DE102006059234A1 - heat exchangers - Google Patents

Abstract

A method of manufacturing an outer plate used for a header tank of a heat exchanger is configured such that an outer plate, an inner plate, and an intermediate plate interposed between the outer and inner plates are brazed together in layers. A thick portion is formed on an outer plate-forming metal plate at a central portion with respect to the width direction thereof. Subsequently, a pressing operation is performed on the metal plate forming the outer plate to form the outwardly curved portion using the thick portion. A joint portion having a radius of curvature of 1 mm or less is formed between an inner wall surface of the convex portion and outer surface surfaces lying on the opposite sides of the convex portion. This method enables the production of an outer plate which reduces the weight while ensuring a sufficient pressure resistance.

Description

BACKGROUND THE INVENTION

The present invention relates to a heat exchanger and a method of manufacturing an outer panel used for sump tanks of a heat exchanger. More particularly, the invention relates to a heat exchanger which can be advantageously used as a gas cooler or a supercritical refrigeration cycle evaporator in which a CO ₂ (carbon dioxide) refrigerant or a similar supercritical refrigerant is used, and a method of manufacturing an outer plate used for collecting tanks Tanks of such a heat exchanger is used.

As used herein, and in the appended claims, the term "supercritical refrigeration cycle" means a refrigeration cycle in which a refrigerant on the high pressure side is in a supercritical state, ie, has a pressure above a critical pressure, the term "supercritical refrigerant" means a refrigerant. which is used in a supercritical refrigeration cycle. Also, here and in the appended claims, the downstream side of the airflow (represented by an arrow X in FIG 1 ) are indicated by the air passage gaps between adjacent Wärmetau shear tubes as the "front" and the opposite side as the "back".

Known conventional heat exchangers for Use in a supercritical Refrigeration circuit include a pair of collection containers spaced from each other are arranged, flat heat exchange tubes, which are parallel at intervals between the two sump tanks are arranged and opposite Have end portions, with the respective sump tanks are connected, and ribs which in respective Luftdurchlaßspalten between adjacent heat exchange tubes (It is based on Japanese Patent Application Laid-open (kokai) No. 2005-300135). Each of the two sump tanks is configured to have an outer plate, an inner plate and an intermediate plate which lies between the outer and the inner plate, soldered together in layers are. The outer plate has one outwards domed Area which extends in the longitudinal direction and has an opening, which is closed by the intermediate plate. The inner plate points a plurality of tube insertion openings in the form of through holes on which is in an area with the outward arched area the outer plate communicates, formed and spaced from each other in the longitudinal direction are arranged. The intermediate plate has a plurality of communication openings on which something bigger than the pipe insertion openings the inner plate and have the shape of through holes, where they are designed are, the respective tube insertion openings to allow with the interior of the outwardly curved portion of the outer panel to communicate. Opposing End portions of the heat exchange tubes are through the respective tube insertion openings of the inner plates and into the respective communication openings the intermediate plates of the two reservoir tanks used. The entire outer peripheral surfaces of opposite end portions the heat exchange tubes are with the respective entire peripheral wall surfaces of the tube insertion holes the inner plates of the two reservoir tanks soldered.

At least an outward corrugated Area of each sump tank serves as one as outward corrugated Area formed refrigerant flow channel, in which the refrigerant in its longitudinal direction flows. In each sump tank are the communication openings the intermediate plate, which with the as the refrigerant flow section, the one through the outside domed Area is formed by communication areas, which in the Intermediate plate are formed, connected.

In the heat exchanger described in the publication is the outer plate, which is a relatively large one Thickness has, produced by a pressing process, to increase the pressure resistance of each sump tank.

ZUSAMMENFASUNG THE INVENTION

A The object of the present invention is to solve the above problem to solve and a heat exchanger, which has a reduced weight and its sump tank has sufficient pressure resistance, and a method of manufacturing an outer panel, which for Collecting tanks a heat exchanger is used to indicate.

