its function.
[0155] In the heat exchanger HA with the receiver tank 2 of the
embodiment, at least the first divided member 13 is made from the
metal plate by using the press forming process, which enables the
connecting member 3 to be manufactured easily and at a low
cost.
[0156] The first divided member 13 is formed with the header
connecting portions 13b and 13c, which can improve brazing, sealing
and reliability relative to a coupling member 11 with the header
connecting parts separated therefrom.
[0157] The connecting portions of the first and second divided
members 13 and 14 are formed at positions apart from the first
header 4, which can improve workability in repairing the coupling
member 11 when the connecting portions are cracked and/or
destroyed.
[0158] The first divided member 13 and the second divided member 14
are formed like the semi-circular cylinders having the bottom
portions, and they are coupled with each other to form the coupling
member 11 that has the bottom and is formed like the circular
cylinder shape, the coupling member 11 being formed with the
adapter-member connecting portion 11a for receiving the adapter
member 12.
[0159] Therefore, the adapter-member connecting portion 11a can be
formed easily and at a low cost because the first and second
divided members 13 and 14 are formed separately from each other to
be coupled with each other.
[0160] In addition, the bottom of the coupling member 11 does not
need to be closed by using an additional lid part. Therefore, its
manufacturing cost can be also held down because the number of
parts thereof can be decreased.
[0161] The concentrating part E1 and the supercooling part E2 of
the first header 4 are formed with the communicating holes 8b and
8c, respectively. The header connecting portions 13b and 13c are
projected toward the first header 4 to be inserted into the
communicating holes 8b and 8c of the tank plate 8, respectively,
and they are formed at their intermediate portions with the stepped
portions 13d that have the vertical surfaces and are contacted with
the outer surface of the first header 4.
[0162] Therefore, the header connecting portions 13b and 13c can be
fixed to the tank plate 8 of the first header 4, being positioned
relative to the first header 4. In addition, they can be firmly
fixed due to increase in contact area thereof, and accordingly the
receiver tank 2 can be stably fixed and supported.
[0163] The header connecting portions 13b and 13c have cross
sections like the ellipse shapes, which can increase the contact
area between the header connecting portions 13b and 13c and the
first header 4. Therefore, the adapter member 12 can be stably
fixed.
[0164] The space O is formed between the header connecting portions
13b and 13c and the outer surface of the first header 4, which can
decrease the heat influence on the first header 4 in the brazing
process. Therefore, they can be stably brazed with each other.
[0165] The positioning means, corresponding to the fitting portions
13e and the edge portions 14a, is provided, at the connecting
portions of the first divided member 13 and the second divided
member 14, to position them.
[0166] Therefore, the first divided member 13 and the second
divided member 14 can be fixed with each other, being positioned
properly.
[0167] It is understood that the invention is not limited to the
above-described embodiment but that various changes and/or
modifications may be made without departing from the spirit and/or
the scope of the present invention.
[0168] For example, the first and second divided members 13 and 14
are manufactured by using a press forming process in the embodiment
described above, and only the first divided member 13 is
press-formed and the second divided member 14 may be formed by
using other process.
[0169] The brazed portions of the heat exchanger with the receiver
tank of the embodiment are not limited to those of the embodiment,
and their positions may be changed appropriately.
INDUSTRIAL AVAILABILITY
[0170] The heat exchanger with the receive tank of the present
invention is not limited to those for motor vehicles, and it is
available for others.
* * * * *