U.S. patent application number 13/139644 was filed with the patent office on 2011-10-13 for heat exchanger and its manufacturing method.
This patent application is currently assigned to CALSONIC KANSEI CORPORATION. Invention is credited to Hiroshi Chikuma, Takumi Funatsu, Yoshihiro Kawai, Makoto Yamazaki.
Application Number | 20110247792 13/139644 |
Document ID | / |
Family ID | 42268709 |
Filed Date | 2011-10-13 |
United States Patent
Application |
20110247792 |
Kind Code |
A1 |
Chikuma; Hiroshi ; et
al. |
October 13, 2011 |
HEAT EXCHANGER AND ITS MANUFACTURING METHOD
Abstract
A heat exchanger 1 includes a pair of tanks 2 and 3 arranged a
certain distance apart from each other, a plurality of tubes 4a
whose both end portions are connected with the pair of tanks 2 and
3, a long receiver tank 5 arranged along and adjacently to the tank
3 and communicatably connected with the tank 3, and a reception
member 20 contained in the receiver tank 5. An upper opening end
portion 13b has an opening portion at one side in a longitudinal
direction of the receiver tank 5 and having a reduced diameter, and
a block member 15 blocks the upper opening end portion 13b. An
entire of the heat exchanger 1 except the reception member 20 and
the block member 15 are integrally formed by a brazing process. The
reception member 20 is inserted through the upper opening end
portion 13b and arranged in the receiver tank 5 after the brazing
process, and then the block member 15 is joined by brazing with the
upper opening end portion 13b after the reception member 20 is
inserted and arranged therein.
Inventors: |
Chikuma; Hiroshi; (Saitama,
JP) ; Kawai; Yoshihiro; (Saitama, JP) ;
Funatsu; Takumi; (Saitama, JP) ; Yamazaki;
Makoto; (Saitama, JP) |
Assignee: |
CALSONIC KANSEI CORPORATION
Saitama-shi, Saitama
JP
|
Family ID: |
42268709 |
Appl. No.: |
13/139644 |
Filed: |
December 7, 2009 |
PCT Filed: |
December 7, 2009 |
PCT NO: |
PCT/JP2009/070448 |
371 Date: |
June 14, 2011 |
Current U.S.
Class: |
165/173 ;
29/890.03 |
Current CPC
Class: |
B23K 1/203 20130101;
Y10T 29/4935 20150115; F28F 19/01 20130101; B23K 1/002 20130101;
F25B 43/003 20130101; F28F 9/0251 20130101; F25B 2339/0442
20130101; F28F 9/0209 20130101; B23K 2101/14 20180801; F28D 1/0535
20130101; F25B 39/04 20130101; B23K 1/0012 20130101; F25B 2339/0441
20130101; B23K 1/008 20130101; F28F 9/0278 20130101; F28F 2220/00
20130101; F28F 9/0229 20130101; F25B 2339/0446 20130101 |
Class at
Publication: |
165/173 ;
29/890.03 |
International
Class: |
F28F 9/02 20060101
F28F009/02; B21D 53/02 20060101 B21D053/02 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 15, 2008 |
JP |
2008-317823 |
Dec 15, 2008 |
JP |
2008-317824 |
Claims
1.-19. (canceled)
20. A heat exchanger comprising: a pair of tanks arranged a certain
distance apart from each other; a plurality of tubes whose both end
portions are communicatably connected with the pair of tanks; a
receiver tank having a main body that is arranged along and near
one of the pair of tanks. the receiver tank being communicatably
connected with the one of the tanks and having an opening end
portion provided at one side in a longitudinal direction of the
main body; a reception member having a shape to be insertable from
the opening end portion-and contained in the receiver tank; and a
close member fixed to the opening end portion to cover the opening
end portion, wherein the opening end portion is a reduced diameter
portion in which an outer diameter of the opening end portion is
set smaller than an outer diameter of the other side in the
longitudinal direction of the main body.
21. The heat exchanger according to claim 20, wherein the main body
of the receiver tank includes a first divided member shaped like a
circular cylinder with a bottom portion, and a second divided
member communicatably connected with the one side in the
longitudinal direction of the first divided member and shaped like
a circular cylinder having the reduced diameter portion whose
diameter is reduced up to the opening end portion.
22. The heat exchanger according to claim 21, wherein the one of
tanks and the first divided member are communicatably connected
with each other through an intermediate member, and wherein a
restricting portion for preventing a relative displacement between
the first divided member and the intermediate portion is formed on
an outer circumference of the first divided member as one unit.
23. The heat exchanger according to claim 22, wherein the
restricting portion restricts the relative displacement of the
intermediate member in a width direction of the heat exchanger.
24. The heat exchanger according to claim 23, wherein the
restricting portion has a cross section shaped like a letter U to
open toward the tank of the heat exchanger, extending in a
longitudinal direction of the first divided member, and wherein the
restricting portion and the intermediate portion are positioned and
joined with each other.
25. The heat exchanger according to claim 24, wherein the
intermediate member is fixed, being sandwiched by both side walls
of the restricting portion, and wherein the both side walls have
across section shaped like a letter U to face to each other.
26. The heat exchanger according to claim 22, wherein the second
divided member is fixed and supported on the one of tanks through a
holding member having the same configuration as the intermediate
member.
27. The heat exchanger according to claim 21, wherein an entire
length of the first divided member is set shorter than an entire
length of the second divided member.
28. The heat exchanger according to claim 20, wherein the reception
member is one of a drying agent and a fluorescent agent.
29. A heat exchanger comprising: a pair of tanks arranged a certain
distance apart from each other; a plurality of tubes whose both end
portions are communicatably connected with the pair of tanks; a
receiver tank having a main body that is arranged along and near
one of the pair of tanks, the receiver tank being communicatably
connected with the one of the tanks and having an opening end
portion provided at one side in a longitudinal direction of the
main body; a reception member having a shape to be insertable from
the opening end portion and contained in the receiver tank; and a
close member fixed to the opening end portion to cover the opening
end portion, wherein the opening end portion is formed to project
outward in the longitudinal direction relative to the one of
tanks.
30. The heat exchanger according to claim 29, wherein the one of
tanks and the first divided member are communicatably connected
with each other through an intermediate member, and wherein a
restricting portion for preventing a relative displacement between
the first divided member and the intermediate portion is formed on
an outer circumference of the first divided member as one unit.
31. The heat exchanger according to claim 30, wherein the
restricting portion restricts the relative displacement of the
intermediate member in a width direction of the heat exchanger.
32. The heat exchanger according to claim 31, wherein the
restricting portion has a cross section shaped like a letter U to
open toward the tank of the heat exchanger, extending in a
longitudinal direction of the first divided member, and wherein the
restricting portion and the intermediate portion are positioned and
joined with each other.
33. The heat exchanger according to claim 32, wherein the
intermediate member is fixed, being sandwiched by both side walls
of the restricting portion, and wherein the both side walls have a
cross section shaped like a letter U o face to each other
34. The heat exchanger according to claim 30, wherein the receiver
tank is fixed to support on the one of tanks through a holding
member having the same configuration as the intermediate
member.
35. The heat exchanger according to claim 29, wherein the reception
member is one of a drying agent and a fluorescent agent.
36. A method for manufacturing a heat exchanger which includes: a
pair of tanks arranged a certain distance apart from each other: a
plurality of tubes whose both end portions are communicatably
connected with the pair of tanks; a receiver tank having a main
body that is arranged along and near one of the pair of tanks, the
receiver tank being communicatably connected with the one of the
tanks and having an opening end portion provided at one side in a
longitudinal direction of the main body; a reception member having
a shape to be insertable from the opening end portion and contained
in the receiver tank; and a close member fixed to the opening end
portion to cover the opening end portion, the method comprising: a
process of preparing the receiver tank that has one of the opening
end portion whose outer diameter is set smaller than an outer
diameter of the other side in the longitudinal direction of the
main body and the opening end portion which project outward in the
longitudinal direction relative to the one of tanks; a process of
preparing the tanks, the plurality of tubes. the reception member
and the close member which constitute the heat exchanger; a process
of integrally forming the whole of the heat exchanger except the
reception member and the close member by brazing; a process of
inserting and arranging the reception member n the receive tank
through the opening end portion after the brazing process; and a
process of joining the close member on the opening end portion by
one of welding and brazing.