• 1) Ein Wärmetauscher mit einem Paar von Sammelbehälter-Tanks, die beabstandet voneinander angeordnet sind, und einer Mehrzahl von flachen Wärmetauschrohren, die parallel zwischen den beiden Sammelbehälter-Tanks angeordnet sind und gegenüberliegende Endbereiche haben, welche mit den jeweiligen Sammelbehälter-Tanks verbunden sind, wobei jeder der beiden Sammelbehälter-Tanks so konfiguriert ist, dass eine Außenplatte, eine Innenplatte und eine Zwischenplatte, welche zwischen der Außenplatte und der Innenplatte liegt, in Schichten zusammengelötet sind, wobei die Außenplatte einen nach außen gewölbten Bereich aufweist, der sich in ihrer Längsrichtung erstreckt und der eine Öffnung aufweist, die von der Zwischenplatte verschlossen ist, wobei die Innenplatte eine Mehrzahl von Rohreinsetzöffnungen in der Form von Durchgangsöffnungen aufweist, welche in einem Bereich, der mit dem nach außen gewölbten Bereich der Außenplatte korrespondiert, und beabstandet voneinander in ihrer Längsrichtung ausgebildet sind, und wobei die Zwischenplatte eine Mehrzahl von Kommunikationsöffnungen in der Form von Durchgangsöffnungen aufweist, welche ausgebildet sind, um den jeweiligen Rohreinsetzöffnungen der Innenplatte zu erlauben, mit dem Inneren des nach außen gewölbten Bereiches der Außenplatte zu kommunizieren, wobei die Außenplatte von jedem Sammelbehälter-Tank aus einer Metallplatte und durch einen an dieser durchgeführten Pressvorgang gebildet ist und ein Verbindungsbereich zwischen einer Innenwandfläche des nach außen gewölbten Bereiches der Außenplatte und einer Fläche der Außenplatte, welche mit der Zwischenplatte verbunden ist, einen Krümmungsradius von 1 mm oder weniger besitzt.
• 2) Ein Wärmetauscher nach Abschnitt 1), worin der Verbindungsbereich zwischen der Innenwandfläche des nach außen gewölbten Bereichs und der Fläche der Außenplatte, welche mit der Zwischenplatte verbunden ist, einen Krümmungsradius von 0,5 mm oder weniger besitzt.
• 3) Ein Wärmetauscher nach Abschnitt 1), worin die Außenplatte eine Dicke von 2 mm oder mehr aufweist.
• 4) Ein Verfahren zur Herstellung einer Außenplatte, welche für einen Sammelbehälter-Tank eines Wärmetauschers verwendbar ist, der so konfiguriert ist, dass eine Außen platte eine Innenplatte und eine Zwischenplatte, welche zwischen der Außenplatte und der Innenplatte liegt, in Lagen zusammengelötet sind, die Außenplatte einen nach außen gewölbten Bereich hat, der sich in eine Längsrichtung von ihr erstreckt und eine Öffnung besitzt, welche durch die Zwischenplatte verschlossen ist, die Innenplatte eine Mehrzahl von Rohreinsetzöffnungen in der Form von Durchgangsöffnungen aufweist, welche in einem Bereich, der mit dem nach außen gewölbten Bereich der Außenplatte korrespondiert, und beabstandet voneinander in ihrer Längsrichtung ausgebildet sind, und wobei die Zwischenplatte eine Mehrzahl von Kommunikationsöffnungen in der Form von Durchgangsöffnungen aufweist, welche ausgebildet sind, um den jeweiligen Rohreinsetzöffnungen der Innenplatte zu erlauben, mit dem Inneren des nach außen gewölbten Bereiches der Außenplatte zu kommunizieren, wobei das Verfahren die Schritte aufweist: Ausbildung eines dicken Bereiches an einer die Außenplatte bildenden Metallplatte an einem Mittelbereich in Bezug auf die Breitenrichtung von dieser, wobei der dicke Bereich dicker als der verbleibende dünne Bereich ist; und Durchführung eines Pressvorgangs an der die Außenplatte bildenden Metallplatte, um den nach außen gewölbten Bereich unter Verwendung des dicken Bereichs so auszubilden, dass ein Verbindungsbereich, der einen Krümmungsradius von 1 mm oder weniger hat, zwischen einer Innenwandfläche des nach außen gewölbten Bereichs und jeder der Flächen der Außenplatte, welche an den gegenüberliegenden Seiten des nach außen gewölbten Bereichs liegen und in die innere Wandfläche übergehen, auszubilden.
• 5) Ein Verfahren zur Herstellung einer Außenplatte, welche für einen Sammelbehälter-Tank eines Wärmetauschers verwendet wird, nach Abschnitt 1), worin der dicke Bereich gebildet wird, in dem ein Pressvorgang an der die Außenplatte bildenden Metallplatte durchgeführt wird.
• 6) Ein Verfahren zur Herstellung einer Außenplatte, welche für einen Sammelbehälter-Tank eines Wärmetauschers verwendet wird, nach Abschnitt 5), worin der dicke Bereich der die Außenplatte bildenden Metallplatte einen Dicke hat, die das 1,05 bis 1,5-fache von der des verbleibenden dünnen Bereichs beträgt.
• 7) Ein Verfahren zur Herstellung einer Außenplatte, welche für einen Sammelbehälter-Tank eines Wärmetauschers verwendet wird, nach Abschnitt 4), worin ein Verbindungsbereich, welcher einen Krümmungsradius von 0,5 mm oder weniger hat, zwischen der Innenwandfläche des nach außen gewölbten Bereichs und jeder der Flächen der Außenplatte, welche an den gegenüberliegenden Seiten des nach außen gewölbten Bereiches liegen und in die Innenwandfläche übergehen, gebildet wird.
• 8) Ein Verfahren zur Herstellung einer Außenplatte, welche für einen Sammelbehälter-Tank eines Wärmetauschers verwendet wird, nach Abschnitt 4), worin die Außenplatte eine Dicke von 2 mm oder mehr in ihrer Endform hat.
• 9) Ein Verfahren zur Herstellung einer Außenplatte, welche für einen Sammelbehälter-Tank eines Wärmetauschers verwendet wird, welcher so konfiguriert ist, dass eine Außenplatte, eine Innenplatte und eine Zwischenplatte, welche zwischen der Außen- und der Innenplatte liegt, miteinander in Lagen verlötet sind, wobei die Innenplatte einen nach außen gewölbten Bereich aufweist, der sich in ihrer Längsrichtung erstreckt und eine Öffnung aufweist, die von der Zwischenplatte verschlossen ist, wobei die Innenplatte eine Mehrzahl von Rohreinsetzöffnungen in der Form von Durchgangsöffnungen aufweist, welche in einem Bereich, der mit dem nach außen gewölbten Bereich der Außenplatte korrespondiert, und beabstandet voneinander in ihrer Längsrichtung ausgebildet sind, und wobei die Zwischenplatte eine Mehrzahl von Kommunikationsöffnungen in der Form von Durchgangsöffnungen aufweist, welche ausgebildet sind, um den jeweiligen Rohreinsetzöffnungen der Innenplatte zu erlauben, mit dem Inneren des nach außen gewölbten Bereiches der Außenplatte zu kommunizieren, wobei das Verfahren die Schritte: ein erster Pressvorgang wird an einer die Außenplatte bildenden Metallplatte durchgeführt, um einen vorläufigen gewölbten Bereich zu bilden, welcher eine Wölbungshöhe hat, die größer als die des nach außen gewölbten Bereichs ist; und ein zweiter Pressvorgang wird an der die Außenplatte bildenden Metallplatte, welche den vorläufigen gewölbten Bereich besitzt, durchgeführt, wobei die die Außenplatte bildenden Metallplatte von den gegenüberliegenden Seiten in Bezug auf die Breitenrichtung von ihr zurückgehalten wird, um den nach außen gewölbten Bereich aus dem vorläufigen gewölbten Bereich zu bilden, so dass ein Verbindungsbereich, welcher einen Krümmungsradius von 1 mm oder weniger hat, zwischen einer Innenwandfläche des nach außen gewölbten Bereiches und jeder der Flächen der Außenplatte, welche an den gegenüberliegenden Seiten des nach außen gewölbten Bereiches liegen und in die Innenwandfläche übergehen, gebildet wird.
• 10) Ein Verfahren zur Herstellung einer Außenplatte, welche für einen Sammelbehälter-Tank eines Wärmetauschers verwendet wird, nach Abschnitt 9), worin der Schritt der Durchführung des zweiten Pressvorgangs umfasst, dass gegenüberliegende Seitenkantenbereiche der die Außenplatte bildenden Metallplatte unter Verwendung von einem Werkzeug, welches für den Pressvorgang verwendet wird, vor der Bildung des nach außen gewölbten Bereichs aus dem vorläufigen gewölbten Bereich abgeschnitten werden und die die Außenplatte bildende Metallplatte mit dem vorläufigen gewölbten Bereich von gegenüberliegenden Seiten in Bezug auf die Breitenrichtung von ihr unter Verwendung des Werkzeugs zurückgehalten wird.
• 11) Ein Verfahren zur Herstellung einer Außenplatte, welche für einen Sammelbehälter-Tank eines Wärmetauschers verwendet wird, nach Abschnitt 9), worin der Verbindungsbereich, welcher einen Krümmungsradius von 0,5 mm oder weniger besitzt, zwischen der Innenwandfläche des nach außen gewölbten Bereiches und jeder der Flächen der Außenplatte, welche an gegenüberliegenden Seiten des nach außen gewölbten Bereichs liegen und in die Innenwandfläche übergehen, gebildet wird.
• 12) Ein Verfahren zur Herstellung einer Außenplatte, welche für einen Sammelbehälter-Tank eines Wärmetauschers verwendet wird, nach Abschnitt 9), worin die Außenplatte eine Dicke von 2 mm oder mehr in ihrer Endform hat.

In order to achieve the above object, the present invention includes the following modes.

