U.S. patent application number 13/501800 was filed with the patent office on 2012-08-09 for evaporator.
This patent application is currently assigned to Showa Denko K.K.. Invention is credited to Naohisa Higashiyama, Hokuto Mine, Motoyuki Takagi.
Application Number | 20120198882 13/501800 |
Document ID | / |
Family ID | 43900241 |
Filed Date | 2012-08-09 |
United States Patent
Application |
20120198882 |
Kind Code |
A1 |
Takagi; Motoyuki ; et
al. |
August 9, 2012 |
EVAPORATOR
Abstract
An evaporator includes a pair of header tanks spaced from each
other in a vertical direction; a plurality of flat heat exchange
tubes 45 which are disposed between the two header tanks such that
their width direction coincides with a front-rear direction and
they are spaced from one another in a left-right direction,
opposite ends portions of the flat heat exchange tubes being
connected to the corresponding header tanks; and corrugated fins 5
each disposed between adjacent heat exchange tubes 45. Each of left
and right portions of front and rear end walls 45a of each heat
exchange tube 45 has a straight slope portion 55 which inclines
outward in the front-rear direction, toward a center portion of the
heat exchange tube 45 with respect to the left-right direction. The
angle formed between the slope portion 55 and the left edge or
right edge of the corresponding corrugated fin 5 is set to 25 to 40
degrees.
Inventors: |
Takagi; Motoyuki;
(Oyama-shi, JP) ; Higashiyama; Naohisa;
(Oyama-shi, JP) ; Mine; Hokuto; (Oyama-shi,
JP) |
Assignee: |
Showa Denko K.K.
Tokyo
JP
|
Family ID: |
43900241 |
Appl. No.: |
13/501800 |
Filed: |
October 15, 2010 |
PCT Filed: |
October 15, 2010 |
PCT NO: |
PCT/JP2010/068140 |
371 Date: |
April 13, 2012 |
Current U.S.
Class: |
62/524 |
Current CPC
Class: |
F28F 1/022 20130101;
F28F 1/04 20130101; F28D 1/05391 20130101; F28F 1/42 20130101; F28D
1/05366 20130101; F28F 1/128 20130101; F25B 39/028 20130101; F28D
2021/0085 20130101 |
Class at
Publication: |
62/524 |
International
Class: |
F25B 39/02 20060101
F25B039/02 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 19, 2009 |
JP |
2009-240209 |
Oct 19, 2009 |
JP |
2009-240211 |
Claims
1. An evaporator comprising a pair of header tanks spaced from each
other in a vertical direction; a plurality of flat heat exchange
tubes which are disposed between the two header tanks such that
their width direction coincides with a front-rear direction and
they are spaced from one another in a left-right direction,
opposite ends portions of the flat heat exchange tubes being
connected to the corresponding header tanks; and corrugated fins
each disposed between adjacent heat exchange tubes, wherein each of
left and right portions of front and rear end walls of each heat
exchange tube has a straight slope portion which inclines outward
in the front-rear direction, toward a center portion of the heat
exchange tube with respect to the left-right direction, and an
angle formed between the slope portion and a left edge or right
edge of the corresponding corrugated fin is 25 to 40 degrees.
2. An evaporator according to claim 1, wherein left and right side
surfaces of each heat exchange tube are in contact with the
corresponding corrugated fins; and a ratio of a length W2 (mm), as
measured in the front-rear direction, of areas of contact between
the left and right side surfaces of the heat exchange tube and the
corresponding corrugated fins to a width W1 (mm) of each heat
exchange tube as measured in the front-rear direction is 80 to
95%.
3. An evaporator according to claim 1, wherein each heat exchange
tube has a width of 10 to 20 mm as measured in the front-rear
direction.
4. An evaporator according to claim 1, wherein each heat exchange
tube has a thickness of 1 to 1.8 mm as measured in the left-right
direction.
5. An evaporator according to claim 1 wherein a plurality of tube
sets each composed of a plurality of flat heat exchange tubes
spaced from one another in the front-rear direction are disposed
between the upper and lower header tanks at predetermined intervals
in the left-right direction; each of the fins is disposed between
tube sets located adjacent to each other in the left-right
direction; and, in each tube set composed of a plurality of the
flat heat exchange tubes, a clearance is formed between the heat
exchange tubes located adjacent to each other in the front-rear
direction, the clearance having a width of 1.5 to 3.5 mm as
measured in the front-rear direction.
6. An evaporator according to claim 1, wherein each heat exchange
tube is provided in a flat hollow body composed of two pressed
rectangular metal plates laminated and joined together; the two
metal plates which constitute the flat hollow body are bulged
outward so as to form the heat exchange tube such that the heat
exchange tube is open at upper and lower ends thereof; each of
front and rear walls of an outward bulged portion of each metal
plate which forms the heat exchange tube is straight and inclines
outward in the front-rear direction, toward a thicknesswise center
portion of the flat hollow body.
7. An evaporator according to claim 6, wherein, at a front edge of
each flat hollow body, one of the two metal plates has a protrusion
formed over the entire length thereof such that a distal end
portion of the protrusion projects beyond the other metal plate and
toward the corrugated fin with which the other metal plate is in
contact.
Description
TECHNICAL FIELD
[0001] The present invention relates to an evaporator suitable for
use in a car air conditioner, which is a refrigeration cycle to be
mounted on an automobile, for example.
[0002] In this specification and the appended claims, the
downstream side (a direction represented by arrow X in FIGS. 1, 2,
8, and 10) of an air flow through air-passing clearances between
adjacent heat exchange tubes will be referred to as the "front,"
and the opposite side as the "rear." Further, the upper, lower,
left-hand, and right-hand sides of FIG. 1 will be referred to as
"upper," "lower," "left," and "right," respectively.
BACKGROUND ART
[0003] The present applicant has proposed an evaporator for a car
air conditioner which satisfies the requirements for reduction in
size and weight and higher performance (refer to Patent Document
1). The evaporator includes a pair of header tanks spaced from each
other in the vertical direction; a plurality of flat heat exchange
tubes which are formed of aluminum extrudate and which are disposed
between the two header tanks such that their width direction
coincides with the front-rear direction and they are spaced from
one another in the longitudinal direction of the header tanks,
opposite ends portions of the flat heat exchange tubes being
connected to the corresponding header tanks; and corrugated fins
each disposed between adjacent heat exchange tubes and having
louvers. The upper header tank includes a refrigerant inlet header
section and a refrigerant outlet header section, which are
juxtaposed in the front-rear direction and are united together. The
lower header tank includes a first intermediate header section
disposed to face the refrigerant inlet header section, and a second
intermediate header section disposed rearward of the first
intermediate header section to face the refrigerant outlet header
section and united with the first intermediate header section. The
upper and lower end portions of the front heat exchange tubes are
connected to the refrigerant inlet header section and the first
intermediate header section, respectively, and the upper and lower
end portions of the rear heat exchange tubes are connected to the
refrigerant outlet header section and the second intermediate
header section. Each of the front and rear end walls of each heat
exchange tube has an arcuate transverse cross section projecting
outward with respect to the front-rear direction.
[0004] Since the evaporator described in Patent Document 1 is
designed to satisfy the requirements for reduction in size and
weight and higher performance, a large amount of condensed water is
produced on the surface of each corrugated fin, whereby the amount
of condensed water per unit volume of the evaporator increases.
Incidentally, an ordinary evaporator is designed such that water
condensed on the fin surface flows downward through clearances
between adjacent louvers. Therefore, in order to enhance water
draining performance, increasing the length of the louvers is
desirable. However, in order to reduce size and weight as in the
case of the evaporator described in Patent Document 1, the
clearance between heat exchange tubes located adjacent to each
other in the longitudinal direction of the header tanks must be
reduced. Therefore, there is a limit on increasing the length of
the louvers, and water draining performance may become insufficient
when the amount of condensed water is large.