37. The method for manufacturing the heat exchanger according to
claim 36, wherein the close member is joined by brazing on the
opening end portion by high-frequency induction heating generated
by a work coil, wherein a temperature measurement means measures a
temperature of a joint portion of the close member in the brazing
process, and wherein a temperature of the high-frequency induction
heating by the work coil is controlled by a feed-back loop
according to the temperature of the joint portion measured by the
temperature measurement means.
38. The method for manufacturing the heat exchanger according to
claim 37, wherein the temperature measurement means includes a
blackbody coating provided on a periphery of the joint portion of
the close member. and a sensor for measuring a temperature change
of the blackbody coating.
Description
TECHNICAL FIELD
[0001] The present invention relates to a heat exchanger and its
manufacturing method.
BACKGROUND OF THE INVENTION
[0002] Patent Document 1 discloses a conventional heat exchanger in
which a drying agent is inserted in a receiver tank whose interior
is sealed by a block member.
[0003] Patent Document 1: Japanese Patent Application Laid-Open
Publication Number 08-110125
DISCLOSURE OF THE INVENTION
Problem(s) to be Solved by the Invention
[0004] However, in the conventional heat exchanger, the block
member is joined by welding to an opening edge portion of the
receiver tank for example in order to improve the pressure
tightness of the receiver tank. In this case, as the receiver tank
and a tank of the heat exchanger are very closer to each other,
problems such as listed below occur.
[0005] Specifically, it is difficult to assure a work space for
joining the block member.
[0006] In addition, the tank of the heat exchanger might deform due
to heat generated when the block member is joined.
[0007] Further, as the heat mass of the receiver tank is large, the
temperature of the block member is not heated up to a desired
temperature and consequently it takes a long time to join.
[0008] The present invention is made to solve the above-described
problems, and its object is to provide a heat exchanger in which a
block member of a receiver tank can be nicely joined so that the
pressure tightness of a receiver tank can be improved.
Means for Solving the Problems
[0009] A heat exchanger of the present invention includes a pair of
tanks arranged a certain distance apart from each other, a
plurality of tubes whose both end portions are communicatably
connected with the pair of tanks, a receiver tank which has a main
body arranged along and adjacently to one of the pair of tanks and
is communicatably connected with the tank, having an opening end
portion at one side in a longitudinal direction of the main tank, a
reception member which is formed to be insertable through the
opening end portion and contained in the receiver tank, and a block
member fixed at the opening end portion to cover the opening end
portion. The opening end portion is formed as a reduced diameter
portion whose outer diameter is set smaller than the outer diameter
of the other side of the main body in the longitudinal direction,
or it is formed to project outward in the longitudinal direction
relative to the one tank.
[0010] A method of the present invention is one for manufacturing a
heat exchanger including a pair of tanks arranged a certain
distance apart from each other, a plurality of tubes whose both end
portions are communicatably connected with the pair of tanks, a
receiver tank which has a main body arranged along and adjacently
to one of the pair of tanks and is communicatably connected with
the tank, having an opening end portion at one side in a
longitudinal direction of the main tank, a reception member which
is formed to be insertable through the opening end portion and
contained in the receiver tank and a block member fixed at the
opening end portion to cover the opening end portion. The method
includes a process of preparing the receiver tank that has one of
the opening end portion whose outer diameter is set smaller than an
outer diameter of the other side in the longitudinal direction of
the main body and the opening end portion which projects outward in
the longitudinal direction relative to the one of tanks, a process
of preparing the tanks, the plurality of tubes, the reception
member and the block member which constitute the heat exchanger, a
process of integrally forming the whole of the heat exchanger
except the reception member and the block member by brazing, a
process of inserting and arranging the reception member in the
receive tank through the opening end portion after the brazing
process, and a process of joining the block member on the opening
end portion by one of welding and brazing.
EFFECT OF THE INVENTION
[0011] The heat exchanger and its manufacturing method of the
present invention are such a construction and a manufacturing
method that they can be equipped with one of the opening end
portion in which the outer diameter of the one side in the
longitudinal direction of the receiver tank containing the
reception member is set smaller than the outer diameter of the main
body of the other side in the longitudinal direction or the opening
end portion projecting outward in the longitudinal direction
relative to the one of tanks. In addition, the whole of the heat
exchanger except the reception member and the block member is
integrally formed by the brazing process or the like, and then the
reception member is inserted and arranged in the receiver tank
after the brazing process and the like. The block member is fixed
by welding or brazing on the opening end portion after the
reception member is inserted and arranged.
[0012] Consequently, the heat exchanger and its manufacturing
method of the present invention can assure a work space for joining
the block member, preventing a harmful effect on the tank during
joining, decreasing jointing material, and improving the efficiency
in joining work, and also improving a brazing performance because
of heat mass of the receiver tank, all together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a front view showing a heat exchanger of a first
embodiment according to the present invention;
[0014] FIG. 2 is an exploded perspective view of a tank of the heat
exchanger of the first embodiment;
[0015] FIG. 3 is a perspective view of the tank shown in FIG.
2;
[0016] FIG. 4 is a an exploded perspective view of the tank shown
in FIG. 2;
[0017] FIG. 5 is a perspective view of the tank shown in FIG.
2;
[0018] FIG. 6 is an exploded perspective view showing a receiver
tank which is used in the heat exchanger of the first
embodiment;
[0019] FIG. 7 is a perspective view of the receiver tank shown in
FIG. 6;
[0020] FIG. 8 is an exploded perspective view of the receiver tank
and intermediate members which are used in the heat exchanger of
the first embodiment;
[0021] FIG. 9 is a cross sectional side view explaining a lower
interior of the receiver tank shown in FIG. 6;
[0022] FIG. 10 is a cross sectional view taken along a line S10-S10
in FIG. 9;
[0023] FIG. 11 is a cross sectional side view explaining an upper
interior of the receiver tank shown in FIG. 6;
[0024] FIG. 12 is an exploded view of a metal filter which is used
in the heat exchanger of the first embodiment;
[0025] FIG. 13 is a top plain view of a bracket member which is
used in the heat exchanger of the first embodiment;
[0026] FIG. 14 is a top plain view (A part is omitted.) of a
periphery of the block member to explain high-frequency induction
heating in the heat exchanger of the first embodiment;
[0027] FIG. 15 is a cross sectional view taken along a line S15-S15
in FIG. 14;
[0028] FIG. 16 is a view explaining a profile of the temperature in
the heat exchanger of the first embodiment;
[0029] FIG. 17 is a view explaining another example of the joining
of the block member shown in FIG. 11;
[0030] FIG. 18 is a view showing other example of the joining of
the block member;
[0031] FIG. 19 is a view showing other example of the joining of
the block member;
[0032] FIG. 20 is a view showing other example of the joining of
the block member;
[0033] FIG. 21 is a view showing other example of the joining of
the block member;
[0034] FIG. 22 is a cross sectional view taken along a line S22-S22
in FIG. 21 and explaining other example of the joining of the block
member;
[0035] FIG. 23 is a cross sectional view taken along a line S23-S23
in FIG. 21 and explaining other example of the joining of the block
member;
[0036] FIG. 24 is a view explaining other example of the joining of
the block member;
[0037] FIG. 25 is a view explaining a high-frequency induction
heating process in a heat exchanger manufacturing method of a
second embodiment of the present invention;
[0038] FIG. 26 is a perspective view of a receiver tank which is
used in a heat exchanger of a third embodiment according to the
present invention;
[0039] FIG. 27 is an exploded perspective view of a receiver tank
which is used in a heat exchanger of a fourth embodiment of the
present invention;
[0040] FIG. 28 is an exploded perspective view of the receiver tank
shown in FIG. 27;
[0041] FIG. 29 is a cross sectional side view explaining an upper
interior of the receiver tank shown in FIG. 28;
[0042] FIG. 30 is a cross sectional view explaining the upper
interior of the receiver tank shown in FIG. 28; and
[0043] FIG. 31 is a view explaining a high-frequency induction
heating process in a heat exchanger manufacturing method of a fifth
embodiment of the present invention.