• 1) A heat exchanger having a pair of header tanks spaced from each other and a plurality of flat heat exchange tubes arranged in parallel between the two header tanks and having opposite end portions connected to the respective header tanks; wherein each of the two header tanks is configured to have an outer panel, an inner panel, and an intermediate panel disposed between the outer panel and the outer panel Inner plate is soldered together in layers, wherein the outer plate has an outwardly curved portion which extends in its longitudinal direction and having an opening which is closed by the intermediate plate, wherein the inner plate has a plurality of tube insertion holes in the form of through holes which is formed in a region corresponding to the convex portion of the outer plate and spaced from each other in the longitudinal direction thereof, and wherein the intermediate plate has a plurality of communication holes in the form of through holes formed to surround the respective tube insertion holes Inner plate to allow to communicate with the interior of the outwardly curved portion of the outer plate, wherein the outer plate of each reservoir tank is formed of a metal plate and by a pressing operation performed on this and a connection area zw An inner wall surface of the convex portion of the outer plate and a surface of the outer plate connected to the intermediate plate have a radius of curvature of 1 mm or less.
• 2) A heat exchanger according to the item 1), wherein the connecting portion between the inner wall surface of the convex portion and the surface of the outer plate connected to the intermediate plate has a radius of curvature of 0.5 mm or less.
• 3) A heat exchanger according to section 1), wherein the outer plate has a thickness of 2 mm or more.
• 4) A method for producing an outer panel usable for a header tank of a heat exchanger configured such that an outer panel is an inner panel and an intermediate plate which is sandwiched between the outer panel and the inner panel are soldered together in layers Outer plate has an outwardly curved portion which extends in a longitudinal direction thereof and has an opening which is closed by the intermediate plate, the inner plate having a plurality of tube insertion openings in the form of through holes, which in a region which with the outer arcuate portion of the outer plate corresponds, and spaced from each other in their longitudinal direction, and wherein the intermediate plate has a plurality of communication openings in the form of through holes, which are formed to allow the respective tube insertion openings of the inner plate, with the interior n of the outwardly curved portion of the outer panel, the method comprising the steps of: forming a thick portion on a metal plate forming the outer panel at a central portion with respect to the width direction thereof, the thick portion being thicker than the remaining thin portion ; and performing a pressing operation on the metal plate forming the outer plate so as to form the convex portion using the thick portion so that a connection portion having a radius of curvature of 1 mm or less between an inner wall surface of the convex portion and each of Form surfaces of the outer plate, which lie on the opposite sides of the outwardly curved portion and pass into the inner wall surface form.
• 5) A method of manufacturing an outer plate used for a header tank of a heat exchanger according to the item 1), wherein the thick portion is formed by performing a pressing operation on the metal plate forming the outer plate.
• 6) A method of manufacturing an outer plate used for a header tank of a heat exchanger according to item 5), wherein the thick portion of the outer plate forming metal plate has a thickness of 1.05 to 1.5 times that of the remaining thin area.
• 7) A method of manufacturing an outer plate used for a header tank of a heat exchanger, according to section 4), wherein a connection portion having a radius of curvature of 0.5 mm or less is interposed between the inner wall surface of the convex portion and Each of the surfaces of the outer plate, which lie on the opposite sides of the outwardly curved portion and merge into the inner wall surface is formed.
• 8) A method of manufacturing an outer panel used for a header tank of a heat exchanger according to Section 4), wherein the outer panel has a thickness of 2 mm or more in its final shape.
• 9) A method of manufacturing an outer panel used for a header tank of a heat exchanger configured such that an outer panel, an inner panel, and an intermediate panel interposed between the outer and inner panels are brazed together in layers wherein the inner plate has an outwardly curved portion extending in the longitudinal direction thereof and having an opening closed by the intermediate plate, the inner plate having a plurality of tube insertion holes in the form of through holes formed in a portion thereof the convex portion of the outer panel corresponds, and spaced from each other in its longitudinal direction formed and wherein the intermediate plate has a plurality of communication holes in the form of through holes formed to allow the respective tube insertion holes of the inner plate to communicate with the inside of the outwardly curved portion of the outer plate, the method comprising the steps of: a first pressing operation is performed on a metal plate forming the outer plate to form a preliminary curved portion having a bulge height larger than that of the bulged portion; and a second pressing operation is performed on the metal plate forming the outer plate having the preliminary curved portion, wherein the metal plate forming the outer plate is restrained therefrom from the opposite sides with respect to the width direction thereof from the outwardly curved portion from the preliminary one to form a curved portion such that a joint portion having a radius of curvature of 1 mm or less between an inner wall surface of the outwardly curved portion and each of the surfaces of the outer plate which lie on the opposite sides of the outwardly curved portion and into the inner wall surface to pass over is formed.
• 10) A method of manufacturing an outer plate used for a header tank of a heat exchanger according to par. 9), wherein the step of performing the second pressing operation includes opposing side edge portions of the metal plate forming the outer plate using a tool is used for the pressing operation, cut off from the provisional arched portion before the formation of the convex portion, and the metal plate forming the outer plate with the provisional arcuate portion is restrained from opposite sides with respect to the width direction thereof using the tool.
• 11) A method of manufacturing an outer plate used for a header tank of a heat exchanger according to the item 9), wherein the joint portion having a radius of curvature of 0.5 mm or less is interposed between the inner wall surface of the convex portion and Each of the surfaces of the outer plate, which lie on opposite sides of the outwardly curved portion and merge into the inner wall surface is formed.
• 12) A method of manufacturing an outer panel used for a header tank of a heat exchanger according to Section 9), wherein the outer panel has a thickness of 2 mm or more in its final form.

at the heat exchanger from section 1) is the outer panel from each sump tank a metal plate and by a pressing process, which at this accomplished is formed, and a connecting portion between an inner wall surface of outward domed Area and a surface the outer panel, which is connected to the intermediate plate, has a radius of curvature of 1 mm or less. Therefore, the stress concentration becomes the connecting portion between the inner wall surface of the convex portion and the area the outer panel, which is connected to the intermediate plate, mitigated, and thus elevated the pressure resistance of the sump tank. Since the pressure resistance by the mitigation of the stress concentration at the connection area between the inner wall surface of the outside domed Area and the area the outer panel, which is connected to the intermediate plate is increased, the thickness of the outer plate compared with the heat exchanger, which is disclosed in the above-mentioned publication become. Accordingly, the weight of the sump tanks and thus the weight of the entire heat exchanger, which the sump tanks used to be reduced.

at the heat exchanger of section 2) has the connection area between the inner wall surface of outward domed Area and the area the outer panel, which is connected to the intermediate plate, a radius of curvature of 0.5 mm or less. Therefore, the stress concentration on the Connecting portion between the inner wall surface of the convex portion and the area the outer panel, which is connected to the intermediate plate, even more effectively mitigated, and thus increased The pressure resistance of the sump tanks even more.

There at the heat exchanger from section 3) the outer panel has a thickness of 2 mm or more, the pressure resistance increases the sump tanks.

In the method of manufacturing an outer plate of section 4), a thick portion is formed on the metal plate forming the outer plate at a central portion with respect to the width direction thereof, the thick portion being thicker than the remaining thin portion, and then a pressing operation is performed on the The outer plate-forming metal plate is made to form the outwardly curved portion using the thick portion. Therefore, the material of the thick portion flows through the pressing tools, whereby a joint portion having a radius of curvature of 1 mm or less between the inner wall surface of the convex portion and each of the surfaces Chen the outer plate, which lie on opposite sides of the outwardly curved portion and pass into the inner wall surface, can be formed. Accordingly, a heat exchanger sump tank using the outer panel manufactured by this method has an increased pressure resistance. As a result, the thickness of the outer panel can be reduced as compared with the heat exchanger disclosed in the above-described publication, and the weight of the sump tanks and hence the weight of the entire heat exchanger using the sump tanks can be reduced ,

In addition, this allows Method of section 4) the use of a high strength aluminum material, on which an extrusion process can not be performed. This also increases the pressure resistance of the heat exchanger sump tank, which uses the outer panel used.

at the method of making an outer panel of section 5) may be the thick area on the outer plate forming metal plate be made relatively easy.

According to the procedure for producing an outer panel from section 6) has the thick area of the outer panel forming metal plate has a thickness which is 1.05 to 1.5 times that of the remaining thin Range is. Therefore, the flow occurs of the material from the thick area by the pressing tools without Mistake on, leaving the the outer panel forming metal plate can be formed into a target shape and Thus, a connection area, which has a radius of curvature of 1 mm or has less, between the inner wall surface of the outwardly arched area and each of the surfaces the outer panel, which on opposite Sides of the outside domed Area lie and pass into the inner wall surface, can be formed.

According to the procedure for producing an outer panel of section 7) becomes a connection area which has a radius of curvature of 0.5 mm or less, between the inner wall surface of the outward domed Area and each of the areas the outer panel, which on the opposite Sides of the outside domed Range and into the inner wall surface, formed. In one Heat exchanger header tank tank, which is the outer plate made by this method verwen det, the stress concentration at the connection area between the inner wall surface of the outside domed Area and the area the outer panel, which is connected to the intermediate plate, more effectively mitigated be, and thus increased The pressure resistance of the sump tank even more.

In in the case where the outer panel to be produced has a thickness of 2 mm or more in its final form, as in the method for Production of an outer panel of section 8) is the transformation into the final shape difficult by pressing, and when pressing the outer plate forming metal plate without the formation of the above thick area performed can, a connection area with a large radius of curvature, for example, 3 mm or more between the inner wall surface of the convex portion and each of the surfaces the outer panel, which on the opposite Sides of the outside domed Are area and go into the inner wall surface, be formed. In a heat exchanger sump tank, one such outer plate used, stresses concentrate on the soldered areas between the intermediate plate and areas of the outer plate, which at the front and rear sides of the outside domed Range, causing the pressure resistance of the heat exchanger reservoir tank can lose weight.

Even in such a case, according to the method of section 4) the radius of curvature the connecting portion between the inner wall surface of the convex portion and each of the surfaces the outer panel, which on the opposite Sides of the outside domed Range and go into the inner wall surface, 1 mm or less be made. Correspondingly Stress concentrations at the soldered areas between the Intermediate plate and areas of the outer plate, which at the front and rear sides of the outside domed Range, be mitigated.