PRIOR ART DOCUMENT
Patent Document
[0005] Patent Document 1: Japanese Patent Application Laid-Open
(kokai) No. 2008-20098
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0006] An object of the invention is to solve the above-described
problem, and provide an evaporator which has an excellent
performance of draining water condensed on the surfaces of
fins.
Means for Solving the Problems
[0007] To achieve the above object, the present invention comprises
the following modes.
[0008] 1) An evaporator comprising a pair of header tanks spaced
from each other in a vertical direction; a plurality of flat heat
exchange tubes which are disposed between the two header tanks such
that their width direction coincides with a front-rear direction
and they are spaced from one another in a left-right direction,
opposite ends portions of the flat heat exchange tubes being
connected to the corresponding header tanks; and corrugated fins
each disposed between adjacent heat exchange tubes, wherein
[0009] each of left and right portions of front and rear end walls
of each heat exchange tube has a straight slope portion which
inclines outward in the front-rear direction, toward a center
portion of the heat exchange tube with respect to the left-right
direction, and an angle formed between the slope portion and a left
edge or right edge of the corresponding corrugated fin is 25 to 40
degrees.
[0010] 2) An evaporator according to par. 1), wherein left and
right side surfaces of each heat exchange tube are in contact with
the corresponding corrugated fins; and a ratio of a length W2 (mm),
as measured in the front-rear direction, of areas of contact
between the left and right side surfaces of the heat exchange tube
and the corresponding corrugated fins to a width W1 (mm) of each
heat exchange tube as measured in the front-rear direction is 80 to
95%.
[0011] 3) An evaporator according to par. 1), wherein each heat
exchange tube has a width of 10 to 20 mm as measured in the
front-rear direction.
[0012] 4) An evaporator according to par. 1), wherein each heat
exchange tube has a thickness of 1 to 1.8 mm as measured in the
left-right direction.
[0013] 5) An evaporator according to par. 1), wherein a plurality
of tube sets each composed of a plurality of flat heat exchange
tubes spaced from one another in the front-rear direction are
disposed between the upper and lower header tanks at predetermined
intervals in the left-right direction; each of the fins is disposed
between tube sets located adjacent to each other in the left-right
direction; and, in each tube set composed of a plurality of the
flat heat exchange tubes, a clearance is formed between the heat
exchange tubes located adjacent to each other in the front-rear
direction, the clearance having a width of 1.5 to 3.5 mm as
measured in the front-rear direction.
[0014] 6) An evaporator according to par. 1), wherein each heat
exchange tube is provided in a flat hollow body composed of two
pressed rectangular metal plates laminated and joined together; the
two metal plates which constitute the flat hollow body are bulged
outward so as to form the heat exchange tube such that the heat
exchange tube is open at upper and lower ends thereof; each of
front and rear walls of an outward bulged portion of each metal
plate which forms the heat exchange tube is straight and inclines
outward in the front-rear direction, toward a thicknesswise center
portion of the flat hollow body.
[0015] 7) An evaporator according to par. 6), wherein, at a front
edge of each flat hollow body, one of the two metal plates has a
protrusion formed over the entire length thereof such that a distal
end portion of the protrusion projects beyond the other metal plate
and toward the corrugated fin with which the other metal plate is
in contact.
Effects of the Invention
[0016] According to the evaporators of par. 1) to 7), each of left
and right portions of the front and rear end walls of each heat
exchange tube has a straight slope portion which inclines outward
in the front-rear direction, toward a center portion of the heat
exchange tube with respect to the left-right direction, and the
angle formed between the slope portion and the left edge or right
edge of the corresponding corrugated fin is 25 to 40 degrees.
Therefore, recesses are formed between the slope portions of the
front and rear end walls of each heat exchange tube and the left
and right edges of the corresponding corrugated fins such that a
corner portion of each recess located on the inner side with
respect to the width direction of the heat exchange tube has an
acute angle. Thus, due to surface tension, condensed water produced
on the surfaces of the corrugated fins flows into the recesses as
if it were drawn into the recesses, and flows downward through the
recesses. Accordingly, the evaporator has an improved performance
of draining the condensed water produced on the surfaces of the
corrugated fins, whereby scattering of condensed water and a drop
in heat exchange performance caused by freezing of condensed water
are prevented.
[0017] According to the evaporator of par. 2), it is possible to
restrain a drop in heat conduction performance caused by a decrease
in the areas of contact between the heat exchange tubes and the
corrugated fins, without preventing the flow of the condensed water
into the recesses formed between the slope portions of the front
and rear end walls of each heat exchange tube and the left and
right edges of the corresponding corrugated fins.
[0018] According to the evaporator of par. 5), in each tube set
composed of a plurality of flat heat exchange tubes disposed
between the two header tanks, a clearance is formed between the
heat exchange tubes located adjacent to each other in the
front-rear direction, and the clearance has a width of 1.5 to 3.5
mm as measured in the front-rear direction. Thus, due to surface
tension, condensed water produced on the surfaces of the corrugated
fins flows into the clearances between the heat exchange tubes of
each tube set located adjacent to each other in the front-rear
direction, as if it were drawn into the clearances, and flows
downward through the clearances. Accordingly, the evaporator has an
improved performance of draining the condensed water produced on
the surfaces of the corrugated fins, whereby scattering of
condensed water and a drop in heat exchange performance caused by
freezing of condensed water are prevented.
[0019] According to the evaporator according to par. 6), the
straight slope portions--which incline outward in the front-rear
direction, toward a center portion of the heat exchange tube with
respect to the left-right direction--can be relatively easily
formed at the left and right portions of the front and rear end
walls of each heat exchange tube. Also, the angle formed between
each slope portion and the left edge or right edge of the
corresponding corrugated fin can be relatively easily set to 25 to
40 degrees.
[0020] According to the evaporator according to par. 7), scattering
of condensed water from the front edge of each flat hollow body can
be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a partially cut-away perspective view showing the
overall structure of an evaporator according to a first embodiment
of the present invention.
[0022] FIG. 2 is a partially omitted enlarged sectional view taken
along line A-A of FIG. 1.
[0023] FIG. 3 is an enlarged sectional view taken along line B-B of
FIG. 2.
[0024] FIG. 4 is a graph showing the results of Experimental
Examples 1 to 2 and Comparative Experimental Examples 1 to 2.
[0025] FIG. 5 is a graph relating to Experimental Examples 1 to 2
and Comparative Experimental Example 1 and showing the relation
among the amount of retained water, contact ratio, and angle
between slope portions of each heat exchange tube and left and
right edges of corresponding corrugated fins.
[0026] FIG. 6 is a graph relating to Experimental Examples 1 to 2
and Comparative Experimental Example 1 and showing the relation
between the ratio of the amount of retained water to the contact
ratio obtained from the graph of FIG. 5, and the angle between
slope portions of each heat exchange tube and left and right edges
of corresponding corrugated fins.
[0027] FIG. 7 is a graph showing the results of Experimental
Examples 3 to 4 and Comparative Experimental Examples 3 to 4.
[0028] FIG. 8 is a view corresponding to FIG. 2 and showing an
evaporator according to a second embodiment of the present
invention.
[0029] FIG. 9 is a partially omitted enlarged sectional view taken
along line C-C of FIG. 8.
[0030] FIG. 10 is a view corresponding to FIG. 2 and showing an
evaporator according to a third embodiment of the present
invention.
[0031] FIG. 11 is a partially omitted enlarged sectional view taken
along line D-D of FIG. 10.