DESCRIPTION OF REFERENCE NUMBERS
[0044] D1 divided plate
[0045] R1, R2, R3, R4, R5, R6, P1, P2, P3 chamber
[0046] 1 heat exchanger
[0047] 2, 3 tank
[0048] 4 core part
[0049] 4a tube
[0050] 4b fin
[0051] 4c reinforcement
[0052] 5 receiver tank
[0053] 6 input connector
[0054] 6a input port
[0055] 7 output connector
[0056] 7a output port
[0057] 8, 9 intermediate member
[0058] 8a, 9a communicating hole
[0059] 8b, 9b, 16b insertion portion
[0060] 8c, 9c, 16c seat portion
[0061] 8d, 9d, 16d contact surface
[0062] 8e, 9e mid portion
[0063] 10a tube plate
[0064] 10b tank plate
[0065] 10c reinforcement hole
[0066] 10d tube hole
[0067] 10e bead portion
[0068] 10f engaging portion
[0069] 10g projecting portion
[0070] 10i, 10j, 11d, 11e communicating hole
[0071] 11 first divided member
[0072] 11a side wall
[0073] 11b bottom portion
[0074] 11c fixation portion (restricting portion)
[0075] 11f caulking portion
[0076] 12 second divided member
[0077] 12a insertion portion
[0078] 12b bead portion
[0079] 12c reduced diameter portion
[0080] 13 main body
[0081] 14, 15 block member
[0082] 14a, 15a bottom portion
[0083] 14b, 15b insertion portion
[0084] 16 holding member
[0085] 17 metal filter
[0086] 17a filter main body part
[0087] 17b flange part
[0088] 17c metal ring
[0089] 19, 60 bracket member
[0090] 19a through-hole
[0091] 20 drying agent
[0092] 31 communicator
[0093] 32 work coil
[0094] 33 controller
[0095] 40 brazing filler metal
[0096] 41 cut-off stepped portion
[0097] 42 claw portion
[0098] 43 enlarged portion
[0099] 50 black-body coating material
[0100] 51 infrared temperature sensor
BEST MODE FOR CARRYING OUT THE INVENTION
[0101] Hereinafter, embodiments of the present invention will be
explained.
First Embodiment
[0102] Hereinafter, a heat exchanger and its manufacturing method
of the first embodiment of the present invention will be described
with reference to the accompanying drawing.
[0103] FIG. 1 is a front view showing the heat exchanger of the
first embodiment, FIG. 2 is an exploded perspective view of a tank
that is used in the heat exchanger of the first embodiment, FIG. 3
is a perspective view of the same, FIG. 4 is an exploded
perspective view of the tank shown in FIG. 2 and FIG. 3, and FIG. 5
is a perspective view of the same.
[0104] FIG. 6 is an exploded perspective view of a receiver tank
that is used in the heat exchanger of the first embodiment, FIG. 7
is a perspective view of the same, FIG. 8 is an exploded
perspective view of the receiver tank and intermediate members of
the first embodiment, FIG. 9 is a cross sectional side view
explaining a lower interior of the receiver tank shown in FIG. 6
and FIG. 7, and FIG. 10 is a cross sectional view taken along a
line S10-S10 in FIG. 9.
[0105] FIG. 11 is a cross sectional view explaining an upper
interior of the receiver tank shown in FIG. 6 and FIG. 7, FIG. 12
is an exploded view of a metal filter that is used in the heat
exchanger of the first embodiment, and FIG. 13 is a top plain view
of a bracket member that is used in the heat exchanger of the first
embodiment.
[0106] FIG. 14 is a top plain view (A part is omitted.) showing a
periphery of a block member to explain high-frequency induction
heating in the heat exchanger of the first embodiment, FIG. 15 is a
cross sectional view taken along a line S15-S15 in FIG. 14, and
FIG. 16 is a view explaining a profile of the temperature in the
heat exchanger of the first embodiment.
[0107] FIG. 17-21 are views explaining other example of the joining
of the block member, FIG. 22 is a cross sectional view taken along
a line S22-S22 in FIG. 21 to explain other example of the joining
of the block member, FIG. 23 is a cross sectional view taken along
a line S23-S23 in FIG. 21 to explain other example of the joining
of the block member, and FIG. 24 is a view showing other example of
the joining of the block member.
[0108] First, an entire construction of the heat exchanger of the
first embodiment will be described.
[0109] As shown in FIG. 1, the heat exchanger 1 of the first
embodiment includes a pair of tanks 2 and 3 that are arranged a
predetermined distance apart from each other in a left and right
direction, a core part 4 that is arranged between the pair of tanks
2 and 3, a long receiver tank 5 that is arranged along and
adjacently to the tank 3, and others.
[0110] The tank 2 has three chambers R1, R3 and R6 that are defined
by four divided plates D1 formed like a plate, and there is
provided an input connector 6 with an inlet port 6a that
communicates with the chamber R1, while there is provided an output
connector with an outlet port 7a that communicates with the chamber
R6.
[0111] The tank 3 has three chambers R2, R4 and R5 that are defined
by four divided plates D1, and there is provided the receiver tank
5 that communicates with the chambers R4 and R5 through
intermediate members 8 and 9.
[0112] As shown in FIG. 2, the tank 2 consists of a tube plate 10a
shaped in a half-tube having a cross section like a letter U, a
tank plate 10b shaped in a half-tube having a cross section like a
letter U and coupled with the tube plate 10a like a box, and the
above-described divided plates D1 attached on inner sides of the
both plates 10a and 10b. The tube plate 10a is formed with
reinforcement holes 10c and tube holes 10d so that they are formed
like a circular projection projecting inward by a burring process.
The end portions of reinforcements 4c, which will be later
described, are inserted through the reinforcement holes 10c and
they are fixed to the tube plate 10a. The end portions of the tubes
4a, which will be later described, are inserted through the tube
holes 10d and they are fixed to the tube plate 10a.
[0113] In addition, at each position of the tube plate 10a where
the divided plate D1 are attached, a pair of bead portions 10e and
10e are projected inward so that they can fix the core part (4)
sides of the divided plates D1 in a state they sandwich the core
part sides thereof.
[0114] Further, on side walls of the tube plate 10a facing each
other, being shaped like the U-letter shape, a plurality of pairs
of engagement portions 10f and 10f shaped like a claw are formed
along a longitudinal direction of the tube plate 10a so as to be
caulked with and fixed to portions of an outer circumference of the
tank plate 10b.
[0115] Incidentally, the configuration, the formation number, the
formation positions and others of the engagement portions 10f and
10f may be set appropriately.
[0116] On the other hand, at the positions of the tank plate 10b
where the divided plates D1 are attached, fixation holes 10h are
formed so that projecting portions 10g formed on the divided plates
D1 can be inserted therein and fixed thereto.
[0117] In addition, at the positions of the tank plate 10b where
the connectors 6 and 7 are fixed, circular communicating holes 10i
and 10j are formed, respectively.
[0118] In addition, as shown in FIG. 3, the divided plates D1 are
placed at predetermined positions and then the both plates 10a and
10b are coupled with each other like a box. The engagement portions
10f and 10f are caulked and fix with the tank plate 10b, so that
the tank 2 is constructed to be capable of being temporally
assembled.
[0119] Further, the connectors 6 and 7 and the tank plate 10 are
constructed to be capable of being temporally assembled in a state
where the connectors 6 and 7 are contacted with the tank plate 10b,
where they are caulked and fixed with circular projecting portions
that are formed like a circular projection by the respective
communicating holes 10i and 10j of the tank plate 10b being formed
by the burring process so as to project outward in advance before
the both plates 10a and 10b are coupled with each other.
[0120] As shown in FIGS. 4 and 5, the tank 3 is constructed to be
capable of being temporally assembled, as well as the tank 2, in
such a way that the to engagement portions 10f and 10f are caulked
and fixed with the tank plate 10b after the both plates 10a and 10b
are coupled with each other like a box in a state where the divided
plates D1 are placed at the certain positions.
[0121] In addition, at the positions of the tank plate 10b where
intermediate plates 8 and 9 are fixed, circular communicating holes
10k and 10m are formed. Further, on the position where a holding
member 16, which will be later described, is fixed, communicating
hole 10n is formed (refer to FIG. 11).
[0122] The core part 4 includes a plurality of flat tubes 4a and
corrugated fins 4b, where the both end portions of tubes 4a are
inserted in and fixed to the tube holes 10d of the tanks 2 and 3
and wave top portions of the fins 4b are contacted with the
adjacent tubes 4.
[0123] In addition, the both sides in a layer direction of the core
part 4 are connected with and reinforced by a pair of reinforcement
4c and 4c where the both end portions thereof are inserted in and
fixed to the reinforcement holes 10c of the tanks 2 and 3.
