HEAT EXCHANGER

Description

TECHNICAL FIELD

The present invention relates to a heat exchanger.

BACKGROUND ART

JP2013-185723A discloses a heat exchanger in which core portions having tank portions are provided so as to be overlapped. A distribution portion communication portion is connected to the tank portion of one of the core portions, and the distribution portion communication portion is connected to an intermediate tank portion. A collection portion communication portion is connected to the intermediate tank portion, and the collection portion communication portion is connected to the tank portion of the other of core portions.

SUMMARY OF INVENTION

However, in this heat exchanger, the tank portion of the one of the core portions and the tank portion of the other of the core portions are connected via the distribution portion communication portion, the intermediate tank portion, and the collection portion communication portion. Therefore, the structure thereof is complex.

An object of the present invention is to provide a heat exchanger capable of simplifying a structure for allowing a heat transfer medium to flow therethrough.

According to an aspect of the present invention, a heat exchanger configured to perform heat exchange between air and a heat transfer medium undergoing a phase change between a liquid phase and a gaseous phase, the heat exchanger includes: core portions provided such that a plurality of core portions are overlapped in an air-flow direction, the core portions each having header tanks provided as a pair facing with each other and a plurality of tubes configured to connect the header tanks to each other and to perform the heat exchange between the heat transfer medium flowing inside the tubes and the air flowing around the tubes; and a passage forming member provided between a first header tank of the header tanks, which is arranged so as to be overlapped, and a second header tank of the header tanks, which is arranged so as to be overlapped, wherein the first header tank and the second header tank each has, at a mutually facing portion thereof, a tank side hole, the passage forming member has a communication hole, the communication hole being configured to allow mutually facing tank side holes of the tank side hole to communicate with each other, and a first hole of the tank side hole and the communication hole is an elongated hole having a length longer than a length of a second hole of the tank side hole and the communication hole in the tank-length direction, the first hole being configured to communicate with the second hole in a plurality of number.

In the heat exchanger of the above aspect, the communication between the tank side hole of the first header tank and the tank side hole of the second header tank, which are arranged so as to be overlapped, is allowed by the communication hole of the passage forming member that is provided between both of the header tanks. Therefore, the communication passage that allows the communication between the first header tank and the second header tank can be formed by the communication hole of the passage forming member that is provided between the first header tank and the second header tank. With such a configuration, the distribution portion communication portion, the intermediate tank portion, and the collection portion communication portion for allowing the communication between the first header tank and the second header tank are not required. Therefore, it is possible to provide the heat exchanger capable of simplifying the structure for allowing the heat transfer medium to flow.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a heat exchanger according to an embodiment of the present invention.

FIG. 2 is an enlarged view of a main part of a header tank.

FIG. 3 is an enlarged view of a main part showing a state in which tubes are inserted into the header tank.

FIG. 4 is a IV-IV sectional view in FIG. 1.

FIG. 5 is a perspective view of a passage forming member.

FIG. 6 is an explanatory diagram showing a relationship between the header tank and the passage forming member.

FIG. 7 is a diagram showing a relationship between a tank side hole and communication holes.

DESCRIPTION OF EMBODIMENTS

In the following, a heat exchanger 10 according to embodiments of the present invention will be described with reference to the drawings.

An overall configuration of the heat exchanger 10 will be described first with reference to FIG. 1. FIG. 1 is a perspective view of the heat exchanger 10 according to the embodiment of the present invention.

The heat exchanger 10 is installed in a vehicle (not shown). The heat exchanger 10 performs a heat exchange between air that is used for air-conditioning and a heat transfer medium that is circulated in an air-conditioning device (not shown) and that undergoes a phase change between a liquid phase and a gaseous phase.

Specifically, the heat exchanger 10 is provided in an HVAC (a Heating Ventilation and Air Conditioning) unit (not shown) through which the air used for the air-conditioning passes. The heat exchanger 10 is a condenser that, when the air-conditioning device performs a cabin-heating operation, performs the heat exchange with the air used for the air-conditioning to heat the air by condensing the heat transfer medium. The present invention is not limited thereto, and the heat exchanger 10 may be an evaporator that, when the air-conditioning device performs a cabin-cooling operation, performs the heat exchange with the air used for the air-conditioning to cool and dehumidify the air by evaporating the heat transfer medium.