DESCRIPTION OF REFERENCE NUMERALS
[0032] (1), (60), (90): evaporator [0033] (2), (3), (61), (62):
header tank [0034] (4), (63): flat hollow body [0035] (5):
corrugated fin [0036] (41), (75): metal plate [0037] (43), (95):
clearance [0038] (44), (92): set of heat exchange tubes juxtaposed
in the front-rear direction [0039] (48), (78): outward bulged
portion [0040] (48a), (78a): front and rear walls [0041] (45),
(76), (91): heat exchange tube [0042] (45a), (76a), (91a): front
and rear end walls [0043] (55), (83), (93): slope portion [0044]
(57), (85): protrusion
MODES FOR CARRYING OUT THE INVENTION
[0045] Embodiments of the present invention will next be described
with reference to the drawings. Like portions and members are
denoted by like reference numerals throughout the drawings, and
repeated description is not provided.
[0046] In the following description, the term "aluminum"
encompasses aluminum alloys in addition to pure aluminum.
First Embodiment
[0047] This embodiment is shown in FIGS. 1 to 3. FIG. 1 shows the
overall structure of an evaporator, and FIGS. 2 and 3 show the
structure of a main portion of the evaporator.
[0048] As shown in FIGS. 1 and 2, an evaporator (1) includes a
first header tank (2) and a second header tank (3) formed of
aluminum and disposed apart from each other in the vertical
direction such that they extend in the left-right direction; a
plurality of flat hollow bodies (4) formed of aluminum and disposed
between the two header tanks (2) and (3) at predetermined intervals
in the left-right direction (the longitudinal direction of the
header tanks (2) and (3)) such that their width direction coincides
with the front-rear direction and their longitudinal direction
coincides with the vertical direction; louvered, corrugated fins
(5) made of aluminum, disposed in air-passing clearances between
the adjacent flat hollow bodies (4) and externally of the left- and
right-end flat hollow bodies (4), and brazed to the flat hollow
bodies (4); and side plates (6) made of aluminum, disposed
externally of the left- and right-end corrugated fins (5) and
brazed to the corrugated fins (5).
[0049] The first header tank (2) includes a refrigerant inlet
header section (7) located on the front side (downstream side with
respect to the air flow direction) and extending in the left-right
direction; a refrigerant outlet header section (8) located on the
rear side (upstream side with respect to the air flow direction)
and extending in the left-right direction; and a connection section
(9) which integrally connects the header sections (7) and (8)
together. A refrigerant inlet pipe (11) made of aluminum is
connected to the refrigerant inlet header section (7) of the first
header tank (2). Similarly, a refrigerant outlet pipe (12) made of
aluminum is connected to the refrigerant outlet header section (8).
The second header tank (3) includes a first intermediate header
section (13) located on the front side and extending in the
left-right direction; a second intermediate header section (14)
located on the rear side and extending in the left-right direction;
and a connection section (15) which integrally connects the header
sections (13) and (14) together.
[0050] The first header tank (2) is composed of a plate-like first
member (16) which is formed, through press work, from an aluminum
brazing sheet having a brazing material layer on each of opposite
sides thereof and to which all the flat hollow bodies (4) are
connected; a second member (17) which is formed, through press
work, from an aluminum brazing sheet having a brazing material
layer on each of opposite sides thereof and which covers the upper
side of the first member (16); a flat partition portion forming
plate (18) which is formed, through press work, from an aluminum
brazing sheet having a brazing material layer on each of opposite
sides thereof or an aluminum bear material and which is interposed
between the first member (16) and the second member (17) and is
brazed to the two members (16) and (17); left and right end members
(19) which are formed, through press work, from an aluminum brazing
sheet having a brazing material layer on each of opposite sides
thereof and which are brazed to the left ends and right ends,
respectively, of the first member (16), the second member (17), and
the partition portion forming plate (18); and a joint plate (21)
which is formed of aluminum, extends in the front-rear direction,
and is brazed to the outer surface of the right end member (19)
such that the joint plate (21) extends across the refrigerant inlet
header section (7) and the refrigerant outlet header section (8).
The refrigerant inlet pipe (11) and the refrigerant outlet pipe
(12) are connected to the joint plate (21). Notably, the joint
plate (21) is formed from an aluminum bear material through press
work.
[0051] The first member (16) has front and rear downward-bulged
header forming portions (22) and (23) which form lower portions of
the refrigerant inlet header section (7) and the refrigerant outlet
header section (8); and a connection wall (24) which connects the
front and rear header forming portions (22) and (23) together and
forms a lower portion of the connection section (9). A plurality of
tube insertion holes (25) elongated in the front-rear direction are
formed in the two header forming portions (22) and (23) of the
first member (21) at predetermined intervals in the left-right
direction such that the positions (with respect to the left-right
direction) of the tube insertion holes (25) formed in the front
header forming portion (22) coincide with those of the
corresponding tube insertion holes (25) formed in the rear header
forming portion (23).
[0052] The second member (17) has front and rear upward-bulged
header forming portions (26) and (27) which form upper portions of
the refrigerant inlet header section (7) and the refrigerant outlet
header section (8); and a connection wall (28) which connects the
front and rear header forming portions (26) and (27) together and
forms an upper portion of the connection section (9).
[0053] The partition portion forming plate (18) has a front
partition portion (29) which divides the interior of the
refrigerant inlet header section (7) into upper and lower spaces
(7A) and (7B); a rear partition portion (31) which divides the
interior of the refrigerant outlet header section (8) into upper
and lower spaces (8A) and (8B); and a connection wall (32) which
connects the two partition portions (29) and (31) together, and
forms an intermediate portion (with respect to the vertical
direction) of the connection section (9). A communication hole (33)
for establishing communication between the upper and lower spaces
(7A) and (7B) within the refrigerant inlet header section (7) is
formed in the front partition portion (29) of the partition portion
forming plate (18) at a position located leftward of the flat
hollow body (4) disposed at the left end. A plurality of circular
communication holes (34) for establishing communication between the
upper and lower spaces (7A) and (7B) of the refrigerant inlet
header section (7) are formed in an intermediate portion (with
respect to the front-rear direction) of the front partition portion
(29) of the partition portion forming plate (18) at predetermined
intervals in the left-right direction. Further, a plurality of
oblong communication holes (35) elongated in the left-right
direction and adapted to establish communication between the upper
and lower spaces (8A) and (8B) of the refrigerant outlet header
section (8) are formed, at predetermined intervals in the
left-right direction, in a rear portion of the rear partition
portion (31) of the partition portion forming plate (18), excluding
left and right end portions of the rear portion. The length of the
oblong communication hole (35) in the central portion is shorter
than those of the remaining oblong communication hole (35).
[0054] The left end member (19) closes the left end openings of the
refrigerant inlet header section (7) and the refrigerant outlet
header section (8), and the right end member (19) closes the right
end openings of the refrigerant inlet header section (7) and the
refrigerant outlet header section (8). Although not illustrated in
the drawings, a refrigerant inlet is formed in a portion (facing
the upper space (7A)) of a portion of the right end member (19)
which portion closes the right end opening of the refrigerant inlet
header section (7), and a refrigerant outlet is formed in a portion
(facing the upper space (8A)) of a portion of the right end member
(19) which portion closes the right end opening of the refrigerant
outlet header section (8). The joint plate (21) has refrigerant
passages which communicate with the refrigerant inlet and the
refrigerant outlet of the right end member (19).
[0055] The second header tank (3) has a structure similar to that
of the first header tank (2), and is disposed upside down with
respect to the first header tank (2). Therefore, like portions are
denoted by like reference numerals.