[0124] As shown in FIGS. 6 and 7, the receiver tank 5 includes a
main body 13 and block members 14 and 15, where the main body 13
consists of a first divided member 11 and a second divided member
12 that are shaped like a circular cylinder and connected with each
other, and the block members 14 and 15 are formed like a dish and
block both opening end portions of the main body 13. On an outer
peripheral portion of the first divided member 11, a fixation
portion 11c are formed along the first divided member 11 over the
entire length thereof, having a cross section shaped like a letter
U opening toward the intermediate members 8 and 9. The fixation
portion 11c has a pair of side walls 11a and 11a that extend along
a center of axis of the first divided member 11 to face each other,
and a flat bottom portion 11b that is provided between the side
walls 11a and 11a perpendicular to the side walls.
[0125] In addition, at the position of the bottom portions 11b
where the intermediate members 8 and 9 are fixed, circular
communicating holes 11d and 11e are formed, respectively.
[0126] Incidentally, at least the first divided member 11 is formed
as one unit by an extrusion process of raw material.
[0127] On the other hand, the second divided member 12 includes an
insertion portion 12a having the same outer diameter as an inner
diameter of an upper end portion of the first divided member 11,
and a reduced diameter 12c having an outer diameter reduced to a
predetermined outer diameter adjacently to a circular bead portion
12b that is formed to project outwardly from the insertion portion
12a.
[0128] The block member 14 is formed to have a bottom portion 14a
shaped like a disc, and an insertion portion 14b that is formed
like a circular projection projecting from an outer circumferential
portion of the bottom portion 14a toward the main body 13 to be
insertable in and engageable with an inner circumferential portion
of the lower opening end portion 13a of the main body 13 (the first
divided member 11).
[0129] The block member 15 is formed to have a bottom portion 15a
shaped like a disc, and an insertion portion 15b that is formed
like a circular projection projecting from an outer circumferential
portion of the bottom portion 15a toward the main body 13 to be
insertable in and engageable with an inner circumferential portion
of the upper opening end portion 13b of the main body 13 (the
second divided member 12).
[0130] In addition, as shown in FIG. 7, an insertion portion 12a of
the second divided member 12 is inserted into the inner
circumference of the upper end portion of the first divided member
11, and then the bead portion 12b is contacted with the upper end
portion of the first divided member 11, so that the both divided
members 11 and 12 can be connected and fixed with each other.
[0131] In addition, the both block members 14 and 15 are pressed in
the inner sides of the upper and lower opening end portions 13a and
13b, respectively, and the bottom portions 14a and 15a are fixed in
a state they are in plane with the end portions 13a and 13b.
[0132] Accordingly, in a main body 13 of the receiver tank 13, the
diameter of an upper opening end portion 13b of the main body 13 is
reduced because that of the diameter-reduced portion 12c of the
second divided member 12 is reduced.
[0133] As shown in FIGS. 8 to 10, the intermediate members 8 and 9
are used to communicatably connect the communicating holes 10k and
10m with the respective communicating holes 11d and 11e of the
receiver tank 5 and to fix the receiver tank 5 to the tank 3. The
intermediate member 8 (9) is provided with a communicating hole 8a
(9a), an insertion portion 8b (9b) and a seat portion 8c (9c) as
shown in FIG. 8. The communicating hole 8a (9a) is formed to have a
circular opening cross section, being penetrated. The insertion
portion 8b (9a) is shaped like a cylinder to project on a tank (3)
side so as to extend a length of the communicating hole 8a (9a).
The seat portion 8c (9c) is shaped like a rectangle and provided at
the receiver tank (5) side.
[0134] In addition, between the insertion portion 8b (9b) of the
intermediate portion 8 (9) and the seat portion 8c (9c), there is
formed with a mid portion 8e (9e) having a contact surface 8d (9d)
to fit an outer circumferential configuration of the tank plate 10b
of the tank 3.
[0135] Incidentally, the opening diameter of the communicating hole
11d (11e) of the fixation portion 11c is set larger in some degree
than that of the communicating hole 8a (9a).
[0136] Further, as shown in FIG. 9, the intermediate portion 8 (9)
is fixed in a state where the insertion portion 8b (9b) is inserted
into the communicating hole 10k (10m) of the tank 3 so that the
contact surface 8d (9d) is contacted with the tank plate 10b of the
tank 3 and the seat portion 8c (9c) is contacted with the bottom
portion 11b of the fixation portion 11c.
[0137] This enables the tank 3 (the communicating holes 10k and
10m) to be communicatably connected with the receiver tank 5 (the
communicating holes 11d and 11e).
[0138] In addition, as shown in FIG. 10, the maid portion 8e (9e)
and the seat portion 8c (9c) of the intermediate member 8 (9) are
fixed by a pair of caulking portions 11f that are formed by the
both side walls 11a and 11a being caulked inward.
[0139] Incidentally, the configuration, the formation number, the
formation position and others of the caulking portion 11f may be
set appropriately, and a positioning construction without using
caulking maybe employed.
[0140] Further, as shown in FIG. 11, the first divided plate 11 is
provided near the mid portion with a holding member 16 having the
same configuration as that of the intermediate member 8 (9).
[0141] In the holding member 16, as well as the intermediate
members 8 and 9, the insertion portion 16b is inserted into the
communicating hole 10n of the tank 3 so that the contact surface
16d is contacted with the tank plate 10b of the tank 3 and the seat
portion 16c is fixed in a state where it contacts with the bottom
portion 11b of the fixation portion 11c.
[0142] Further, not shown in the drawings, the holding member 16 is
fixed by a pair of caulking portions 11f as well as the
intermediate members 8 and 9. This enables the receiver tank 5 to
be supported in a stable state on the tank 3 through the
intermediate portions 8 and 9 and the holding member 16.
[0143] As shown in FIG. 9, a metal filter 17 is provided between
the communicating hole 11d and the communicating hole 11e in the
divided member 11. As shown in FIG. 12, the metal filter 17
consists of a filter main body part 17a, a flange part 17b and a
metal ring 17c.
[0144] The filter main body part 17a has pores like a mesh and it
is formed like a circular cylinder having a bottom portion and
opened below.
[0145] The flange part 17b is formed like a circular cylinder in
which its diameter increases toward the lowest portion, and the
inner diameter of the upper end portion is formed to be slightly
smaller than the inner diameter of the lower end portion of the
filter main body part 17a.
[0146] The metal ring 17c is formed like a circular cylinder, and
the inner diameter thereof is formed to be slightly larger than the
outer diameter of the lower end portion of the filter main body
part 17a.
[0147] Thus, the inner side of the lower end portion of the filter
main body part 17a is overlapped with the upper end portion of the
flange portion 17b, so that these three parts are fixed to one
another.
[0148] Further, as shown in FIG. 9, the metal filter 17 is fixed by
press-in between the communicating hole 11d and the communicating
hole 11e inside of the main body 11.
[0149] Accordingly, a chamber P1 is formed in the receiver tank 5
to communicate with the chamber R4 of the tank 3 through the
communicating hole 8a of the intermediate member 8.
[0150] In addition, a chamber P2 is formed to communicate with the
chamber P1 through the filter main body part 17a of the metal
filter 17 and also to communicate with the chamber R5 of the tank 3
through the communicating hole 9a of the intermediate member 9.
[0151] On the other hand, as shown in FIG. 11, near the upper end
portion of the first divided member 11, there is provided a bracket
member 19 with a plurality of through-holes 19a (also refer to FIG.
13).
[0152] This bracket member 9 forms a chamber P3 at an upper
position of the main body 13, which communicates with the chamber
P1 through the through-hole 19a and contains a reception member
20.
[0153] The reception member 20 in the heat exchanger 1 of the first
embodiment is a drying agent, which is contained in a breathable
cloth sack in a state of particles. This structure is not limited,
large drops of the drying agent may be contained directly in the
chamber P3.
[0154] In addition, a fluorescent agent may be contained instead of
the drying agent.
[0155] Besides, each construction member, except the reception
member 20, of the heat exchanger 1 of the first embodiment is made
of aluminum, or alloy mainly containing aluminum, stainless and so
on.
[0156] Further, at least one side of contact portions of each
construction member to be joined is provided with a brazing sheet,
or brazing filler material where flux is coated or pasted in
advance.
[0157] Next, the operation of the heat exchanger and its
manufacturing method of the first embodiment will be described.
[0158] In order to manufacture the heat exchanger 1 like this,
first, the entire of the heat exchanger 1 is temporally
assembled.
[0159] In this case, in order to temporally assemble the receiver
tank 5 with the tank 3, first, the both divided member 11 and 12
are joined to temporally assemble the main body 13, and then the
metal filter 17 and the bracket member 19 are inserted and arranged
in the interior thereof as shown FIG. 9 and FIG. 11.
[0160] Subsequently, the block member 14 is pressed from a lower
side to be fixed to the lower opening end portion 13a of the main
body 13.