The heat exchanger 10 has: an upstream-side core portion 20 that is arranged on the upstream side of the air-flow direction 12; a downstream-side core portion 22 that is arranged on the downstream side of the air-flow direction; and reinforcing members 23 that are respectively provided on both end portions of the heat exchanger 10. The upstream-side core portion 20 and the downstream-side core portion 22 are arranged so as to be overlapped with each other in the air-flow direction 12.

The upstream-side core portion 20 and the downstream-side core portion 22 are provided with: a pair of header tanks 24 that extend in the lateral direction; a plurality of tubes 26 that are provided between the header tanks 24 forming the pair; and fins (not shown) that are provided between the tubes 26. The header tanks 24, the tubes 26, and the fins that are provided between the tubes 26 are made of a metal such as aluminum and are integrally joined to each other by brazing, etc.

In addition, the heat exchanger 10 is provided with passage forming members 28 that are provided between the header tanks 24 of the upstream-side core portion 20 and the header tanks 24 of the downstream-side core portion 22, which are arranged so as to be overlapped with each other.

The upstream-side core portion 20 is divided at the central portion in the arrangement direction of the tubes 26 and has a first divided core portion 30 and a second divided core portion 32, each having independent flow path for the heat transfer medium. The downstream-side core portion 22 is divided at the central portion in the arrangement direction of the tubes 26 and has a third divided core portion 34 and a fourth divided core portion 36, each having independent flow path of the heat transfer medium.

Tube

The respective tubes 26 provided on the respective core portions 20 and 22 connect the header tanks 24 of the respective core portions 20 and 22 to each other and performs the heat exchange between the heat transfer medium that flows inside the tubes 26 and the air that flows around the tubes 26.

The respective core portions 20 and 22 are provided so as to intersect with the air-flow direction such that the air can flow between the respective tubes 26. The respective core portions 20 and 22 are provided so as to be overlapped with each other in the air-flow direction such that the air can flow through in a consecutive manner. In the heat exchanger 10 of this embodiment, although two core portions 20 and 22 are provided side by side to form two layers arranged in the front and rear direction, the number of the core portions is not limited to two and a plurality of core portions may be provided.

The tubes 26 are arranged side by side in parallel, thereby being layered with interval gaps. The tubes 26 are each formed to have a flat shape and are layered in the thickness direction. The fins are respectively provided in interval gaps between adjacent tubes 26. The tubes 26 are layered in the direction that intersects with the air-flow direction 12. The tubes 26 is formed with an inner flow passage through which the heat transfer medium flows.

Fins

The fins are provided between the adjacent tubes 26, and are layered alternately with the tubes 26. The fins are formed to have a wave-like shape along the longitudinal direction of the tubes 26 and are joined to two adjacent tubes 26. The air supplied by a blower (not shown) of the air-conditioning device flows around the plurality of tubes 26 and the fins. Therefore, the heat transfer medium that flows inside the tubes 26 can undergo the heat exchange with the air via surfaces of the tubes 26 and the fins. As described above, the fins promote the heat exchange between the heat transfer medium and the air.

Reinforcing Members

The reinforcing members 23 are respectively provided on both end portions of the upstream-side core portion 20 and the downstream-side core portion 22. The reinforcing members 23 are in contact with the fins that are provided on both end portions of the upstream-side core portion 20 and the downstream-side core portion 22. End portions of the reinforcing members 23 in the longitudinal direction are respectively engaged with the header tanks 24, thereby linking and reinforcing between the pair of header tanks 24. When the tubes 26 and the fins are brazed to form the upstream-side core portion 20 and the downstream-side core portion 22, the reinforcing members 23 are integrated with the upstream-side core portion 20 and the downstream-side core portion 22 by being brazed to the fins.

Header Tank

An interior of each of the header tanks 24 of the upstream-side core portion 20 is divided at the central portion in the arrangement direction of the tubes 26, and the header tanks 24 have a first upper header tank 40 that forms the first divided core portion 30 and a second upper header tank 42 that forms the second divided core portion 32. In addition, the header tanks 24 of the upstream-side core portion 20 has a first lower header tank (not shown) that forms the first divided core portion 30 and a second lower header tank 46 that forms the second divided core portion 32. The first lower header tank and the second lower header tank 46 are internally communicated. In this embodiment, although a case in which the first lower header tank and the second lower header tank 46 are separate bodies will be described, this embodiment is not limited thereto. For example, the first lower header tank and the second lower header tank 46 may be integrated into a single unit.