[0056] Notably, the two header forming portions (22) and (23) of
the first member (16) of the second header tank (3) form upper
portions of the first intermediate header section (13) and the
second intermediate header section (14), and the two header forming
portions (26) and (27) of the second member (17) of the second
header tank (3) form lower portions of the first intermediate
header section (13) and the second intermediate header section
(14). Also, the interior of the first intermediate header section
(13) is divided into upper and lower spaces (13A) and (13B) by the
front partition portion (29) of the partition portion forming plate
(18), and the interior of the second intermediate header section
(14) is divided into upper and lower spaces (14A) and (14B) by the
rear partition portion (31) of the partition portion forming plate
(18). Furthermore, an intermediate portion of the connection
portion (15) with respect to the vertical direction is formed by
the connection wall (32) of the partition portion forming plate
(18).
[0057] The second header tank (3) differs from the first header
tank (2) in the following points.
[0058] The first difference is that a plurality of communication
portions (36) for establishing communication between the lower
space (13B) of the first intermediate header section (13) and the
lower space (14B) of the second intermediate header section (14)
are provided at predetermined intervals (with respect to the
left-right direction) in a portion of the second member (17) which
portion separates the lower spaces (13B) and (14B) of the two
intermediate header sections (13) and (14) from each other. The
communication portions (36) are provided at a plurality of
locations such that each communication portion (36) is provided
between two flat hollow bodies (4) located adjacent to each other
with respect to the left-right direction and such that the amount
of refrigerant within the second intermediate header section (14)
can be made uniform along the longitudinal direction of the second
header tank (3).
[0059] The second difference is that, in place of the communication
hole (33) and the circular communication holes (34), a plurality of
relatively large rectangular communication holes (37) elongated in
the left-right direction are formed in the front partition portion
(29) of the partition portion forming plate (18) at predetermined
intervals in the left-right direction; and that, in place of the
oblong communication holes (34), a plurality of circular
communication holes (through holes) (38) are formed in a rear
portion of the rear partition portion (31) of the partition portion
forming plate (18) at predetermined intervals in the left-right
direction.
[0060] The third difference is that the refrigerant inlet and the
refrigerant output are not formed in the right end member (21), and
the joint plate (21) is not brazed thereto.
[0061] As shown in FIGS. 2 and 3, each of the flat hollow bodies
(4) is formed through a process of making two rectangular metal
plates (41) from an aluminum brazing sheet through press working,
and brazing the two rectangular metal plates (41), over the entire
length thereof, along front and rear edge portions thereof and
along center portions thereof with respect to the front-rear
direction. Each of the flat hollow bodies (4) has two heat exchange
tubes (45), the number of which is equal to the number of the
header sections (7) and (8) of the first header tank (2) and the
number of the header sections (13) and (14) of the second header
tank (3). The heat exchange tubes (45) extend in the vertical
direction, and are open at the upper and lower ends thereof. The
heat exchange tubes (45) of each flat hollow body (4) are provided
through formation of outward bulged portions (48) on the two metal
plates (41) over the entire length thereof in regions between
brazed portions (46) of the front and rear edge portions of the two
metal plates (41), and brazed portions (47) of the center portions
(with respect to the front-rear direction) of the two metal plates
(41). The heat exchange tubes (45) have a flat shape such that
their width direction coincides with the front-rear direction. Each
flat hollow body (4) has a tube set (44) including a plurality of
(two in the present embodiment) of flat heat exchange tubes (45)
whose width direction coincides with the front-rear direction and
which are spaced from each other in the front-rear direction. In
each tube set (44), clearances (43) are formed between the heat
exchange tubes (45) located adjacent to each other in the
front-rear direction. That is, a plurality of tube sets (44)--each
composed of a plurality of flat heat exchange tubes (45) disposed
such that their width direction coincides with the front-rear
direction and they are spaced from one another in the front-rear
direction--are disposed between the first header tank (2) and the
second header tank (3) at predetermined intervals in the left-right
direction; and each of the corrugated fins (5) is disposed between
the tube sets (44) (sets of the heat exchange tube (45)) located
adjacent to each other in the left-right direction.
[0062] Upper and lower end portions of the brazed portions (46) of
the front and rear edge portions of the two metal plates (41) of
each flat hollow body (4) are cut such that the formed cutouts
extend from the outer edges with respect to the front-rear
direction to the upper and lower end surfaces, respectively. The
cutouts are denoted by (51). Also, upper and lower end portions of
the brazed portions (47) of the center portions (with respect to
the front-rear direction) of the two metal plates (41) of each flat
hollow body (4) have a width (as measured in the front-rear
direction) greater than those of the remaining portions, and
cutouts (52) are formed in wide brazed portions (47a) such that the
cutouts (52) extend from the respective outer ends with respect to
the vertical direction. Notably, due to provision of the width
brazed portions (47a) on each flat hollow body (4), upper and lower
end portions of each heat exchange tube (45) is narrower than the
reaming portions as measured in the front-rear direction. As a
result of formation of the cutouts (51) in the brazed portions (46)
of the front and rear edge portions and formation of the cutouts
(52) in the width brazed portions (47a) of the center portions with
respect to the front-rear direction, the upper and lower end
portions of each heat exchange tube (45) project outward with
respect to the vertical direction from the remaining portions. The
projecting portions serve as insertion portions (53) inserted into
the tube insertion holes (25) of the first header tank (2) and the
second header tank (3). The flat hollow bodies (4) are brazed to
the first members (16) of the two header thanks (2) and (3) as
follows. The upper and lower insertion portions (53) of the front
heat exchange tubes (45) are inserted into the front tube insertion
holes (25) of the first members (16) of the first header tank (2)
and the second header tank (3). Similarly, the upper and lower
insertion portions (53) of the rear heat exchange tubes (45) are
inserted into the rear tube insertion holes (25) of the first
members (16) of the first header tank (2) and the second header
tank (3). At the time of the insertion operation, bottom side
portions of the cutouts (51) of the brazed portions (46) of the
front and rear edge portions of each flat hollow body (4) and
bottom side portions of the cutouts (52) of the width brazed
portions (47a) of the center portions of the flat hollow body (4)
are brought into contact with the outer surfaces of the two header
forming portions (22) and (23) of the respective first members (16)
of the first header tank (2) and the second header tank (3),
whereby the end portions of the flat hollow bodies (4) are
positioned. In this state, the flat, hollow bodies (4) are brazed
to the first members (16) of the first header tank (2) and the
second header tank (3). The corrugated fins (5) are shared by the
front and rear heat exchange tubes (45) of the corresponding flat
hollow bodies (4). The crest portions or trough portions of each
corrugated fin (5) are brazed to the corresponding heat exchange
tube (45). Also, a plurality of louvers are formed on connection
portions of each corrugated fin (5) located between the crest
portions and trough portions thereof. Moreover, a corrugated inner
fin (54) formed of aluminum is disposed in each flat hollow body
(4) such that the corrugated inner fin (54) extends through the
interiors of the two heat exchange tubes (45), and is brazed to the
two metal plates (41).
[0063] Straight slope portions (55) are provided on left and right
portions of front and rear end walls (45a) of the two heat exchange
tubes (45) of each flat hollow body (4). The straight slope
portions (55) incline outward with respect to the front-rear
direction, toward the center portions of the heat exchange tubes
(45) (with respect to the left-right direction). That is, front and
rear walls (48a) of the outward bulged portions (48) of the metal
plates (41) of each flat hollow body (4), which portions form the
two heat exchange tubes (45), linearly incline in an outward
direction with respect to the front-rear direction, toward the
thicknesswise center of the flat hollow body (4). Thus, recess
portions (56) are formed between the outer surfaces of the slope
portions (55) of the front and rear end walls (45a) of the heat
exchange tubes (45) of each flat hollow body, and the left and
right edge portions of the corresponding corrugated fins (5). A
corner portion of each recess (56) located on the inner side with
respect to the width direction of the heat exchange tubes (45) has
an acute angle. The angle .theta. formed between each of the slope
portions (55) of the front and rear end walls (45a) of the two heat
exchange tubes (45) and the left or right edge portion of the
corresponding corrugated fin (5) is set to 25 to 40 degrees in
consideration of drainage of water condensed on the surfaces of the
flat hollow bodies (4) and the corrugated fins (5). Also, when the
width of the heat exchange tubes (45) as measured in the front-rear
direction is represented by W1 (mm) and the length (as measured in
the front-rear direction) of contact areas where the left and right
side surfaces of the heat exchange tubes (45) are in contact with
the corresponding corrugated fins (5) is represented by W2 (mm),
preferably, a contract ratio W2/W1; i.e., the ratio of W2 (the
length (as measured in the front-rear direction) of the areas of
contact between the left and right side surfaces of the heat
exchange tubes (45) and the corresponding corrugated fins (5)) to
W1 (the width of the heat exchange tubes (45) as measured in the
front-rear direction), is 80 to 95%. Furthermore, preferably, the
width W1 of the heat exchange tubes (45) as measured in the
front-rear direction is 10 to 20 mm, and the thickness H of the
heat exchange tubes (45) as measured in the left-right direction is
1 to 1.8 mm.