[0161] Next, the intermediate members 8 and 9 and the holding
member 16 are inserted and arranged inside of the fixation portion
11c as shown in FIG. 9 and FIG. 11, and then the both side walls
11a and 11a are caulked to form the caulking portions 11f and 11f
(refer to FIG. 10).
[0162] In this case, the both side walls 11a and 11a contact with
the side surfaces of the seat portions 8c and 9c of the
intermediate members 8 and 9 to guide the intermediate members 8
and 9, so that the intermediate members 8 and 9 can be precisely
positioned in a front and rear direction thereof (a width direction
of the core part 4).
[0163] In addition, the seat positions 8c and 9c and the mid
portions 8e and 9e of the intermediate members 8 and 9 are fixed by
the respective caulking portions 11f and 11f, thereby the seat
portions 8c and 9c of the intermediate portions 8 and 9 being held
in a state where they adhere tightly to the both side walls 11a and
11a and the bottom portion 11b.
[0164] This caulking provides a relative positioning between the
intermediate members 8 and 9 and the fixation portion 11c, and the
intermediate members 8 and 9 are temporally fixed to the fixation
portion 11c in a state where the communicating holes 8a and 9a and
the communicating holes 11d and 11e are positioned relatively to
each other.
[0165] Further, the opening diameter of the communicating hole 11d
(11e) is set slightly larger than that of the communicating hole 8a
(9a), so that some relative displacement in a vertical direction
therebetween can be allowed.
[0166] Similarly, the holding member 16 can be temporally fixed in
a state where the holding member 16 and the fixation portion 11c
are positioned relatively to each other.
[0167] Next, the insertion portions 8b and 9b of the intermediate
members 8 and the insertion portion 16b of the holding member 16
are inserted in the communicating holes 1k, 10m, 10n of the tank 3,
respectively, and they are fixed with each other, all together with
the receiver tank 5, so that the receiver tank 5 is temporally
assembled with the tank 3.
[0168] Thus, the temporally assembling of all the construction
members of the heat exchanger 1 is finished except the block member
15 and the reception member 20.
[0169] Next, the thus temporally assembled heat exchanger 1 is
heat-processed in a heating furnace, thereby the portions of
construction members to be joined being brazed to be integrally
formed.
[0170] The brazing process of the heat exchanger 1 is normally
carried out in a state where the core part 4 is placed in a state
it is horizontally laid.
[0171] As a result, a weight of the receiver tank 5 acts on the
intermediate members 8 and 9 in the vertical direction, so that the
relative displacement therebetween becomes large with high
possibility especially in the width direction of the core part
4.
[0172] Incidentally, the relative displacement between the
intermediate members 8 and 9 and the receiver tank 5 causes a
problem in that pressure loss of flowing medium increases due to
the displacement between the communicating hole 8a (9a) and the
communicating hole 11d (11e).
[0173] As its conventional measures, the open diameter of the
communicating hole 11d (11e) is set slightly larger than that of
the communicating hole 8a (9a) so as to allow the displacement
therebetween, but the setting the opening diameter of the
communicating hole 11d (11e) too large causes a problem in that a
sufficient joint area of the intermediate member 8 (9) and the
receiver tank 5 cannot be assured, which brings the increase in
size of the intermediate members 8 and 9 and deterioration in
brazing.
[0174] In order to solve the above-described problem, in the heat
exchanger 1 of the first embodiment, the both side walls 11a and
11a are contacted with the side surfaces of the seat portions 8c
and 9c of the intermediate members 8 and 9, and then the seat
portions 8c and 9c are fixed by the caulking portions 11f and
11f.
[0175] Accordingly, there is no possibility in the displacement of
the intermediate members 8 and 9 in the brazing process, and these
members can be brazed in a state where they are nicely
positioned.
[0176] In addition, the positioned state is maintained after the
brazing process, and thereby it improves the joint durability,
consequently improving the durability of the heat exchanger 1.
[0177] Incidentally, the first divided member 11 and the second
divided member 12 can be nicely joined by providing a brazing
filler material ring containing flux (flux cored wire) between the
upper end portion of the first divided member 11 and the bead
portion 12b of the second divided member 12.
[0178] Next, as shown in FIG. 11, the reception member 20 is
inserted and arranged in the chamber P3 through the upper opening
end portion 13b of the main body 13 of the receiver tank 5.
[0179] Next, the block member 15 is fixed by press in the upper
opening end portion 13, the high-frequency induction heating method
is executed to braze a contact portion (hereinafter referred to as
a joint portion B of the block member 15, and indicated by a heavy
line in FIG. 15) between the outer circumference of the insertion
portion 15b of the block member 15 and the inner circumference of
the upper opening end portion 13b of the main body 13.
[0180] Incidentally, the high-frequency induction heating method is
similar to technology described in Japanese Patent Application
Publication No. 07-9119 and Japanese Patent Application Publication
No. 06-295782, so that its contents will be briefly described.
[0181] Specifically, the high-frequency induction heating method
uses the phenomenon in that conductive material (current carrying
material) placed in a work coil where high-frequency current runs
is rapidly heated by the heat generation due to the overcurrent
loss generated in the conductive material under the electromagnetic
induction operation and the heat generation due to the hysteresis
loss (heat quantity generated due to vibration and friction of each
molecule in magnetic material by alternate current magnetic
flux).
[0182] As shown in FIG. 14 and FIG. 15, in the first embodiment,
not-shown brazing filler material (brazing sheet) is provided on
the outer surface of the block member 15.
[0183] In addition, the work coil 32 shaped like a loop and
electrically connected to a communicator 31 is arranged to surround
the circumference of the joint portion B of the block member
15.
[0184] Incidentally, the work coil 32 may be a single-loop one
shaped like S2, not a multi-loop one.
[0185] In addition, the communicator 31 is electrically connected
to a controller 33.
[0186] The rewritable memory of the controller 33 stores a control
method of the communicator 31 as program, and the controller 33
executes the program to output a command signal to the communicator
31 to output high-frequency current, thereby controlling heat
adjustment of the joint portion B.
[0187] Incidentally, the controller 33 previously stores data on a
relationship between an elapsed time from heating start-time and a
target temperature at the joint portion B of the block member 15 as
shown in FIG. 16, and it outputs the command signal setting the
target temperature to the communicator 31.
[0188] Thus, it controls temperature rising at the joint portion B
of the block member 15, realizing stable jointing by brazing.
[0189] The high-frequency current runs in the work coil 32 from the
communicator 31 when the controller 33 outputs the command signal.
The joint portion B of the block member 15 arranged in the work
coil 32 is heated, and thereby the brazing filer metal on the joint
portion is melted. This brazing process provides nice jointing of
the block member 15 and the second divided member.
[0190] Incidentally, in this process, as the outer surface of the
bottom portion 15a of the block member 15 and the outer surface of
the insertion portion 15b are connected with each other through a
gently curved surface, a part of the brazing filler material on a
portion relatively apart from the joint portion B surely flows in
and fills the joint portion B, namely between the outer
circumference of the insertion portion 15b and the inner
circumference of the upper opening end portion 13b of the main body
13 in the block member 15, due to the capillary phenomenon.
[0191] In the prior invention, in a case where the block member 15
is jointed with the receiver tank 5 by welding for example, the
workability in welding is not good and the heat generated during
welding might have a harmful efect on the tank 3 because the
receiver tank 5 is very near the tank 3.
[0192] In addition, in a case of the brazing process by using the
high-frequency induction heat generated in the work coil 32, a
certain clearance cannot be set between the work coil 32 and the
main body (accurately the joint portion B of the block member) and
might cause deterioration in brazing.
[0193] Incidentally, the certain clearance is an import item for
setting in the high-frequency induction heating, too.
[0194] Alternatively, even in a case where the certain clearance
can be set between the work coil 32 and the main body, as the work
coil is very near the tank 3, the heat generated during the
high-frequency induction heating might melt the brazing filler
material on the joint portion of the tank 3.
[0195] On the contrary, in the heat exchanger of the first
embodiment, as described above, the upper end portion side of the
receiver tank 5 is reduced in diameter because it is the reduced
diameter portion 12c of the second divided member 12. Accordingly,
a sufficient clearance H can be assured between the main body 13
(the reduced diameter portion 12c) and the tank 3 near the joint
portion B of the block member 15.
[0196] Thus, a work space for sufficiently jointing can be assured
by ensuring the certain clearance between the work coil 32 and the
main body 13 (the joint portion of the block member 15).