An interior of each of the header tanks 24 of the downstream-side core portion 22 is divided at the central portion in the arrangement direction of the tubes 26, and the header tanks 24 have a third upper header tank 50 that forms the third divided core portion 34 and a fourth upper header tank 52 that forms the fourth divided core portion 36. In addition, the header tanks 24 of the downstream-side core portion 22 have a third lower header tank 54 that forms the third divided core portion 34 and a fourth lower header tank 56 that forms the fourth divided core portion 36. The third lower header tank 54 and the fourth lower header tank 56 are partitioned from each other.

FIG. 2 is an enlarged view of a main part of the header tanks 24. FIG. 3 is an enlarged view of a main part showing a state in which the tubes 26 are inserted into the header tanks 24. FIG. 4 is a IV-IV sectional view in FIG. 1.

As shown in FIG. 4, each of the header tanks 24 has a tubular shape elongated in the arrangement direction of the tubes 26 (see FIG. 1). Each of the upper header tanks 40, 50, (42, 52) is formed to have a substantially rectangular cross-section. In a state in which the heat exchanger 10 is attached, an upper surface 60 of each of the upper header tanks 40, 50, (42, 52) is formed to have a curved shape in which the center portion in the width direction is projected upwards.

As shown in FIG. 2, the first upper header tank 40 and the third upper header tank 50 each has, at a mutually facing portion thereof, tank side holes 62 (only the first upper header tank 40 is shown). Similarly, the second upper header tank 42 and the fourth upper header tank 52 each has, at a mutually facing portion thereof, the tank side holes 62. Note that FIG. 2 representatively shows the main part of the first upper header tank 40 of the first divided core portion 30.

Each of the upper header tanks 40, (42, 50, 52) has, for example, five tank side holes 62. Each of the tank side holes 62 is an elongated hole elongated in the length direction of each of the upper header tanks 40, (42, 50, 52). The respective tank side holes 62 are arranged at predetermined intervals in the length direction of the header tanks 24, and there are connecting portions 64 between adjacent tank side holes 62.

With such a configuration, compared with a case in which a single tank side hole 62 that is elongated in the length direction of the header tanks 24 is formed on each of the upper header tanks 40, (42, 50, 52), deterioration in the rigidity of each of the upper header tanks 40, (42, 50, 52) is suppressed.

As shown in FIGS. 3 and 4, each of the header tanks 24 has a plurality of tube insertion ports 66 into which the tubes 26 are respectively inserted. When an imaginary region 68 extending in the circumferential direction of each of the header tanks 24 through the connecting portion 64 between the adjacent tank side holes 62 is assumed, the tube insertion ports 66 include those that open in the imaginary region 68 (see FIG. 3).

As shown in FIG. 3, each of the tube insertion ports 66 is formed by burring. An edge portion of each of the tube insertion ports 66 is formed with a standing wall 70 that supports the inserted tube 26 at its peripheral surface and that reinforces the tube insertion port 66 (see FIG. 4).

As shown in FIG. 1, a pair of the header tanks 24 are provided for each of the core portions 20 and 22 so as to face with each other. The header tanks 24 are arranged such that both end portions of the plurality of tubes 26 in the longitudinal direction are respectively inserted. Each of the header tanks 24 temporarily stores the heat transfer medium.

The end portions of each of the upper header tanks 40, 42, 50, 52, the end portion of the first lower header tank, and the end portion of the third lower header tank 54 are respectively closed by closing members 72. A relay member 74 for relaying piping is provided at the end portion of the second lower header tank 46 and the end portion of the fourth lower header tank 56.

The heat transfer medium used for the air-conditioning enters the first header tank 24 of each of the core portions 20 and 22. The heat transfer medium that has entered the first header tank 24 flows through each of the plurality of tubes 26. The heat transfer medium undergoes the heat exchange with the air while it is flowing through the tubes 26. The heat transfer medium that has flown through the tubes 26 flows into the second header tank 24 of each of the core portions 20 and 22.