In the method of manufacturing an outer plate of section 9), a first pressing operation is performed on the metal plate forming the outer plate to form a preliminary outwardly curved portion having a bulge height larger than that of the bulged portion, and then, a second pressing operation is performed on the metal plate forming the outer plate having the preliminary curved portion, with the metal plate forming the outer plate being retained therefrom from the opposite sides with respect to the width direction thereof. Therefore, the convex portion can be formed from the preliminary curved portion, and the radius of curvature of the connecting portion between the inner wall surface of the convex portion and each of the surfaces of the outer plate which are on the opposite sides of the convex portion and pass into the Innenwandflä surface, can be made 1 mm or smaller. Accordingly, a heat exchanger sump tank using the outer panel made by this method has increased pressure resistance. As a result, the thickness of the outer panel can be reduced as compared with the heat exchanger disclosed in the above-described publication, and the weight of the sump tanks and hence the weight of the entire heat exchanger using the sump tanks can be reduced ,

In addition, this allows Method of section 9) the use of a high strength aluminum material, where an extrusion process can not be performed. This also increases the pressure resistance of the sump tank, which produced the outer panel used.

According to the procedure for producing an outer panel of section 10) when the second pressing operation is performed, Side edge area of the outer panel forming metal plate using a tool, which for the pressing process is used, prior to the formation of the outwardly arched area from the temporary arched area the outer plate is cut off forming metal plate with the temporary arched area from opposite sides in terms of the width direction of her using the tool retained. Therefore, the outer plate forming Metal plate from the opposite Pages withheld without error become.

According to the procedure for producing an outer panel from section 11) becomes one in the connection area, which one radius of curvature of 0.5 mm or less, between the inner wall surface of the outward domed Area and every area the outer panel, which on opposite Sides of the outside arched area lie and go into the inner surface formed. In a heat exchanger sump tank, which is the outer plate made by this method used, can Stress concentrations at the connection area between the Inner wall surface of the outside domed Area and the area the outer panel, which is connected to the intermediate plate, more effectively mitigated be, and thus increased The pressure resistance of the sump tank even more.

In in the case where the outer panel to be produced has a thickness of 2 mm or more in its final form, as in the method for Production of an outer panel of section 12) is the transformation into the final shape difficult by pressing, and when pressing one the outer plate forming metal plate without the formation of the above-described preliminary curved portion carried out can be, a connection area with a large radius of curvature of, for example 3 mm or more between the inner wall surface of the outwardly arched area and each of the surfaces the outer panel, which on the opposite Sides of the outside domed Are area and go into the inner wall surface, be formed. In a heat exchanger sump tank, which is such an outer panel used, stresses concentrate on the soldered areas between the intermediate plate and areas of the outer plate, which at the front and rear sides of the outside domed Range, causing the pressure resistance of the heat exchanger reservoir tank can lose weight.

Even in such a case, however, in accordance with the procedure of Section 9) the radius of curvature the connecting plate between the inner wall surface of the convex portion and each of the surfaces the outer panel, which on the opposite Sides of the outside domed Range and go into the inner wall surface, 1 mm or smaller be made. Correspondingly the stress concentrations at the soldered areas between the Intermediate plate and areas of the outer plate, which at the front and rear sides of the convex portion lie, be mitigated.

SHORT DESCRIPTION OF THE DRAWINGS

1 is a perspective view showing the overall construction of a gas cooler, in which the heat exchanger is used according to the present invention;

2 is a fragmentary view in vertical section, the gas cooler of 1 shows when seen from the back to the front;

3 FIG. 11 is an exploded perspective view illustrating a first header tank of the gas cooler of FIG 1 shows;

4 is an enlarged view in section along the line AA of 2 ;

5 is an enlarged view in section along the line BB of 2 ;

6 is an enlarged view in section along the line CC of 5 ;

7 is a set of views showing a method of manufacturing the outer plate of the first header tank of the gas cooler of 1 shows;

8th FIG. 11 is an exploded perspective view illustrating a method of manufacturing the first header tank of the gas cooler of FIG 1 demonstrate;

9 FIG. 11 is an exploded perspective view illustrating a method of manufacturing a second header tank of the gas cooler of FIG 1 shows;

10 is a cross-sectional view showing a heat exchange tube of the gas cooler of 1 shows,

11 is a fragmentary enlarged view of the 10 ;

12 is a set of views illustrating a method of manufacturing the heat exchanger used in the 10 is shown, shows and

13 is a view showing a method of making the in the 9 shown heat exchange tube shows.

DESCRIPTION THE PREFERRED EMBODIMENT

When next Become embodiments of the Present invention described in detail with reference to the drawings become. These embodiments be implemented by a heat exchanger according to the present Invention of a gas cooler a supercritical Refrigeration circuit used becomes.

In the following description, the upper, lower, left and right sides of the 1 and 2 respectively labeled "top", "bottom", "left" and "right". Furthermore, in the following description, the term "aluminum" in addition to pure aluminum and aluminum alloys.

The 1 and 2 show the overall construction of a gas cooler in which the heat exchanger according to the present invention is used. The 3 and 6 show the configuration of essential areas of the gas cooler the 1 , The 7 and 8th show a method of manufacturing the sump tanks. The 10 and 11 show a heat exchange tube. The 12 shows a method of manufacturing the heat exchange tube.

With reference to the 1 includes a gas cooler 1 a supercritical refrigeration cycle in which a supercritical refrigerant such as CO ₂ is used, two sump tanks 2 and 3 which extend vertically and are spaced from each other in the left-right direction, a plurality of flat heat exchange tubes 4 parallel between the two sump tanks 2 and 3 and spaced from each other in the vertical direction, corrugated fins 5 , which in respective air passage gaps between adjacent heat exchange tubes 4 and on the outside of the heat exchange tubes 4 arranged at the upper and lower ends and in each case with the adjacent heat exchange tubes 4 or the heat exchange tubes 4 soldered at the upper or lower ends, and side plates 6 made of aluminum, which is outside the respective corrugated ribs 5 the upper and lower ends are arranged and soldered to them. In the case of this embodiment, the sump tank becomes 2 on the right as the "first sump tank" and the sump tank 3 on the left side referred to as "second sump tank".

Like this in the 2 to 6 is shown, is the first reservoir tank 2 configured to have an outer panel 7 , an inner plate 8th and an intermediate plate 9 which is between the outer panel 7 and the inner plate 8th lies, are soldered together in layers. The outer plate 7 and the inner plate 8th are each made of a brazing sheet, which has a Lötmaterialschicht on its opposite sides, here an aluminum brazing sheet. The intermediate plate 9 is made of a bright metal material, here a bare aluminum material.

The outer plate 7 has a plurality of, here two, domed outwardly curved areas 11A and 11B which are spaced from each other in the vertical direction. The outward curved areas 11A and 11B extend vertically and have the same camber height, length and width. At the outer plate 7 is a peripheral area around a leftward opening of each of the convex portions 11A and 11B with the intermediate plate 9 soldered, creating the intermediate plate 9 the left-facing openings of the outwardly arched areas 11A and 11B covered. As a result, the interior of each of the outwardly curved portions serves 11A and 11B as a refrigerant flow portion whose upper and lower ends are closed. These areas of the first collection tank 2 , which with the respective outwardly arched areas 11A and 11B correspond, serve as respective collection container sections. The radius of curvature R of a connection area 26 the inner wall surface between each outwardly arched area 11A and 11B and each of the inner surfaces of the outer panel 7 , which at the front and rear sides of the outwardly arched area 11A and 11B in front are not larger than 1 mm, preferably not larger than 0.5 mm (see FIGS 5 and 6 ). The outer plate 7 has a thickness of 2 mm or more.

A refrigerant inlet 12 is in a summit area of the upper outwardly arched area 11A the outer panel 7 educated. An inlet element 13 made of metal, here a bare aluminum material, a Kühlmitte inflow 14 in communication with the refrigerant inlet 12 is with the outer surface of the convex portion 11A using the solder material on the outer surface of the outer plate 7 soldered. A refrigerant outlet 15 is in a summit area of the lower outwardly arched area 11B educated. An outlet element 16 made of metal, here a bare aluminum material, which has a refrigerant outflow channel 17 in communication with the refrigerant outlet 15 is with the outer surface of the convex portion 11B using the solder material on the outer surface of the outer plate 7 soldered. The outer plate 7 is made by pressing from an aluminum brazing sheet having a brazing material layer on its opposite sides.