[0197] In addition, the work coil 32 does not excessively approach
the tank 3, and there is no possibility of a harmful effect of the
heat generated during the high-frequency induction heating on the
tank 3, so that the tank 3 can be protected.
[0198] In addition, as the reduced diameter portion 12c of the
second divided member 12 is reduced in diameter, the heat mass of
the main body 13 can be decreased, thereby the smooth rising of the
temperature being obtained at the joint portion of the block member
15.
[0199] Further, the joint area of the joint portion of the block
member 15 can be decreased, and the usage of brazing filler
material can be also decreased to decline in cost and shorten the
amount of the time for jointing.
[0200] Further, the joint area of the joint portion of the block
member 15 is decreased, which assures high shelter density (high
pressure tightness).
[0201] In addition, the control of the communicator 31 by the
controller 33 adjusts the temperature rising of the joint portion
of the block member 15 to obtain stable jointing by brazing.
[0202] Thus, in the heat exchanger 1 of the first embodiment, the
block member 15 can be nicely jointed by brazing with the upper
opening end portion 13b of the main body 13, so that very high
pressure tightness can be obtained relative to a pressure-tightened
structure of the block member using a seal member and a twisted
groove.
[0203] Incidentally, the block member 15 is joined by brazing under
the high-frequency induction heating with the upper portion of the
main body 13 in the heat exchanger of the first embodiment, while
welding may be replaced. In this case, the similar operation and
effects can be obtained.
[0204] <As to the joint portion of the block member>
[0205] Next, a configuration of the joint portion B of the block
member 15 will be described with reference to FIGS. 17 to 24.
[0206] Incidentally, in FIGS. 17 to 24, the brazing filler material
40 flows in the joint portion B of the block member 15 due to the
capillary phenomenon to joint by brazing, although their drawings
and explanations are omitted.
[0207] As shown in FIG. 17, a powdery brazing filler material 40 is
placed near the upper portion of the joint portion B of the block
member 15, on which the flux may be coated, to joint by brazing.
Alternatively, as shown in FIG. 18, the jointing by brazing may be
carried out after providing a brazing filler material ring
containing flux (flux cored wire).
[0208] Further alternatively, as shown in FIG. 19(a), the inner
circumference of the upper opening end portion 13b of the main body
13 may be formed with a circular cut-off stepped portion 41, with
which the insertion portion 15b of the block member 15 is engaged
as shown in FIG. 19(b), to easily determine an insertion margin
needed when the block member 15 is pressed into the main body
13.
[0209] Further alternatively, as shown in FIG. 20(a), the inner
circumference of the upper opening end portion 13b of the main body
13 may be formed with a circular cut-off stepped portion 41, with
which the block member 15 shaped like a dish is engaged as shown in
FIG. 20(b).
[0210] Thus, the insertion margin needed for pressing the block
member 15 into the main body 13 can be easily determined, and the
block member 15 can be decreased in weight and size, the chamber P3
can be enlarged (enlargement of the reception member 20), and the
heat mass can be decreased, and so on.
[0211] In this case, the brazing filer material 40 is provided on
the outer surface of the block member 15.
[0212] Further alternatively, as shown in FIGS. 21 to 23, the
insertion portion 15b of the block member 15 may have a depression
formed by being bent toward the main bode (13) side and provided
with claw portions 42 to be engaged with the upper end portion of
the main body 13 at a plurality of positions of the outer
circumference thereof.
[0213] Then, the brazing filler material 40 may be placed on the
upper opening end portion 13b of the main body 13 except the claw
portions 43, and they are joined by brazing similarly.
[0214] Further alternatively, as shown in FIG. 24(a), the insertion
portion 15b of the block member 15 may have a depression formed by
bending toward the main bode (13) side and provided with an
enlarged portion 43 enlarged outward by flaring.
[0215] Then, the brazing filler material 40 may be placed on the
inner side of the enlarged portion 43 to join by brazing similarly
to the previous case. In this case, the brazing filler material 40
can be positively conducted toward the joint portion of the block
member 15 due to a slanted surface of the enlarged portion 43.
[0216] <As to the pressure tightness of the receiver
tank>
[0217] As the receiver tank 5 of the heat exchanger 1 is fixed by
brazing with the block member 15, the pressure tightness thereof
can be greatly improved relative to the conventional heat
exchangers.
[0218] In addition, as the joint area of the joint portion of the
block member 15 is decreased, the shelter density (the pressure
tightness) thereof can be set higher. Therefore, the reliability of
products can be improved.
[0219] Further, it can be applied to a cooling circuit for vehicle
interior air-conditioning where the high-pressured CO.sub.2 is a
flowing medium.
[0220] <As to design freedom of the interior of the receiver
tank>
[0221] In the heat exchanger 1 of the embodiment 1, a fixation
portion 11c is formed on the outer circumference of the receiver
tank 5 (the first divided member 11), and the fixation potion 11c
fixes the seat portions 8c and 9c, functioning as the joint portion
of the intermediate portions 8 and 9 and the receiver tank 5, so as
to communicatably connect therebetween.
[0222] Thus, there is no possibility of nearness and contact of the
seat portions 8c and 9c and the reception member in the receiver
tank 5, where the seat portions 8c and 9c function as the joint
portion B of the intermediate members 8 and 9 and the receiver tank
5. Therefore, the design freedom of the interior of the receiver
tank 5 can be enlarged.
[0223] Accordingly, in the heat exchanger 1 of the first
embodiment, the design freedom can be enlarged in size, arrangement
and others of the metal filter 17.
[0224] <As to the operation of the heat exchanger>In the
thus-constructed heat exchanger, first, the flowing medium at a
high temperature at approximately 60.degree. C., which flows in the
chamber R1 of the tank 2 from the compressor side through the inlet
port 6a of the input connector 6, is cooled down due to the heat
exchange between the flowing medium and airflow generated during a
vehicle running or airflow generated by a fan that passes through
the core part 4, while the flowing medium flows through the chamber
R2 of the tank 3, the chamber R3 of the tank 2, and the chamber R4
of the tank 3, turning in these order through the respective tubes
4a.
[0225] Next, as shown in FIG. 9, the flowing medium (indicated by
broken arrows) that has flowed in the chamber R4 of the tank 3
flows in the chamber P1 of the receiver tank 5 through the
communicating holes 8a of the intermediate member 8 to be separated
into gas and liquid, and then it flows in the chamber P2 through
the metal filter 17.
[0226] In this case, the filter main body part 17a of the metal
filter 17 can remove contaminants contained in the flowing
medium.
[0227] In addition, in the case where the reception member 20 is a
drying agent, water in the receiver tank 5 can be absorbed, thereby
the gas-liquid separation performance being improved.
[0228] Alternately, in a case where the reception member 20 is a
fluorescent agent, the leakage of the flowing medium can be easily
detected when the shelter density of the interior of the receiver
tank 5 is damaged from any cause.
[0229] Next, the flowing medium in the chamber P2 flows in the
chamber R5 of the tank 3 through the communicating hole 9a of the
intermediate member 9.
[0230] Finally, the flowing medium that flows in the chamber R5 of
the tank 3 is cooled down due to the heat exchange between the
flowing medium and the airflow generated during the vehicle running
or the airflow generated by the fan that pass through the core part
4, while the flowing medium flows through the chamber R6 of the
tank 2 through the respective tubes 4a, and then it is outputted
toward the evaporator through the output port 7a of the output
connector 7 to function as, what is called, a condenser.
[0231] Next, the effects of the heat exchanger 1 and its
manufacturing method of the first embodiment will be listed
below.
[0232] (1) The heat exchanger 1 includes the pair of tanks 2 and 3
arranged a certain distance apart from each other, the plurality of
tubes 4a whose both end portions are connected with the pair of
tanks 2 and 3, the long receiver tank 5 arranged adjacently to and
along the tank 3 and connected with the tank 3, and the reception
member 20 contained in the receiver tank 5, where the upper opening
end portion 13b has the opening portion at the one side in the
longitudinal direction of the receiver tank 5 and having the
reduced diameter and the block member 15 blocks the upper opening
end portion 13b. The entire of the heat exchanger 1 except the
reception member 20 and the block member 15 are integrally formed
by the brazing process. The reception member 20 is inserted through
the upper opening end portion 13b and arranged in the receiver tank
5 after the brazing process, and the block member 15 is brazed with
the upper opening end portion 13b after the reception member 20 is
inserted and arranged.
[0233] Therefore, the block member 15 of the receiver tank 5 can be
nicely joined, thereby the pressure tightness of the receiver tank
5 being improved.