[0064] At each of the front and rear edges of each flat hollow body
(4), a protrusion (57) is formed on one of the two metal plates
(41) over the entire length thereof such that a distal end portion
of the protrusion (57) projects beyond the other metal plate (41)
and toward the corrugated fin (5) with which the other metal plate
(41) is in contact. That is, a protrusion (57) whose distal end
projects rightward beyond the right metal plate (41) is formed at
the front edge of the left metal plate (41) of the flat hollow body
(4) over the entire length thereof, and another protrusion (57)
whose distal end projects leftward beyond the left metal plate (41)
is formed at the rear edge of the right metal plate (41) of the
flat hollow body (4) over the entire length thereof.
[0065] In each tube set (44) including the flat hollow bodies (4),
preferably, the width S (as measured in the front-rear direction)
of the clearances (43) formed between the heat exchange tube (45)
located adjacent to each other in the front-rear direction is 1.5
to 3.5 mm. If the width S of the clearances (43) as measured in the
front-rear direction is smaller than 1.5 mm, condensed water having
been produced on the surfaces of the corrugated fins (5) and flowed
into (as if it had been drawn into) the clearances (43) between the
front and rear heat exchange tubes (45) of each tube set (44) by
means of surface tension stagnates at the clearances (43) due to
surface tension, which hinders a downward flow of the condensed
water. If the width S of the clearances (43) as measured in the
front-rear direction is greater than 3.5 mm, condensed water
produced on the surfaces of the corrugated fins (5) becomes less
likely to be drawn into the clearances (43). Also, preferably, the
thickness H of the heat exchange tubes (45) as measured in the
left-right direction is 1 to 1.8 mm, the width W of the heat
exchange tubes (45) as measured in the front-rear direction is 10
to 20 mm.
[0066] In manufacture of the evaporator (1), component members
thereof excluding the inlet pipe (11) and the outlet pipe (12) are
assembled together, and brazed together.
[0067] The evaporator (1), together with a compressor and a
condenser serving as a refrigerant cooler, constitutes a
refrigeration cycle which uses a chlorofluorocarbon-based
refrigerant. This refrigeration cycle is installed in a vehicle,
such as an automobile, as a car air conditioner.
[0068] In the evaporator (1) described above, while the compressor
is ON, a two-phase refrigerant of vapor-liquid phase having passed
through the compressor, the condenser, and an expansion valve
enters the upper space (7A) of the refrigerant inlet header section
(7) from the refrigerant inlet pipe (11); flows through the lower
space (7B) of the same, the front heat exchange tubes (45) of the
flat hollow bodies (4), the upper space (13A) of the first
intermediate header section (13), the lower space (13B) of the
same, the lower space (14B) of the second intermediate header
section (14), the upper space (14A) of the same, the rear heat
exchange tubes (45) of the flat hollow bodies (4), the lower space
(8B) of the refrigerant outlet header section (8), and the upper
space (8A) of the same; and flows out to the refrigerant outlet
pipe (12).
[0069] While flowing through the front and rear heat exchange tubes
(45) of the flat hollow bodies (4), the refrigerant is subjected to
heat exchange with air flowing through the air-passing clearances
between the adjacent flat hollow bodies (4). Then, the refrigerant
flows out from the evaporator (1) in a vapor phase.
[0070] At that time, condensed water is produced on the surfaces of
the corrugated fins (5). Due to surface tension, the condensed
water flows into the recesses (56) formed between the outer
surfaces of the slopes portions (55) of the front and rear end
walls (45a) of the heat exchange tubes (45) of each flat hollow
body (4) and the left and right edges of the corresponding
corrugated fins (5), as if the condensed water were drawn into the
recesses (56). After that, the condensed water flows downward via
the recesses (56). Accordingly, the evaporator (1) has an improved
condensed water draining performance, whereby a drop in the
performance of the evaporator (1) is prevented. Furthermore,
frontward scattering of condensed water is restrained by the action
of the protrusion (57) at the front edge of each flat hollow body
(4).
[0071] Next, experimental examples which were performed by use of
the flat hollow bodies (4) of the evaporator (1) according to the
first embodiment will be described along with comparative
experimental examples.
Experimental Example 1
[0072] There was prepared an assembly which was equivalent to an
assembly obtained by removing the two header tanks (2) and (3), the
refrigerant inlet pipe (11), and the refrigerant outlet pipe (12)
from the evaporator (1) of the first embodiment, and in which only
the flat hollow bodies (4), the corrugated fins (5), and the side
plates (6) were brazed together. The angle .theta. between each of
the slope portions (55) of the front and rear end walls (45a) of
the two heat exchange tubes (45) of each flat hollow body (4) and
the left or right edge portion of the corresponding corrugated fin
(5) was 25 degrees. The assembly was immersed in water within a
tank for removal of air remaining within the assembly. After that,
the assembly was allowed to stand for 30 minutes. Subsequently, the
assembly was lifted such the flat hollow bodies (4) became
vertical, and was removed from the water. In this state, the weight
of the assembly was measured for 30 minutes so as to investigate a
change in the amount of retained water.
Experimental Example 2
[0073] An assembly identical with that used in Experimental Example
1 except that the angle .theta. between each of the slope portions
(55) of the front and rear end walls (45a) of the two heat exchange
tubes (45) and the left or right edge portion of the corresponding
corrugated fin (5) was set to 35 degrees was prepared, and a change
in the amount of retained water was investigated in the same manner
as in Experimental Example 1. Notably, the width W1 of the heat
exchange tubes (45) as measured in the front-rear direction and the
thickness H of the heat exchange tubes (4) as measured in the
left-right direction are the same as those of the heat exchange
tubes used in the Experimental Example 1.
Comparative Experimental Example 1
[0074] An assembly identical with that used in Experimental Example
1 except that the angle .theta. between each of the slope portions
(55) of the front and rear end walls (45a) of the two heat exchange
tubes (45) and the left or right edge portion of the corresponding
corrugated fin (5) was set to 45 degrees was prepared, and a change
in the amount of retained water was investigated in the same manner
as in Experimental Example 1. Notably, the width W1 of the heat
exchange tubes (45) as measured in the front-rear direction and the
thickness H of the heat exchange tubes (4) as measured in the
left-right direction are the same as those of the heat exchange
tubes used in the Experimental Example 1.
Comparative Experimental Example 2
[0075] Instead of the flat hollow bodies (4), tube pairs each
composed of two heat exchange tubes spaced from each other in the
front-rear direction were brazed together with the corrugated fins
(5) and the side plates (6), whereby an assembly was prepared. The
heat exchange tubes had the same structure as that disclosed in
Patent Document 1; i.e., the front and rear end walls of the heat
exchange tubes had an arcuate shape, as viewed on a transverse
cross section, which was convex outward with respect to the
front-rear direction. Notably, the heat exchange tubes used in
Comparative Experimental Example 2 have the same width (as measured
in the front-rear direction) and thickness (as measured in the
left-right direction) as those of the heat exchange tubes used in
the Experimental Example 1. A change in the amount of retained
water was investigated in the same manner as in Experimental
Example 1.