A plurality of tube insertion holes 18 which are elongated in the front-rear direction are through the inner plate 8th trained and vertically spaced from each other. An upper half group of pipe insertion openings 18 are within a vertical range, which with the upper outward arched area 11A the outer panel 7 corresponds, trained. Similarly, a subset of the tube insertion holes 18 within a vertical area, which coincides with the lower outwardly arched area 11B corresponds, trained. The pipe insertion openings 18 have a front-to-back length that's slightly longer than the front-to-back width of the outward-arched areas 11A and 11B is so that the front and rear end portions of the tube insertion openings 18 each outwardly beyond the front and rear ends of the outwardly arched areas 11A and 11B protrude. The front and rear edge portions of the inner plate 8th each have integral Abdeckwandungen 19 on. The cover walls 19 protrude to the right so that their ends the outer surface of the outer plate Oberflä 7 reach and the respective border areas between the outer panel 7 and the intermediate plate 9 cover along the total length of the border areas. The cover walls 19 are each with the front and rear side surfaces of the outer panel 7 and the intermediate plate 9 soldered. The projecting end of each of the cover walls 19 has a plurality of integrally formed engaging portions 21 which are vertically spaced from each other. The intervention areas 21 the Abdeckwandungen 19 stand with the outer surface of the outer panel 7 engaged and soldered to this.

The intermediate plate 9 has communication openings 22 in the form of through holes, around the tube insertion holes 18 the inner plate 8th to allow with the interior of the outward arched areas 11A and 11B they are equal in number to the number of tube insertion holes 18 , The communication openings 22 fall with respect to the position with the respective tube insertion openings 18 the inner plate 8th together and have the same width as the tube insertion holes 18 , The intermediate plate 9 has stepped areas 25 , which on the peripheral wall surface of each communication opening 22 the intermediate plate 9 are formed on opposite portions thereof with respect to the opening direction (front and rear end portions) so that the stepped portions 25 at an intermediate position with respect to the thickness direction of the intermediate plate 9 are arranged. The stepped areas 25 stand in Be zug on the opening longitudinal direction of the connection opening 22 inside. A corresponding end surface of the corresponding heat exchanger tube 4 stands with the stepped areas 25 engaged. The projection height of the stepped area 25 the intermediate plate from the peripheral wall surface of the communication opening 22 is determined so that they are the refrigerant channels 4a , which will be described later, of the heat exchanger tube 4 does not cover.

An upper half group of pipe insertion holes 18 the inner plate 8th communicates with the interior of the upper outwardly arched area 11A via an upper half group of the respective communication openings 22 the intermediate plate 9 , Likewise, a subgroup communicates the tube insertion holes 18 with the interior of the lower outwardly arched area 11B via a subgroup of the respective communication openings of the intermediate plate 9 , All communication ports 22 which align with the interior of the upper outward arched area 11A communicate with each other via communication areas 23 , and all communication ports 22 which arched with the interior of the lower outward 11B communicate with each other via other communication areas 23 , The communication areas 23 by cutting off areas between the adjacent communication openings 22 in the intermediate plate 9 educated. Therefore, the intermediate plate 9 a refrigerant flow portion communicating with the refrigerant flow portion within the convex portion 11B communicates, on.

The second sump tank 3 has substantially the same construction as the first header tank 2 and like features and parts are designated by like reference numerals. The two sump tanks 2 and 3 are arranged so that the respective inner plates 8th opposite each other. The second sump tank 3 is different from the first sump tank 2 in that the outer plate 7 dome-shaped outwardly curved portions provided in a number one smaller than that of the outwardly curved portions 11A and 11B of the first sump tank 2 is, and here a single domed outward arched area 24 which extends from an upper end portion to a lower end portion of the outer plate 7 extends and the outwardly arched areas 11A and 11B of the first sump tank 2 opposite; and that the outwardly arched area 24 has no refrigerant inlet and no refrigerant outlet; that all tube insertion holes 18 the inner plate 8th with the interior of the outwardly arched area 24 over all respective communication openings 22 the intermediate plate 9 communicate; and that all communication ports 22 the intermediate plate 9 about the communication areas 23 which is achieved by cutting off areas between adjacent communication openings 22 are trained to communicate with each other. The outwardly arched area 24 has the same curvature height and width as the outwardly arched areas 11A and 11B of the first sump tank 2 , At the outer plate 7 is a peripheral area which is a rightward opening of the outwardly arched area 24 lies around with the intermediate plate 9 soldered, creating the intermediate plate 9 the rightward opening of the outwardly arched area 24 covered. As a result, the interior of the convex portion serves 24 as a refrigerant flow portion whose upper and lower ends are closed. An area of the second sump tank 3 , which with the outwardly arched area 24 corresponds, serves as a sump portion. The thickness of the outer panel 7 is 2 mm or larger. All communication ports 22 and the communication areas 23 the intermediate plate 9 form a refrigerant flow section which communicates with the interior of the outwardly curved region 24 communicated. Also in the second header tank, the radius of curvature R of a joint area 26 between the inner wall surface of the convex portion 24 and each of the inner surfaces of the outer panel 7 , which at the front and rear sides of the outwardly arched area 24 are provided and which extend in the left-right direction, not greater than 1 mm and preferably not greater than 0.5 mm. The two sump tanks 2 and 3 be like in the 7 to 9 shown produced.

First, a metal plate forming the outer plate 16 which consists of an aluminum brazing sheet having a layer of brazing material on each opposite side, subjected to a pressing operation, to the outer plate 7 which the outwardly arched areas 11A and 11B or the outwardly arched area 24 to produce, as in 7 is shown. More specifically, a first pressing operation is performed on the metal plate forming the outer plate 60 performed as in the 7 (a) is shown by a first upper tool 61 which is a depression forming a thick area 62 on its underside, and a lower tool 63 which has a pair of side edges retaining projections 64 Having on its top, is used, creating a thicker area 65 is formed at a central portion with respect to the width direction, the thick portion having a thickness larger than that of the thin portions at the opposite sides of the thick portion (see 7 (b) , Preferably, the thickness of the thick area 65 1.05 to 1.5 times the thickness of the thin areas. If the thickness of the thick area 65 less than 1.05 times the thickness of the thin areas, it becomes difficult to join 26 so as to obtain a radius of curvature R of 1 mm or less in a second pressing operation which will be described later. Furthermore, it is difficult to press the thick area 65 be formed so that it receives a thickness of more than 1.5 times the thickness of the thin NEN areas. In the example shown, the thick area becomes 65 produced in the first pressing operation in such a manner that a central portion of the metal plate forming the outer plate 60 bulges upwards in relation to the width direction. The process for producing the thick area 65 is not limited to this, however, and the thick area 65 can be made by the central portion of the metal plate forming the outer plate 65 bulged outward or the central portion of the outer plate forming metal plate 65 is bulged up and down.

Subsequently, a second pressing on the outer plate forming metal plate 60 with the thick area 65 using a second upper tool 66 and a second lower tool 68 carried out. The second upper tool 66 has a concave area at the bottom 67 to the outer shape of an outwardly arched area 11A ( 11B . 24 ) to build. The second lower tool 68 has a convex area at the top 69 to the inner shape of the outwardly arched area 11A ( 11B . 24 ), and a pair of projections retaining the side edges 70 , So is the ge outward arched area 11A ( 11B . 24 ) using the thick area 65 trained (see 7 (c) ). In this case, aluminum material flows from the metal plate forming the outer plate 60 through the space, which is between the concave area 67 of the second upper tool 66 and the convex area 69 of the second lower tool 68 is formed. Thus, the radius of curvature R of the connection area 26 between the inner wall surface of the convex portion 11A ( 11B . 24 ) and the undersides of the outer panel 7 , which at the front and rear sides of the outwardly arched area 11A ( 11B . 24 ) and continuously with the inner wall surface are made to be 1 mm or smaller. In this way, the outer panel 7 produced. It should be noted that the refrigerant inlet 12 and the refrigerant outlet 12 in the outer panel 7 for the first sump tank 2 be formed.