[0234] (2) The block member 15 is joined by brazing with the upper
opening end portion 13 due to the high-frequency induction heat
generated by the work coil 32.
[0235] Therefore, the block member 15 can be joined by brazing with
the opening end portion in an easy way in addition to the operation
and the effects similar to those in (1).
[0236] Further, the work coil 32 can be sufficiently assured to
have a certain clearance from the main body 13.
[0237] (3) The receiver tank 5 includes the first divided member 11
shaped like a circular cylinder with the bottom portion, and the
second divided member 12 that is communicatably connected with the
one side of the first divided member 11 in the longitudinal
direction and shaped like a circular cylinder with the reduced
diameter portion 12 whose diameter is decreased up to the outer
diameter of the upper opening end portion 13.
[0238] Therefore, the upper opening end portion 13b can be easily
formed so as to have the diameter being decreased at the one side
of the receiver tank 5 in the longitudinal direction.
[0239] In addition, it can be easily manufactured because the
amount of processing such as cutting becomes smaller relative to
that in a case where the receiver tank 5 is formed as one unit.
Further, the area of the joint portion B of the block member 15 can
be decreased, and accordingly the cost of material (flux and
brazing filler material) used for the joining can be reduced.
[0240] (4) The tank 3 and the first divided member 11 are
communicatably connected through the intermediate members 8 and 9,
and the restricting portion (the fixation portion 11c) is formed as
one unit to prevent the relative displacement of the intermediate
members 8 and 9 on the outer circumferential portion of the first
divided member 11.
[0241] Therefore, the intermediate members 8 and 9 can be fixed
with the receiver tank 5 with a high degree of accuracy.
[0242] (5) The restricting portion (the fixation portion 11c)
restricts the relative displacement of the intermediate members 8
and 9 in the width direction of the heat exchanger 1.
[0243] Therefore, it can prevent the relative displacement of the
intermediate members 8 and 9 in the width direction of the heat
exchanger 1, where the displacement is a particular problem during
the joining by brazing.
[0244] (6) The restricting portion (the fixation portion 11c) has
the cross section shaped like a letter U to open toward the tank 3
of the heat exchanger 1, and it extends in the longitudinal
direction of the first divided member 11.
[0245] The intermediate members 8 and 9 are slid along the
restricting portion (the fixation portion 11c) so as to be guided
therein, and they are positioned and then joined by brazing.
[0246] Therefore, it can obtain the operation and effects similar
to those in (5).
[0247] (7) The intermediate members 8 and 9 are fixed with the
restricting portion (the fixation portion 11c) by caulking the both
side walls 11a and 11a facing to each other, which have the cross
section shaped like a letter U. Therefore, the intermediate members
8 and 9 can be positioned in a stable state thereof.
[0248] (8) The second divided member 12 is fixed on the tank 3
through the holding member 16 having the configuration similar to
those of the intermediate members 8 and 9.
[0249] Therefore, the number of kinds of parts can be
decreased.
[0250] (9) The reception member employs the drying agent 20 (or the
fluorescent agent).
[0251] Therefore, the reception member, which cannot be contained
in the brazing process of the entire of the heat exchanger 1 like
the drying agent, the fluorescent agent and the like, can be used
preferably in a case where it is arranged.
[0252] (10) The method is used for manufacturing the heat exchanger
including the pair of tanks 2 and 3 arranged a certain distance
apart from each other, the plurality of tubes 4a whose both end
portions are connected with the pair of tanks 2 and 3, the long
receiver tank 5 arranged along and adjacently to the tank 3 and
connected with the tank 3, and the reception member 20 contained in
the receiver tank 5, where the upper opening end portion 13b has
the opening portion at the one side in the longitudinal direction
of the receiver tank 5 and having the reduced diameter and the
block member 15 blocks the upper opening end portion 13b. The
method has the process of integrally forming by the brazing process
the entire of the heat exchanger 1 except the reception member 20
and the block member 15, the process of inserting the reception
member 20 through the upper opening end portion 13b and arranging
the reception member 20 in the receiver tank 5 after the brazing
process, and the process of the joining by brazing the block member
15 with the upper opening end portion 13b after the reception
member 20 is inserted and arranged therein.
[0253] Therefore, it can obtain the operation and the effects
similar to those in (1).
Second Embodiment
[0254] Hereinafter, a heat exchanger and its manufacturing method
of a second embodiment of the present invention will be described
with reference to the accompanying drawings.
[0255] In the second embodiment, the construction members similar
to those of the first embodiment are indicated by the same
reference numbers. Their explanations are omitted and only
different ones will be in detail described.
[0256] FIG. 25 is a view explaining high-frequency induction
heating in the heat exchanger and its manufacturing method of the
second embodiment.
[0257] As shown in FIG. 25, in the heat exchanger and its
manufacturing method of the second embodiment, blackbody coating
material 50 is applied on the periphery of a joint potion of a
block member 15 in advance, and an infrared temperature sensor 51
is provided to measure the surface temperature of the blackbody
coating material 50.
[0258] In addition, the temperature detected by the infrared
temperature sensor 51 is sequentially transmitted to a controller
33.
[0259] Incidentally, the block member 15 in the second embodiment
employs the type explained in FIGS. 21 to 23 of the first
embodiment, which is not limited. The position and the number of
the blackbody coating material 50 may be set appropriately.
[0260] Then, the controller 33 checks the temperature transmitted
sequentially from the infrared temperature sensor 51 and the
temperature profile explained in FIG. 16 of the first embodiment so
as to accord with each other, it controls by a feed-back loop,
sending a command signal for adjusting heating to a communicator
31.
[0261] Accordingly, in the heat exchanger and its manufacturing
method of the second embodiment, the temperature can be managed
according to a situation of the temperature rising of the joint
portion of the block member 15, thereby providing a nice joining by
brazing.
[0262] Specifically, in the high-frequency induction heating, the
brazing performance changes according to a minor difference of the
individual joint portion of the block member 15, the outside air
temperature and the humidity. Therefore, the temperature of the
joint portion is measured to always obtain the stable brazing
performance, thereby quality of products being improved.
[0263] Incidentally, a noncontact type temperature sensor such as a
radiation thermometer may be employed to measure the temperature of
the block member 15.
[0264] In addition, the blackbody coating material 50 may be
provided on the whole of the surface of the block member 15. In
this case, no other reflected heat enters the infrared temperature
sensor 51, and consequently the temperature can be detected with a
high degree of accuracy.
[0265] Nex 5, the heat exchanger and its manufacturing method of
the second embodiment has the effects listed below in addition to
those of the first embodiment.
[0266] (11) The block member 15 is joined by brazing with the upper
opening end portion 12b by the high-frequency heating generated by
the work coil 32. The temperature of the joint portion of the block
member 15 is measured by a temperature measurement means (the
blackbody coating material 50 and the infrared temperature sensor
41). The temperature of the to high-frequency heating by the work
coil 32 is controlled by the feed-back loop according to the
temperature change of the joint portion detected by the temperature
measurement means (the blackbody coating material 50 and the
infrared temperature sensor 41).
[0267] Therefore, the jointing by brazing of the block member 15
can be stably carried out.
[0268] (12) The temperature measurement means includes the
blackbody coating material 50 provided on the periphery of the
joint portion of the block member 15, and the infrared temperature
sensor 41 for measuring the temperature change of the blackbody
coating material 50.
[0269] Therefore, the operation and effect similar to those of (11)
can be obtained.
Third Embodiment
[0270] Herein, a heat exchanger and its manufacturing method of a
third embodiment of the present invention will be described with
reference to the accompanying drawings.
[0271] In the third embodiment, the construction members similar to
those of the first embodiment are indicated by the same reference
numbers. Their explanations are omitted and only different ones
will be in detail described.
[0272] FIG. 26 is a perspective view of a receiver tank that is
used in the heat exchanger of the third embodiment.
[0273] As shown in FIG. 26, in the heat exchanger of the third
embodiment, the entire length of a first divided member 11 of a
receiver tank 5 is set shorter to a large extent relative to that
of a second divided member 12.
[0274] In addition, at the position corresponding to a holding
member 16, a bracket member 60, which has a configuration shaped
like the first divided member 11 whose length is shortened, is
joined by brazing on the outer circumference of the second divided
member 12.
[0275] Therefore, the holding member 16 can be joined by brazing
with the second divided member 12 through the bracket member
60.