[0076] FIG. 4 shows the results of Experimental Examples 1 to 2 and
Comparative Experimental Examples 1 to 2. As is clear from the
results shown in FIG. 4, in Experimental Examples 1 to 2, the
amount of retained water after elapse of 30 minutes is smaller as
compared with Comparative Experimental Example 1 to 2, and
excellent draining performance is attained.
[0077] FIG. 5 shows the relation among the amount of retained
water, the contact ratio W2/W1, and the angle .theta. obtained from
Experimental Example 1 to 2 and Comparative Experimental Example 1.
As described previously, the contract ratio W2/W1 is the ratio of
W2 (the length (as measured in the front-rear direction) of the
areas of contact between the left and right side surfaces of the
heat exchange tubes and the corresponding corrugated fins) to W1
(the width of the heat exchange tubes as measured in the front-rear
direction). The angle .theta. is the angle between each of the
slope portions of the front and rear end walls of the heat exchange
tubes and the left or right edge portion of the corresponding
corrugated fin.
[0078] FIG. 6 shows the relation between the ratio of the water
retraining amount to the contact ratio W2/W1 and the angle .theta.
between each of the slope portions of the front and rear end walls
of the heat exchange tubes and the left or right edge portion of
the corresponding corrugated fin. The graph of FIG. 6 means that,
when the ratio of the water retraining amount to the contact ratio
W2/W1 is small, it is possible to restrain a drop in heat
conduction performance caused by a decrease in the areas of contact
between the heat exchange tubes and the corrugated fins, while
preventing a drop in draining performance. Accordingly, the results
shown in FIG. 6 demonstrate that, when the angle .theta. between
each of the slope portions of the front and rear end walls of the
heat exchange tubes and the left or right edge portion of the
corresponding corrugated fin is 25 to 40 degrees, the condensed
water draining performance can be enhanced, while a required
thermal conductivity is secured.
Experimental Example 3
[0079] There was prepared an assembly which was equivalent to an
assembly obtained by removing the two header tanks (2) and (3), the
refrigerant inlet pipe (11), and the refrigerant outlet pipe (12)
from the evaporator (1) of the first embodiment, and in which only
the flat hollow bodies (4), the corrugated fins (5), and the side
plates (7) were brazed together. The width S (as measured in the
front-rear direction) of the clearances (43) formed between the
front and rear heat exchange tubes (45) of each flat hollow body
(4) was 1.6 mm. The assembly was immersed in water within a tank
for removal of air remaining within the assembly. After that, the
assembly was allowed to stand for 30 minutes. Subsequently, the
assembly was lifted such the flat hollow bodies (4) became
vertical, and was removed from the water. The assembly was held in
this state for 30 minutes, and the amount of retained water after
elapse of 30 minutes was measured.
Experimental Example 4
[0080] An assembly identical with that used in Experimental Example
3 except that the width S (as measured in the front-rear direction)
of the clearances (43) formed between the front and rear heat
exchange tubes (45) of each flat hollow body (4) was 2.8 mm was
prepared, and the amount of retained water after elapse of 30
minutes was measured in the same manner as in Experimental Example
3. Notably, the width W of the heat exchange tubes (45) as measured
in the front-rear direction and the thickness H of the heat
exchange tubes (45) as measured in the left-right direction are the
same as those of the heat exchange tubes used in the Experimental
Example 1.
Comparative Experimental Example 3
[0081] An assembly identical with that used in Experimental Example
3 except that the width S (as measured in the front-rear direction)
of the clearances (43) formed between the front and rear heat
exchange tubes (45) of each flat hollow body (4) was 1.0 mm was
prepared, and the amount of retained water after elapse of 30
minutes was measured in the same manner as in Experimental Example
3. Notably, the width W of the heat exchange tubes (45) as measured
in the front-rear direction and the thickness H of the heat
exchange tubes (45) as measured in the left-right direction are the
same as those of the heat exchange tubes used in the Experimental
Example 1.
Comparative Experimental Example 4
[0082] Instead of the flat hollow bodies (4), tube pairs each
composed of two heat exchange tubes having the same structure as
that of the heat exchange tubes used in the above-described
Comparative Experimental Example 2 were brazed together with the
corrugated fins (5) and the side plates (6), whereby an assembly
was prepared. Notably, the heat exchange tubes used in Comparative
Experimental Example 4 have the same width (as measured in the
front-rear direction) and thickness (as measured in the left-right
direction) as those of the heat exchange tubes used in the
Experimental Example 3; and the width (as measured in the
front-rear direction) of the clearances formed between the front
and rear heat exchange tubes of each tube set was the same as that
of the assembly used in the Experimental Example 3. The amount of
retained water after elapse of 30 minutes was measured in the same
manner as in Experimental Example 3.
[0083] FIG. 7 shows the results of Experimental Examples 3 to 4 and
Comparative Experimental Examples 3 to 4. As is clear from the
results shown in FIG. 7, in Experimental Examples 3 to 4, the
amount of retained water after elapse of 30 minutes is smaller as
compared with Comparative Experimental Example 3 to 4, and
excellent draining performance is attained. Therefore, in order to
enhance the water draining performance of the evaporator, the width
(as measured in the front-rear direction) of the clearances formed
between the heat exchange tubes adjacent to each other in the
front-rear direction must be set to 1.5 to 3.5 mm.
Embodiment 2
[0084] This embodiment is shown in FIGS. 8 and 9. FIGS. 8 and 9
show the structure of a main portion of an evaporator according to
the present embodiment.
[0085] As shown in FIGS. 8 and 9, an evaporator (60) includes a
first header tank (61) and a second header tank (62) formed of
aluminum and disposed apart from each other in the vertical
direction such that they extend in the left-right direction; a
plurality of flat hollow bodies (63) formed of aluminum and
disposed between the two header tanks (61) and (62) such that their
width direction coincides with the front-rear direction and they
are spaced from one another in the left-right direction; corrugated
fins (5) made of aluminum, disposed in air-passing clearances
between the adjacent flat hollow bodies (63) and externally of the
left- and right-end flat hollow bodies (63), and brazed to the flat
hollow bodies (63); and side plates (not shown) made of aluminum,
disposed externally of the left- and right-end corrugated fins (5)
and brazed to the corrugated fins (5).
[0086] The entirety of the first header tank (61) serves as a
refrigerant inlet header section (65), and the entirety of the
second header tank (62) serves as a refrigerant outlet header
section (66). A refrigerant inlet pipe (not shown) is connected to
the refrigerant inlet header section (65) of the first header tank
(61), and a refrigerant outlet pipe (not shown) made of aluminum is
connected to the refrigerant outlet header section (66) of the
second header tank (62).
[0087] The first header tank (61) is composed of a plate-like first
member (67) which is formed, through press work, from an aluminum
brazing sheet having a brazing material layer on each of opposite
sides thereof and to which all the flat hollow bodies (63) are
connected; a second member (68) which is formed, through press
work, from an aluminum brazing sheet having a brazing material
layer on each of opposite sides thereof and which covers the upper
side of the first member (67); a flat partition portion forming
plate (69) which is formed, through press work, from an aluminum
brazing sheet having a brazing material layer on each of opposite
sides thereof or an aluminum bear material and which is interposed
between the first member (67) and the second member (68) and is
brazed to the two members (67) and (68); and left and right end
members (not shown) which are formed, through press work, from an
aluminum brazing sheet having a brazing material layer on each of
opposite sides thereof and which are brazed to left ends and right
ends, respectively, of the first member (67), the second member
(68), and the partition portion forming plate (69).