In addition, an aluminum brazing sheet having a brazing material layer on each of its opposite sides is press-pressed around the inner plates 8th , respectively, the tube insertion openings 18 , the cover walls 19 and an engagement area forming noses 21A , which are just from the Abdeckwandung 19 extend, have, manufacture. Furthermore, a bright aluminum material is subjected to a pressing operation to the intermediate plates 9 produce, which in each case the communication openings 22 , the step areas 25 and the communication areas 23 exhibit.

Next, as in the 8th and 9 shown is the three plates 7 . 8th and 9 stacked on each other, the noses 21A so bent that they are the engaging areas 21 form, which engage with the outer panel 7 Come men, whereby a provisional arrangement is formed. Subsequently, the provisional assemblies are heated at a predetermined temperature, thereby using the outer layer of solder material 7 and the solder layers of the inner plate 8th the three plates 7 . 8th and 9 be soldered together, the Abdeckwandungen 19 and the front and rear end surfaces of the intermediate plate 9 and the outer panel 7 be soldered together, the above areas 26 and the respective inclined areas 27 be soldered together, and the engagement areas 21 and the outer plate 7 be soldered together. This will be the two sump tanks 2 and 3 produced.

As it is in the 10 and 11 is shown includes the heat exchange tube 4 opposing flat upper and lower walls 31 and 32 (a pair of flat walls), front and back sidewalls 33 and 34 , which respectively extend over the front and rear side ends of the upper and lower walls 31 and 32 extend, and a plurality of reinforcing walls 35 , which at fixed intervals between the front and rear side walls 33 and 34 be deployed and along and between the upper and lower walls 31 and 32 extend. Due to this structure, the heat exchange tube 4 inside a plurality of refrigerant channels 4a on, which are arranged in the width direction.

The front side wall 33 has a double wall structure and includes an elongated projection forming an outer side wall 36 which is integral with the front end of the upper wall 31 is formed in a downward-flattened state and extends along the entire height of the heat exchange tube 4 extends, an elongated projection forming an inner side wall 37 which is on the inside of the outer side wall forming projection 36 arranged and integral with the upper wall 31 is formed in a downwardly pursed state, and an inner side wall forming an elongate projection 38 , which is integral with the front end of the lower wall 32 is formed in an upwardly protected state. The outer side wall forming elongated projection 36 is with the two inner side wall forming elongated projections 37 and 38 and the bottom wall 32 while its lower end portion is engaged with a front side edge portion of the lower surface of the lower wall 32 stands. The two inner side wall forming elongated projections 37 and 38 are soldered together as they clash. The rear side wall 34 is integral with the upper and lower walls 31 and 32 educated. A lead 38a is integrally formed in the head end surface of the inner sidewall forming portion 38 the lower wall 32 formed and extends in the longitudinal direction of the inner side wall forming projection 38 along its entire length. A deepening 37a is at the head end face of the inner side wall forming elongated jump ahead 37 the upper wall 31 formed and extends in the longitudinal direction of the inner side wall-forming elongated projection 37 over its entire length. The lead 38a is in the depression 37a pressed.

The reinforcement walls 35 are formed so that the reinforcing wall forming elongated projections 40 and 41 which is integral with the top wall 31 are formed in a pulled-down state, and the reinforcing wall-forming elongated projections 42 and 43 which is integral with the bottom wall 32 are formed in an upwardly pulled state, are soldered together, while the reinforcing wall forming elongate projections 40 and 41 each against the reinforcing wall forming elongated Vor jumps 43 and 42 bump. The upper wall 31 has the elongate projections forming the reinforcement wall 40 and 41 which have different projection heights and are arranged alternately in the front-rear direction. The bottom wall 32 has the elongate projections forming the reinforcement wall 42 and 43 which have different projection heights and are arranged alternately in the front-rear direction. The reinforcing wall forming elongated projections 40 with a long projection height of the upper wall 31 and the respective reinforcing wall forming elongated protrusions 43 with a short projection height of the lower wall 32 are soldered together. The reinforcing wall forming elongated projections 41 with a short projection height of the upper wall 31 and the respective reinforcing wall-forming elongated protrusions 42 with a long projection height of the lower wall 32 are soldered together. In the following, the elongated projections forming the reinforcing wall will be described 40 and 42 with a long projection height of the upper and lower walls 31 and 32 called the first reinforcing wall forming elongate projections. Likewise, the elongated protrusions forming a reinforcing wall become 41 and 43 with a short projection height of the upper and lower walls 31 and 32 called the second reinforcing wall forming elongate projections. A deepening 44 ( 45 ) is in the head end face of the second reinforcing wall forming elongated protrusion 41 ( 43 ) of the upper wall 31 (lower wall 32 ) and extends in the longitudinal direction of the second reinforcing wall forming elongated projection 41 ( 43 ) along its entire length. A head end portion of the first reinforcing wall forming elongated protrusion 42 ( 40 ) of the lower wall 32 (upper wall 31 ) is in the depression 44 ( 45 ) of the second reinforcing wall forming elongated projection 41 ( 43 ) of the upper wall 31 (lower wall 32 ) fitted. While the head end portions of the first reinforcing wall forming elongated projections 40 and 42 the upper and lower walls 31 and 32 each in the respective wells 45 and 44 are inserted, the reinforcing wall forming elongated projections 40 and 43 soldered together and become the reinforcing wall forming elongated projections 41 and 42 soldered together.

The heat exchange tube 4 is using a pipe-forming metal sheet 50 made as in 12 (a) is shown. The tube-forming metal sheet 50 is made by rolling from an aluminum brazing sheet having a brazing material layer on each of its opposite sides. The tube-forming metal sheet 50 has a flat, an upper wall forming area 51 (flat wall forming area); a flat, a lower wall forming area 52 (flat wall forming area), a connection area 53 which is the area forming the upper wall 51 and the area forming the lower wall 52 connects and is designed to the rear side wall 34 to build; the inner side wall forming elongated projections 37 and 38 which are integral with the lateral walls of the upper wall forming and the lower wall forming areas 51 and 52 opposite to the connection area 53 are formed in an upwardly pulled state and which are adapted to an inner region of the front side wall 31 to build; a portion forming the elongated projection of the outer side wall 54 extending outwardly from the side end of the upper wall forming area 51 opposite to the connection area 53 extends, and a plurality of reinforcing wall-forming elongated projections 40 . 41 . 42 and 43 which are integral with the upper wall forming and the lower wall forming areas 51 and 52 are formed in an upwardly pulled state and at fixed intervals in the width direction of the tube-forming metal sheet 50 are arranged. The first reinforcing wall forming elongated projections 40 of the lower wall forming area 51 and the second reinforcing wall forming protrusions 43 of the upper wall forming area 52 are symmetrical with respect to the center line of the width direction of the connection portion 53 arranged. Likewise, the second reinforcing wall forming elongated projections 41 of the upper wall forming area 51 and the first reinforcing wall forming elongated protrusions 42 of the lower wall forming area 52 symmetrical with respect to the center line of the width direction of the connecting portion 53 arranged. The lead 38a is at the head end surface of the inner side wall forming elongated projection 38 of the lower wall forming area 52 trained, and the depression 37a is in the head end face of the inner side wall forming elongated projection 37 of the upper wall forming area 51 educated. The depression 44 ( 45 ) into which an end portion of the first reinforcing wall forming elongated projection 42 ( 40 ) of the lower wall forming area 52 (the upper wall forming area 51 ) is in the head end face of the second reinforcing wall forming elongated projection 41 ( 43 ) of the upper wall forming area 51 (the bottom wall forming area 52 ) educated.

The elongated projections forming the inner side wall 37 and 38 and the reinforcing wall forming elongated projections 40 . 41 . 42 and 43 are integrally formed by rolling on one side of the aluminum brazing sheet whose opposite sides are covered with a brazing material, whereby a brazing material layer (not shown) on the opposite side surfaces and the head end surfaces of the inner side wall forming elongated projections 37 and 38 and on the reinforcing wall forming elongated projections 40 . 41 . 42 and 43 , on the peripheral surfaces of the recesses 44 and 45 the elongate protrusions forming the second reinforcing wall 41 and 43 and on the vertically opposite surfaces of the upper wall forming and the lower wall forming areas 51 and 52 and on the outer side wall forming the elongated projection forming area 54 is trained.