[0276] In addition, the bracket member 60 can be easily obtained by
setting a to cut-off length of the first divided member 11 to be
adjusted according to the entire length of the bracket member 60 in
its manufacture.
[0277] Herein, the first divided member 11 is made as one molded
part by extrusion processing of raw material in order to assure its
formability. Therefore, the fixation portion 11c is formed along
the entire length in the longitudinal direction of the first
divided member 11. As the length of the first divided member 11 is
set shorter than that of the second divided member 12, the entire
lengths of the both side walls 11a and 11a can be set shorter, As a
result, the weight and the heat mass of the first divided member 11
can be suppressed to the maximum.
[0278] Therefore, in the heat exchanger of the third embodiment,
the main body 13 can be formed smaller in weight and size, and the
joining of the block member 15 by brazing can be nicely carried out
because of reduction in its heat mass.
[0279] Next, the heat exchanger and its manufacturing method of the
third embodiment have the effects described below in addition to
those of the first embodiment.
[0280] (13) The entire length of the first divided member 11 is set
shorter than that of the second divided member 12.
[0281] Therefore, the main body 13 can be formed smaller in weight
and size, and the joining of the block member 15 by brazing can be
nicely carried out because of the reduction in heat mass.
Fourth Embodiment
[0282] Herein, a heat exchanger and its manufacturing method of a
fourth embodiment of the present invention will be described with
reference to the accompanying drawings.
[0283] The fourth embodiment solves the problem of the prior art by
changing a length of a main body without dividing the main body of
a receive tank into a first divided member and a second divided
member, and also without decreasing a diameter of a part of the
main body.
[0284] FIG. 27 is an exploded perspective view of the receive tank
that is used in a heat exchanger of the fourth embodiment. FIG. 28
is a perspective view of the receiver tank. FIG. 29 is a cross
sectional side view explaining an upper interior of the receiver
tank.
[0285] In the heat exchanger and its manufacturing method of the
fourth embodiment, the construction members similar to those of the
first embodiment are indicated by the same reference numbers. Their
explanations are omitted and only different ones will be in detail
described.
[0286] As shown in FIGS. 27 and 28, the receiver tank 5 is equipped
with the main body 11 shaped like a circular cylinder, and block
members 14 and 15 shaped like a dish and covering opening end
portions 12a and 12b of the main body 11.
[0287] A periphery of an upper end portion of the main body 11 is
formed as a cylinder portion 13 shaped like a circular cylinder.
The main body 11 is formed as the cylinder portion shaped like the
circular cylinder by a cutting off a portion of the upper end of a
fixation portion 11c after shape forming raw material by extrusion
processing.
[0288] On the other hand, the block member 14 is formed with a
bottom portion 14a shaped like a disc, and an insertion portion 14b
rising like a circular projection from an outer circumference of
the bottom portion 14a toward the main body 11 and insertable to be
engaged with an inner circumference of a lower opening end portion
12a.
[0289] The block member 15 is formed with a bottom portion 15a
shaped like a disc and an insertion portion 15b rising like a
circular projection from an outer circumference of the bottom
portion 15a toward the main body 11 and insertable to be engaged
with an inner circumference of a lower opening end portion 12b.
[0290] Further, as shown in FIG. 28, the both block members 14 and
15 are pressed into the inner sides of the respective upper and
lower opening end portions 12a and 12b of the main body 11 so that
the bottom portions 14a and 15b can be fixed in a state where they
are in plane with end portions 12a and 12b.
[0291] As shown in FIG. 29, a periphery of an upper end portion of
the main body 11 has a cylinder portion 13 projecting higher
relative to the tank 3 by the height length L1 outward in the
longitudinal direction. This height length L1 is set to assure a
work space for joining the intermediate member 15 and the main body
11 at the joining process thereof in a state where the joint
portion B (refer to FIG. 30) of the block member 15 and the main
body 11 is placed over the upper end of the tank 3 and also to
allow a deformation of the tank 3 due to the heating of the joint
portion B.
[0292] The other construction members are constructed similarly to
those of the first embodiment.
[0293] The thus-constructed heat exchanger of the fourth embodiment
is assembled similarly to the first embodiment. In this case, as
the cylinder portion 13 of the receiver tank 5 projects upward
higher relative to the tank 3 by the height length L1 in the
joining the joint portion B as shown in FIG. 29, nothing exists
near the periphery of the upper opening end portion 12 (and the
block member 15) of the main body 11 because the work coil 32 is
positioned over the tank 3
[0294] Therefore, a sufficient space for joining operation can be
assured.
[0295] Consequently, a certain clearance can be easily assured
between the work coil 32 and the main body 11 (the joint portion of
the block member 15).
[0296] In addition, there is no possibility of a harmful effect on
the tank 3 due to heat generated by the high-frequency induction
heating, so that the tank 3 can be protected.
[0297] The assembly and operation of the others are similar to
those of the first embodiment, and accordingly their explanations
are omitted.
[0298] In the heat exchanger and its manufacturing method of the
fourth embodiment, the heat exchanger 1 includes the pair of tanks
2 and 3 arranged the certain distance apart from each other, the
plurality of tubes 4a whose both end portions are connected with
the pair of tanks 2 and 3, the long receiver tank 5 arranged along
and adjacently to the tank 3 and connected with the tank 3, and the
reception member 20 contained in the receiver tank 5, where the
upper opening end portion 13b has the opening portion at the one
side in the longitudinal direction of the receiver tank 5 and
having the reduced diameter and the block member 15 blocks the
upper opening end portion 13b. The whole of the heat exchanger 1
except the reception member 20 and the block member 15 are
integrally joined by brazing. The reception member 20 is inserted
in the receiver tank 5 through the upper opening end portion 12b to
be arranged therein after the brazing process, and the block member
15 is joined by brazing on the upper opening end portion 12b after
the reception member 20 is inserted and arranged therein.
[0299] In addition, the block member 15 is joined by brazing on the
upper opening end portion 12b by the high-frequency induction
heating generated by the work coil 32 after the reception member 20
is inserted and arranged in the receiver tank 5.
[0300] Therefore, the fourth embodiment has the following effect in
addition to the above-described (1), (2) and (9) of the first
embodiment.
[0301] (14) Only setting the length of the main body 11 of the
receiver tank 5 to be longer than that of the upper end of the tank
3 enables the receiver tank 5 to be easily manufactured.
Fifth Embodiment
[0302] In a method for manufacturing a heat exchanger of the fifth
embodiment, the high-frequency induction heating as well as that of
the second embodiment is applied to the heating of the heat
exchanger of the fourth embodiment.
[0303] As shown in FIG. 31, the blackbody coating material 50 is
applied in advance on the periphery of the joint portion of the
block member 15, and the infrared temperature sensor 51 is provided
to measure the surface temperature of the blackbody coating
material 50.
[0304] The temperature detected by the infrared temperature sensor
51 is sequentially transmitted to the controller 33.
[0305] The position and the number of the blackbody coating
material 50 may be set appropriately.
[0306] The controller 33 sequentially checks the temperature
transmitted from the infrared temperature sensor 51 and the
temperature profile explained in FIG. 16 of the first embodiment
with each other, and it controls by the feed-back loop so as to
accord them with each other, sending a command signal for adjusting
the heating to a communicator 31.
[0307] Accordingly, in the heat exchanger and its manufacturing
method of fifth embodiment, the temperature can be managed
according to a situation of the temperature rising of the joint
portion of the block member 15, thereby providing a nice joining by
brazing.
[0308] Specifically, in the high-frequency induction heating, the
brazing performance changes according to a minor difference of the
individual joint portion of the block member 15, the outside air
temperature and the humidity. Therefore, the temperature of the
joint portion is measured so that the stable brazing performance
can be always obtained and thereby the quality of products can be
improved.
[0309] Incidentally, a noncontact type temperature sensor such as a
radiation thermometer may be employed in order to measure the
temperature of the block member 15.
[0310] In addition, the blackbody coating material 50 may be
provided on the whole of the surface of the block member 15. In
this case, no other reflected heat enters the infrared temperature
sensor 51, and accordingly the temperature can be detected with a
high degree of accuracy.
[0311] As explained above, the method for manufacturing the heat
exchanger of the fifth embodiment can obtain the effects similar to
those of the second embodiment.
[0312] As described above, the present invention is not limited to
the above-described embodiments, a design changes and the like are
contained in the present invention as long as they do not depart
from the subject-matter of the present invention.
[0313] For example, the reception member is not limited to the
drying agent and the fluorescent agent, and it may be one of the
various pipes, the metal filters and others.
* * * * *