[0088] The first member (67) forms a lower portion of the
refrigerant inlet header section (65), and the second member (68)
forms an upper portion of the refrigerant inlet header section
(65). A plurality of tube insertion holes (71) elongated in the
front-rear direction are formed in the first member (67) at
predetermined intervals in the left-right direction. The partition
portion forming plate (69) has a partition portion (73) which
divides the interior of the refrigerant inlet header section (65)
into upper and lower spaces (65A) and (65B). A plurality of
relatively large rectangular communication holes (74) elongated in
the left-right direction are formed in each of front and rear
portions of the partition portion (73) of the partition portion
forming plate (69) at predetermined intervals in the left-right
direction. The left and right end members close the left and right
end openings of the refrigerant inlet header section (65). A
refrigerant inlet is formed in the left end member or the right end
member at a position corresponding to the upper space (65A).
[0089] The second header tank (62) has a structure similar to that
of the first header tank (61), and is disposed upside down with
respect to the first header tank (61). Therefore, like portions are
denoted by like reference numerals.
[0090] Notably, the first member (67) of the second header tank (3)
forms an upper portion of the refrigerant outlet header section
(66), and the second member (68) thereof forms a lower portion of
the refrigerant outlet header section (66). The partition portion
(73) of the partition portion forming plate (69) divides the
interior of the refrigerant outlet header section (66) into upper
and lower spaces (66A) and (66B). A refrigerant outlet is formed in
the left end member or the right end member at a position
corresponding to the lower space (66B).
[0091] Each of the flat hollow bodies (63) is formed through a
process of making two rectangular metal plates (75) from an
aluminum brazing sheet through press working, and brazing the two
rectangular metal plates (75), over the entire length thereof,
along front and rear edge portions thereof. Each of the flat hollow
bodies (63) has only one heat exchange tube (76), the number of
which is equal to the number of the header section (65) of the
first header tank (61) and the number of the header section (66) of
the second header tank (62). The heat exchange tube (76) extends in
the vertical direction, and is open at the upper and lower ends
thereof. The heat exchange tube (76) of each flat hollow body (63)
is provided through formation of outward bulged portions (78) on
the two metal plates (75) over the entire length thereof in a
region between brazed portions (77) of the front and rear edge
portions of the two metal plates (75). The heat exchange tube (76)
has a flat shape such that its width direction coincides with the
front-rear direction.
[0092] Upper and lower end portions of the brazed portions (77) of
the front and rear edge portions of the two metal plates (75) of
each flat hollow body (63) are cut such that the formed cutouts
extend from the outer edges with respect to the front-rear
direction to the upper and lower end surfaces, respectively. The
cutouts are denoted by (81). As a result of formation of the
cutouts (81) in the brazed portions (77) of the front and rear edge
portions, the upper and lower end portions of each heat exchange
tube (76) project outward with respect to the vertical direction
from the remaining portions. The projecting portions serve as
insertion portions (82) inserted into the tube insertion holes (71)
of the first header tank (61) and the second header tank (63). The
flat hollow bodies (63) are brazed to the first members (67) of the
two header thanks (61) and (62) as follows. The upper and lower
insertion portions (82) of the heat exchange tubes (76) are
inserted into the tube insertion holes (71) of the first members
(67) of the first header tank (61) and the second header tank (62).
At the time of the insertion operation, bottom side portions of the
cutouts (81) of the brazed portions (77) of the front and rear edge
portions of each flat hollow body (63) are brought into contact
with the outer surfaces of the respective first members (67) of the
first header tank (61) and the second header tank (62), whereby the
end portions of the flat hollow bodies (63) are positioned. In this
state, the flat hollow bodies (63) are brazed to the first members
(67) of the first header tank (61) and the second header tank (62).
The crest portions or trough portions of the corrugated fins (5)
are brazed to the corresponding heat exchange tube (76). Moreover,
a corrugated inner fin (79) formed of aluminum is disposed in the
heat exchange tube (76) of each flat hollow body (63), and is
brazed to the two metal plates (75).
[0093] Straight slope portions (83) are provided on left and right
portions of front and rear end walls (76a) of the heat exchange
tube (76) of each flat hollow body (63). The straight slope
portions (83) incline outward with respect to the front-rear
direction, toward the center portion (with respect to the
left-right direction) of the heat exchange tube (76). That is,
front and rear walls (78a) of the outward bulged portions (78) of
the metal plates (75) of each flat hollow body (63), which portions
form the heat exchange tube (76), linearly incline in an outward
direction with respect to the front-rear direction, toward the
thicknesswise center of the flat hollow body (63). Thus, recess
portions (84) are formed between the outer surfaces of the slope
portions (83) of the front and rear end walls (76a) of the heat
exchange tube (76) of each flat hollow body (63), and the left and
right edge portions of the corresponding corrugated fins (5). A
corner portion of each recess (84) located on the inner side with
respect to the front-rear direction has an acute angle. The angle
.theta. formed between each of the slope portions (83) of the front
and rear end walls (76a) of each heat exchange tube (76) and the
left or right edge portion of the corresponding corrugated fin (5)
is set to 25 to 40 degrees in consideration of drainage of water
condensed on the surfaces of the flat hollow bodies (63) and the
corrugated fins (5). Also, when the width of the heat exchange tube
(76) as measured in the front-rear direction is represented by W1
(mm) and the length (as measured in the front-rear direction) of
contact areas where the left and right side surfaces of the heat
exchange tube (76) are in contact with the corresponding corrugated
fins (5) is represented by W2 (mm), preferably, a contract ratio
W2/W1; i.e., the ratio of W2 (the length (as measured in the
front-rear direction) of the areas of contact between the left and
right side surfaces of the heat exchange tube (76) and the
corresponding corrugated fins (5)) to W1 (the width of the heat
exchange tube (76) as measured in the front-rear direction), is 80
to 95%. Furthermore, preferably, the width W1 of the heat exchange
tube (76) as measured in the front-rear direction is 10 to 20 mm,
and the thickness H of the heat exchange tubes (76) as measured in
the left-right direction is 1 to 1.8 mm.
[0094] At each of the front and rear edges of each flat hollow body
(63), a protrusion (85) is formed on one of the two metal plates
(75) over the entire length thereof such that a distal end portion
of the protrusion (85) projects beyond the other metal plate (75)
and toward the corrugated fin (5) with which the other metal plate
(75) is in contact. That is, a protrusion (85) whose distal end
projects rightward beyond the right metal plate (75) is formed at
the front edge of the left metal plate (75) of the flat hollow body
(63) over the entire length thereof, and another protrusion (85)
whose distal end projects leftward beyond the left metal plate (75)
is formed at the rear edge of the right metal plate (75) of the
flat hollow body (63) over the entire length thereof.
[0095] The evaporator (60), together with a compressor and a
condenser serving as a refrigerant cooler, constitutes a
refrigeration cycle which uses a chlorofluorocarbon-based
refrigerant. This refrigeration cycle is installed in a vehicle,
such as an automobile, as a car air conditioner.
[0096] In the evaporator (60) described above, while the compressor
is ON, a two-phase refrigerant of vapor-liquid phase having passed
through the compressor, the condenser, and an expansion valve
enters the refrigerant inlet header section (65) of the first
header tank (61) from the refrigerant inlet pipe via the
refrigerant inlet of the right end member or the left end member;
flows through the heat exchange tubes (76) and the refrigerant
outlet header section (66); and flows out to the refrigerant outlet
pipe.
[0097] While flowing through the heat exchange tubes (76) of the
flat hollow bodies (63), the refrigerant is subjected to heat
exchange with air flowing through the air-passing clearances
between the adjacent flat hollow bodies (63). Then, the refrigerant
flows out from the evaporator (60) in a vapor phase.