The tube-forming metal sheet 50 is gradually applied to opposite side edges of the connection area 53 by a roll forming process (see 11 (b) ) until a hairpin shape is adopted. The elongated projections forming the inner side wall 37 and 38 are caused to butt against each other, the head end portions of the first reinforcing wall forming elongated protrusions 40 and 42 be in the respective wells 45 and 44 the second reinforcing wall forming elongated projections 43 and 41 used, and the lead 38a gets into the recess 37a pressed.

Next is the area 54 which forms the elongated protrusion forming the outer side wall, along the outer surfaces of the elongated protrusions forming the inner side wall 37 and 38 folded, and one of its head end portions is deformed so as to engage with the lower wall forming portion 52 comes, creating a folded element 55 is obtained (see 11 (c) ).

Subsequently, the folded element 55 heated at a predetermined temperature around the head end portions of the inner side wall-forming elongated projections 37 and 38 to solder, the Kopfendbereiche the first and second reinforcing wall forming elongated projections 40 and 43 to solder, the Kopfendbereiche the first and second reinforcing wall forming elongated projections 42 and 41 to solder, and the area 54 which forms the elongated projection forming the outer side wall with the elongated projections forming the inner side wall 37 and 38 and with the lower wall forming area 52 to solder. In this way, the heat exchange tube 4 produced.

While opposite end portions of the heat exchange tubes 4 through the respective tube insertion openings 18 the inner plates 8th and in the respective communication openings 22 the intermediate plates 9 the sump tanks 2 and 3 are used and the end surfaces of the opposite end portions of the respective step areas 25 the intermediate plates 9 abut, the opposite end portions of the heat exchange tubes 4 with the respective peripheral wall surfaces of the tube insertion holes 18 the inner plates 8th and with the respective peripheral wall surfaces of the communication holes 22 the intermediate plates 9 using the brazing material layers of the inner plates 8th and the brazing material layers of the tube-forming metal sheets 50 soldered.

As a result, right end portions of the upper half group of heat exchange tubes become 4 with the first sump tank 2 connected to the interior of the upper outward arched area 11a communicate, and become left end areas with the second sump tank 3 connected to the interior of the outward arched area 24 to communicate. In addition, right end portions of a sub-half of the heat exchange tubes 4 with the first sump tank 2 connected to the interior of the lower outward arched area 11B to communicate, and left end areas are with the second sump tank 3 connected to the interior of the outward arched area 24 to communicate.

Each of the ribbed ribs 5 is made in a waveform of a brazing sheet, here an aluminum brazing sheet, which has a layer of brazing material on each opposite side.

The gas cooler 1 is made by the following steps:
There are the two aforementioned provisional arrangements for further processing to the sump tanks 2 and 3 , a plurality of the aforementioned folded elements 55 and a plurality of corrugated fins 55 prepared; the two provisional arrangements are arranged so as to be mutually spaced with their inner plates spaced opposite each other; the folded elements 55 and the ribbed ribs 5 are arranged alternately; the opposite end portions of the folded elements 55 be through the respective tube insertion openings 18 the inner plates 8th and in the respective communication openings 22 the intermediate plates 9 of the two provisional arrangements, and the end surfaces of the opposite end portions are brought toward the respective step portions 25 the intermediate plate 9 to bump; the side plates 6 be outside of the respective corrugated ribs 5 arranged at opposite ends; the inlet element 13 and the outlet element 16 are each on the outwardly arched areas 11A and 11B on the outer plate 7 , which is used to the first sump tank 2 arranged to form; the necessary areas of preliminary orders will be like Soldered above to thereby the sump tanks 2 and 3 to form the necessary areas of folded elements 55 are brazed as described above to thereby heat exchange tubes 4 to form the heat exchange tubes 4 be with the sump tanks 2 and 3 soldered, the ribbed ribs 5 be with the heat exchange tubes 4 soldered, the side plates 6 be with the respective corrugated ribs 5 soldered, and the inlet element 13 and the outlet element 16 are each with the outwardly arched areas 11A and 11B soldered.

The gas cooler 1 forms a supercritical refrigeration cycle together with a compressor, an evaporator, a pressure reducing device and an intermediate heat exchanger to perform a heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator. The refrigeration cycle is installed in a vehicle, eg in a car, as a car air conditioner.

In the gas cooler described above 1 CO ₂ flows out of a compressor through the refrigerant inflow channel 14 the inlet element 13 and enters the upper outward arched area 11A of the first sump tank 2 through the refrigerant inlet 12 one. Then the CO _{2 flows} distributed in the refrigerant channels 4a from all heat exchange tubes 4 which is in communication with the upper outward arched area 11A are. The CO ₂ in the refrigerant channels 4a flows to the left through the refrigerant channels 4a and enters the outwardly arched area 24 of the second sump tank 3 one. The CO ₂ in the outwardly arched area 24 flows down through the interior of the outwardly arched area 24 and through the communication areas 23 the intermediate plate 9 , flows distributed in the refrigerant channels 4a all heat exchange tubes 4 which is in communication with the lower outward arched area 11B are, changes its direction, flows to the right through the refrigerant channels 4a , and enters the lower outward arched area 11B of the first sump tank 2 one. Subsequently, the CO _{2 flows} out of the gas cooler 1 over the refrigerant outlet 15 and the refrigerant outflow channel 17 the outlet element 16 out. While passing through the refrigerant channels 4a the heat exchange tubes 4 CO ₂ is subjected to heat exchange with the air which passes through the air passage column in the direction of the arrow X, which in the 1 and 12 is shown flowing, being cooled.

The 13 shows another method for producing the outer panel 7 the two sump tanks 2 and 3 ,

First, a first pressing operation is performed on a metal plate forming the outer plate 60 , which consists of an aluminum brazing sheet having a layer of brazing material on its opposite sides, as shown in FIG 13 (a) is shown using a first upper tool 80 and a first lower tool 82 carried out. The first upper tool 80 has a concave area at the bottom 81 which has a depth greater than the height of the outwardly arched area 11A ( 11B . 24 ) measured on its outside. The first lower tool 82 has a convex area at the top 83 , which has a height which is greater than the height of the outwardly arched area 11A ( 11B . 24 ) measured on its inside. Thus, a temporary arched area 84 formed, which has a height which is greater than the outwardly arched area 11A ( 11B . 24 ) (see 13 (b) ).

Subsequently, a second pressing on the outer plate forming metal plate 60 using a second upper tool 85 a second lower tool 89 carried out. The second upper tool 85 has a concave area at the bottom 86 for forming the outer shape of the outwardly curved portion 11A ( 11B . 24 ), and a pair of protrusions 88 , the cutting blades 87 at their lower ends and the outer plate forming metal plate 60 from the opposite side with respect to the width direction. The second lower tool 89 has a convex area at the top 90 to the inner shape of the outwardly arched area 11A ( 11B . 24 ) to build. Before the temporary arched area 84 to the outward arched area 11A ( 11B . 24 ) are formed opposite side edge portions of the outer plate forming metal plate 60 by means of the cutting blades 87 the projections 88 of the second upper tool 85 cut.

After this cutting process, the tentatively curved area becomes 84 in the outward curved area 11A ( 11B . 24 ) through the concave area 86 and the convex area 90 formed, wherein the outer plate forming metal plate 60 with the tentatively arched area 84 from opposite sides with respect to the width direction through the protrusions 88 of the second upper tool 85 is limited. At this time, the aluminum material of the metal plate forming the outer plate flows 60 through the space, which is between the concave area 86 of the second upper tool 85 and the convex area 90 of the second lower tool 89 is formed. Thus, the radius of curvature R of the connection area 26 between the inner wall surface of the convex portion 11A ( 11B . 24 ) and the lower sides of the outer panel 7 , which at the front and rear sides of the outwardly curved Be rich 11A ( 11B . 24 ) and are continuous with the inner wall surface, 1 mm or smaller. In this way, the outer panel 7 produced.