Passage Forming Member

As shown in FIG. 1, the passage forming member 28 is provided between the first upper header tank 40 of the first divided core portion 30 and the third upper header tank 50 of the third divided core portion 34, which are arranged so as to be overlapped. In addition, the passage forming member 28 is provided between the second upper header tank 42 of the second divided core portion 32 and the fourth upper header tank 52 of the fourth divided core portion 36, which are arranged so as to be overlapped.

FIG. 5 is a perspective view of the passage forming member 28. FIG. 6 is an explanatory diagram showing the relationship between between the header tank 24 and the passage forming member 28.

As shown in FIG. 5, the passage forming member 28 is an elongated member. The passage forming member 28 is formed to have a Y-shaped cross-section by having a plate-shaped insertion piece 80 that is inserted between the core portions 20 and 22, which are arranged so as to be overlapped, and a bifurcated portion 82 formed on an end portion of the insertion piece 80.

As shown in FIG. 4, the thickness dimension T1 of the insertion piece 80 is greater than the thickness dimension T2 of each of the header tanks 24.

The outer side surfaces of a first piece 84 and a second piece 86 forming the bifurcated portion 82 each has a curved surface that follows a curved surface of the upper surface 60 of each of the upper header tanks 40, 50, (42, 52). With such a configuration, in a state in which the insertion piece 80 of the passage forming member 28 is arranged between adjacent upper header tanks 40, 50, (42, 52), the first piece 84 of the bifurcated portion 82 comes into surface contact with the upper surface 60 of the one upper header tank 50, (40, 42, 52). In addition, the second piece 86 of the bifurcated portion 82 comes into surface contact with the upper surface 60 of the other upper header tank 40, (42, 50, 52).

Then, in a state in which the first piece 84 and the second piece 86 of the bifurcated portion 82 respectively come into surface contact with the upper surfaces 60 of the respective upper header tanks 40, 50, (42, 52), an amount of insertion of the passage forming member 28 into a gap between the adjacent upper header tanks 40, 50, (42, 52) is determined. In addition, in this inserted state, the passage forming member 28 is brazed to each of the upper header tanks 40, 50, (42, 52).

As shown in FIG. 6, the insertion piece 80 of the passage forming member 28 has ten communication holes 90 that allow the tank side holes 62 facing with each other to communicate with each other. The communication holes 90 are each an oval hole whose length dimension is shorter than that of the tank side hole 62, and two communication holes 90 communicate with a single tank side hole 62.

In this embodiment, although the tank side hole 62 is made as the elongated hole whose length is longer than that of the communication hole 90, this embodiment is not limited thereto. For example, the communication hole 90 may be made as an elongated hole whose length is longer than that of the tank side hole 62.

As shown in FIG. 4, the thickness dimension T1 of the insertion piece 80 of the passage forming member 28 is greater than the thickness dimension T2 of each of the header tanks 24. Therefore, in a state in which the pressure in each of the header tanks 24 is increased, the pressure receiving area per unit length formed by an inner circumferential surface of the communication hole 90 of the insertion piece 80 is greater than the pressure receiving area per unit length formed by an inner circumferential surface of the tank side hole 62 of each of the header tanks 24.

Therefore, when the communication hole 90 is made as the elongated hole, the total pressure receiving area formed by the inner circumferential surface of the communication hole 90 is increased. Consequently, because the pressure applied to the inner circumferential surface of the communication hole 90 is increased, the communication hole 90 may be deformed.

Thus, in this embodiment, by making the tank side hole 62 as the elongated hole whose length is longer than that of the communication hole 90, the increase in the total pressure receiving area formed by the inner circumferential surface of the communication hole 90 is suppressed, and the deformation of the communication hole 90 is suppressed in advance.

FIG. 7 is a diagram showing the relationship between the tank side hole 62 and the communication holes 90, and FIG. 7 shows a state in which the passage forming member 28 is set between the respective upper header tanks 50, (40, 42, 52), which are arranged so as to be overlapped.