[0098] At that time, condensed water is produced on the surfaces of
the corrugated fins (5). Due to surface tension, the condensed
water flows into the recesses (84) formed between the outer
surfaces of the slopes portions (83) of the front and rear end
walls (76a) of the heat exchange tube (76) of each flat hollow body
(63) and the left and right edges of the corresponding corrugated
fins (5), as if the condensed water were drawn into the recesses
(84). After that, the condensed water flows downward via the
recesses (84). Accordingly, the evaporator (60) has an improved
condensed water draining performance, whereby a drop in the
performance of the evaporator (1) is prevented. Furthermore,
frontward scattering of condensed water is restrained by the action
of the protrusion (85) at the front edge of each flat hollow body
(63).
Third Embodiment
[0099] This embodiment is shown in FIGS. 10 and 11. FIGS. 10 and 11
show the structure of a main portion of an evaporator according to
the present embodiment.
[0100] As shown in FIGS. 10 and 11, an evaporator (90) includes a
first header tank (2) and a second header tank (3), which have the
same structures as those of the first header tank (2) and the
second header tank (3) of the evaporator (1) of the first
embodiment and which are disposed apart from each other in the
vertical direction. A plurality of tube sets (92) are disposed
between the two header tanks (2) and (3) at predetermined intervals
in the left-right directions. Each tube set (92) includes two flat
heat exchange tubes (91), the number of which is equal to the
number of the header sections (7) and (8) of the first header tank
(2) and the number of the header sections (13) and (14) of the
second header tank (3). The flat heat exchange tubes (91) are
formed of aluminum extrudate and disposed such that their width
direction coincides with the front-rear direction and they are
spaced from each other in the front-rear direction. Corrugated fins
(5) made of aluminum are disposed in air-passing clearances between
adjacent tube sets (92) each composed of the front and rear heat
exchange tubes (91), and externally of the left- and right-end tube
sets (92), and brazed to the corresponding heat exchange tubes
(91). Side plates (not shown) made of aluminum are disposed
externally of the left- and right-end corrugated fins (5) and
brazed to the corrugated fins (5). In each set (92) composed of two
heat exchange tubes (91) adjacent to each other in the front-rear
direction, a clearance (95) is formed between the two heat exchange
tubes (91).
[0101] The front and rear heat exchange tubes (91) are brazed to
the first members (16) of the two header thanks (2) and (3) as
follows. Upper and lower end portions of the front heat exchange
tubes (91) are inserted into the front tube insertion holes (25) of
the first members (16) of the first header tank (2) and the second
header tank (3). Similarly, upper and lower end portions of the
rear heat exchange tubes (91) are inserted into the rear tube
insertion holes (25) of the first members (16) of the first header
tank (2) and the second header tank (3). In this state, the front
and rear heat exchange tubes (91) are brazed to the first members
(16) of the first header tank (2) and the second header tank (3).
The corrugated fins (5) are shared by the front and rear heat
exchange tubes (91). The crest portions or trough portions of each
corrugated fin (5) are brazed to the corresponding heat exchange
tube (91).
[0102] Straight slope portions (93) are provided on left and right
portions of front and rear end walls (91a) of each heat exchange
tube (91). The straight slope portions (93) incline outward with
respect to the front-rear direction, toward the center portion of
the heat exchange tube (91) with respect to the left-right
direction. Portions of the front and rear end walls (91a) between
the two slope portions (93) are orthogonal to the left and right
edges of the corrugated fins (5). Thus, recess portions (94) are
formed between the outer surfaces of the slope portions (93) of the
front and rear end walls (91a) of each heat exchange tube (91) and
the left and right edge portions of the corresponding corrugated
fins (5). A corner portion of each recess (94) located on the inner
side with respect to the width direction of the heat exchange tubes
(91) has an acute angle. The angle .theta. formed between each of
the slope portions (93) of the front and rear end walls (91a) of
each heat exchange tubes (91) and the left or right edge portion of
the corresponding corrugated fin (5) is set to 25 to 40 degrees in
consideration of drainage of water condensed on the surfaces of the
heat exchange tubes (91) and the corrugated fins (5). Also, when
the width of the heat exchange tubes (91) as measured in the
front-rear direction is represented by W1 (mm) and the length (as
measured in the front-rear direction) of contact areas where the
left and right side surfaces of the heat exchange tubes (91) are in
contact with the corresponding corrugated fins (5) is represented
by W2 (mm), preferably, a contract ratio W2/W1; i.e., the ratio of
W2 (the length (as measured in the front-rear direction) of the
areas of contact between the left and right side surfaces of the
heat exchange tube (91) and the corresponding corrugated fins (5))
to W1 (the width of the heat exchange tubes (91) as measured in the
front-rear direction), is 80 to 95%. Furthermore, preferably, the
width W1 of the heat exchange tubes (91) as measured in the
front-rear direction is 10 to 20 mm, and the thickness H of the
heat exchange tubes (91) as measured in the left-right direction is
1 to 1.8 mm.
[0103] In each tube set (92) composed of the front and rear heat
exchange tubes (91), preferably, the width S (as measured in the
front-rear direction) of the clearance (95) formed between the heat
exchange tubes (91) located adjacent to each other in the
front-rear direction is 1.5 to 3.5 mm. If the width S of the
clearance (63) as measured in the front-rear direction is smaller
than 1.5 mm, condensed water having been produced on the surfaces
of the corrugated fins (5) and flowed into (as if it had been drawn
into) the clearance (95) between the front and rear heat exchange
tubes (91) of each tube set (92) by means of surface tension
stagnates at the clearance (95) due to surface tension, which
hinders a downward flow of the condensed water. If the width S of
the clearance (95) as measured in the front-rear direction is
greater than 3.5 mm, condensed water produced on the surfaces of
the corrugated fins (5) becomes less likely to be drawn into the
clearance (95).
[0104] The evaporator (90), together with a compressor and a
condenser serving as a refrigerant cooler, constitutes a
refrigeration cycle which uses a chlorofluorocarbon-based
refrigerant. This refrigeration cycle is installed in a vehicle,
such as an automobile, as a car air conditioner.
[0105] In the evaporator (90) described above, while the compressor
is ON, a two-phase refrigerant of vapor-liquid phase having passed
through the compressor, the condenser, and an expansion valve
enters the upper space (7A) of the refrigerant inlet header section
(7) from the refrigerant inlet pipe (11); flows through the lower
space (7B) of the same, the front heat exchange tubes (91), the
upper space (13A) of the first intermediate header section (13),
the lower space (13B) of the same, the lower space (14B) of the
second intermediate header section (14), the upper space (14A) of
the same, the rear heat exchange tubes (91), the lower space (8B)
of the refrigerant outlet header section (8), and the upper space
(8A) of the same; and flows out to the refrigerant outlet pipe
(12).
[0106] While flowing through the front and rear heat exchange tubes
(91), the refrigerant is subjected to heat exchange with air
flowing through the air-passing clearances between the tube sets
(92) each composed of adjacent heat exchange tubes (91). Then, the
refrigerant flows out from the evaporator (90) in a vapor
phase.
[0107] At that time, condensed water is produced on the surfaces of
the corrugated fins (5). Due to surface tension, the condensed
water flows into the recesses (94) formed between the outer
surfaces of the slopes portions (93) of the front and rear end
walls (91a) of each heat exchange tube (91) and the left and right
edges of the corresponding corrugated fins (5), as if the condensed
water were drawn into the recesses (94). After that, the condensed
water flows downward via the recesses (94). Accordingly, the
evaporator (90) has an improved condensed water draining
performance, whereby a drop in the performance of the evaporator
(1) is prevented.
INDUSTRIAL APPLICABILITY
[0108] The evaporator according to the present invention is
suitable for use in a refrigeration cycle which constitutes a car
air conditioner.
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