In the embodiment described above, each outer plate 7 made of an aluminum brazing sheet having a brazing material layer on its opposite sides, and the outer plate 7 and the intermediate plate 9 are soldered together using the solder layer of the outer plate. The way in which the outer panel 7 and the intermediate plate 9 but not limited thereto, and the outer plate 7 and the intermediate plate 9 can be soldered together as follows: Each outer plate 7 is made of an aluminum brazing sheet having a brazing material layer only on an outer end surface of the left-right direction (a surface opposite to the corresponding intermediate plate 9 has); and the intermediate plate 9 becomes an aluminum brazing sheet having a brazing material layer only on an outer surface in the left-right direction (a surface facing the outer plate 7 has); and the outer plate 7 and the intermediate plate 9 are using the solder layer of the intermediate plate 9 soldered together.

In the embodiment described above, the heat exchanger of the present invention is used in a gas cooler of a supercritical refrigeration cycle. However, the heat exchanger of the present invention can also be used in an evaporator of the above-mentioned supercritical refrigeration cycle. This evaporator, together with a compressor, a gas cooler, a pressure reducing device and an intermediate heat exchanger to perform heat exchange between a refrigerant from the gas cooler and a refrigerant from the evaporator, forms a supercritical refrigeration cycle using a supercritical refrigerant such as CO ₂ . This refrigeration cycle is installed in a vehicle, eg in a car, as a car air conditioner.

Although CO _{2 is used} as a supercritical refrigerant of a supercritical refrigeration cycle in the above-described embodiments, the refrigerant is not limited to this, but ethylene, ethane, nitrogen oxide or the like may alternatively be used.

The embodiment described above is used to form the heat exchange tube 4 a folded element 55 which is formed by bending a tube-forming metal sheet in the form of an aluminum brazing sheet having a brazing material layer on each opposite side. However, the present invention is not limited thereto. For example, an aluminum extrudate having a brazing material layer on its outer surfaces may be used to form the heat exchange tube 4 to build.

SUMMARY THE REVELATION

One heat exchangers includes two sump tanks and a plurality of heat exchange tubes. The sump tanks each contain an outer panel, an inner plate and an intermediate plate. The outer panel has one or more outward domed Areas on. The inner plate has a plurality of tube insertion holes on. The intermediate plate has communication holes to communicate the pipe insertion openings with the outside domed Area of the sump tank to enable. One Pair of inclined areas, which are in a diverging Way are inclined in the direction of the inner plate from are in inner side edge regions at opposite wall surfaces from every communication opening, which is in the opening longitudinal direction extends, trained. Protruding areas of the inner panel become formed by areas of the inner plate, which at opposite Edges of each tube insertion opening, located in the opening longitudinal direction extend, are formed, bent in the direction of the intermediate plate become. The above ranges are closely related to the corresponding ones soldered inclined areas.

Claims (12)

A heat exchanger having a pair of header tanks spaced from each other and a plurality of flat heat exchange tubes arranged in parallel between the two header tanks and having opposite end portions connected to the respective header tanks, each one the two header tanks are configured such that an outer panel, an inner panel and an intermediate panel interposed between the outer panel and the inner panel are brazed together in layers, the outer panel having an outwardly curved portion extending in its longitudinal direction and which has an opening closed by the intermediate plate, the inner plate having a plurality of tube insertion holes in the form of through holes which are in a region corresponding to the outwardly curved portion of the outer plate and spaced from each other in their L formed in the longitudinal direction, and wherein the intermediate plate has a plurality of communication openings in the form of through holes, which are formed to the respective Tube insertion holes of the inner plate to allow to communicate with the interior of the outwardly curved portion of the outer plate, wherein the outer plate of each reservoir tank from a metal plate and formed by a pressing operation is formed and a connecting portion between an inner wall surface of the outwardly curved portion the outer plate and a surface of the outer plate, which is connected to the intermediate plate, has a radius of curvature of 1 mm or less. A heat exchanger according to claim 1, wherein the connecting portion between the inner wall surface of outward domed Area and the area the outer panel, which is connected to the intermediate plate, a radius of curvature of 0.5 mm or less. A heat exchanger according to claim 1, wherein the outer panel has a thickness of 2 mm or more. A method of making an outer panel which for a sump tank a heat exchanger usable, which is configured so that an outer panel an inner plate and an intermediate plate which between the outer plate and the inner plate lies, soldered together in layers, the outer plate one outwards arched area has, which is in a longitudinal direction extends from it and an opening has, which is closed by the intermediate plate, the inner plate a plurality of tube insertion openings in the form of through holes which is in an area with the outwardly arched area the outer panel corresponds, and spaced from each other in their longitudinal direction are formed, and wherein the intermediate plate is a plurality of communication ports in the form of through holes which are formed to the respective tube insertion openings to allow the inner plate, with the interior of the outwardly arched area the outer panel to communicate, the method comprising the steps of: education a thick area on a metal plate forming the outer plate at a central area with respect to the width direction thereof, the thick area being thicker than the remaining thin area is; and execution a pressing operation on the metal plate forming the outer plate, around the outward arched area be formed using the thick area so that a connection area, the a radius of curvature of 1 mm or less, between an inner wall surface of the outward domed Area and each of the areas the outer panel, which on the opposite sides of the outside domed Lie area and go over in the inner wall surface, form. A method of making an outer panel which for a sump tank a heat exchanger is used, according to claim 1, wherein the thick region is formed is in which a pressing operation on the outer plate forming metal plate carried out becomes. A method of making an outer panel which for a sump tank a heat exchanger is used, according to claim 5, wherein the thick region of the outer plate forming metal plate has a thickness of 1.05 to 1.5 times from the one of the remaining thin one Range is. A method of making an outer panel which for a sump tank a heat exchanger is used, according to claim 4, wherein a connection region, which a radius of curvature of 0.5 mm or less, between the inner wall surface of the outward domed Area and each of the areas the outer panel, which on the opposite Sides of the outward arched area lie down and go over to the inner wall surface, is formed. A method of making an outer panel which for a sump tank a heat exchanger is used, according to claim 4, wherein the outer plate has a thickness of 2 mm or more in its final form. A method of manufacturing an outer panel used for a header tank of a heat exchanger configured such that an outer panel, an inner panel, and an intermediate plate interposed between the outer and inner panels are brazed together in layers the inner plate has an outwardly bulging portion extending in the longitudinal direction thereof and having an opening closed by the intermediate plate, the inner plate having a plurality of tube insertion holes in the form of through holes formed in a portion corresponding to the one of Figs outer arcuate portion of the outer plate corresponds, and spaced from each other in their longitudinal direction, and wherein the intermediate plate has a plurality of communication openings in the form of through holes, which are formed to allow the respective tube insertion openings of the inner plate, with the Inner surfaces of the convex portion of the outer plate to communicate, the method comprising the steps: a first pressing operation is carried out on a metal plate forming the outer plate to form a preliminary curved portion having a buckling height, which is greater than that of the au ßen arched area is; and a second pressing operation is performed on the metal plate forming the outer plate having the preliminary curved portion, wherein the metal plate forming the outer plate is restrained therefrom from the opposite sides with respect to the width direction thereof from the outwardly curved portion from the preliminary one to form a curved portion so that a connection portion having a radius of curvature of 1 mm or less, between an inner wall surface of the outwardly curved portion and each of the surfaces of the outer plate, which lie on the opposite sides of the outwardly curved portion and in the Pass inside wall surface, is formed. A method of making an outer panel which for a sump tank a heat exchanger used according to claim 9, wherein the step of performing the second pressing operation includes opposing side edge portions the outer plate forming metal plate using a tool which for the Pressing is used, prior to the formation of the outwardly curved area from the provisional domed Be cut off area and the outer plate forming metal plate with the provisional domed Area of opposite Using pages related to the width direction of her retained by the tool becomes. A method of making an outer panel which for a sump tank a heat exchanger used according to claim 9, wherein the connecting region, which a radius of curvature of 0.5 mm or less, between the inner wall surface of the outward domed Area and each of the areas the outer panel, which on opposite Sides of the outside domed Lie area and merge into the inner wall surface, is formed. A method of making an outer panel which for a sump tank a heat exchanger used according to claim 9, wherein the outer panel has a thickness of 2 mm or more in its final form.