As shown in FIG. 7, the length dimension L1 of the tank side hole 62 of each of the upper header tanks 50, (40, 42, 52) is longer than the length dimension L2 from a first end 92 to a second end 94 of a pair of adjacent communication holes 90. Specifically, the length dimension L1 of the tank side hole 62 is, for example, 0.5 mm longer than the length dimension L2 from the first end 92 to the second end 94 for the pair of adjacent communication hole 90.

With such a configuration, even in a case in which the passage forming member 28 is arranged so as to be displaced along the length direction of the respective upper header tanks 50, (40, 42, 52), misalignment of the pair of communication holes 90 with respect to the tank side hole 62 is suppressed. Thus, narrowing of a communication passage, which is formed by a communicating portion between the communication holes 90 and the tank side holes 62 is suppressed.

Relay Member

As shown in FIG. 1, the relay member 74 has a second lower tank connection pipe 100 that communicates with the second lower header tank 46 and a fourth lower tank connection pipe 102 that communicates with the fourth lower header tank 56. In addition, the relay member 74 has a third lower tank connection pipe 104 that communicates with the third lower header tank 54. Pipes (not shown), through which the heat transfer medium flows, are respectively connected to the respective connection pipes 100, 102, and 104.

The heat transfer medium enters the first divided core portion 30 through the passage forming member 28 after it has entered the third lower header tank 54 from a supply pipe through the third lower tank connection pipe 104, flown in the tubes 26, and entered the third divided core portion 34. The heat transfer medium that has entered the first divided core portion 30 is recovered by a recovery pipe via the first lower header tank, the second lower header tank 46, and the second lower tank connection pipe 100.

The heat transfer medium enters the second divided core portion 32 through the passage forming member 28 after it has entered the fourth lower header tank 56 from the supply pipe through the fourth lower tank connection pipe 102, flown in the tubes 26, and entered the fourth divided core portion 36. The heat transfer medium that has entered the second divided core portion 32 is recovered by the recovery pipe via the second lower header tank 46 and the second lower tank connection pipe 100.

According to the embodiment mentioned above, the advantages described below are afforded.

The heat exchanger 10 is the heat exchanger 10 that performs the heat exchange between the air and the heat transfer medium that undergoes the phase change between the liquid phase and the gaseous phase. The heat exchanger 10 is provided with the core portions 20 and 22 each having: the header tanks 24 provided as a pair facing with each other; and the plurality of tubes 26 configured to connect the header tanks 24 to each other and performs the heat exchange between the heat transfer medium that flows inside the tubes 26 and the air that flows around the tubes 26. The respective core portions 20 and 22 are provided such that a plurality of core portions 20 and 22 are overlapped in the air-flow direction 12. The heat exchanger 10 is provided with the passage forming member 28 provided between the first header tank 24 of the header tanks 24 and the second header tank 24 of the header tanks 24, which are arranged so as to be overlapped.

The first header tank 24 and the second header tank 24 each has, at a mutually facing portion thereof, the tank side hole 62. The passage forming member 28 has the communication hole 90, the communication hole 90 being configured to allow mutually facing tank side holes 62 of the tank side hole 62 to communicate with each other. A first hole 62 of the tank side hole 62 and the communication hole 90 is the elongated hole having the length longer than the length of a second hole 90 of the tank side hole 62 and the communication hole 90, and the first hole 62 being configured to communicate with the second hole 90 in a plurality of number.

According to the heat exchanger 10 having such a configuration, the tank side holes 62 of the first header tank 24, which is arranged so as to be overlapped, and the tank side holes 62 of the second header tank 24, which is arranged so as to be overlapped, are allowed to communicate with each other by the communication holes 90 of the passage forming member 28 that is provided between both of the header tanks 24. Therefore, the communication passage that allows communication between the first header tank 24 and the second header tank 24 can be formed by the communication holes 90 of the passage forming member 28 that is provided between the first header tank 24 and the second header tank 24.

With such a configuration, there is no need to provide the distribution portion communication portion, the intermediate tank portion, and the collection portion communication portion for allowing the communication between the first header tank 24 and the second header tank 24. Therefore, it is possible to provide the heat exchanger 10 capable of simplifying the structure for allowing the heat transfer medium to flow.

In addition, the first hole 62 of the tank side hole 62 and the communication hole 90 is the elongated hole having the length longer than the length of the second hole 90 in the length direction of the header tanks 24, and the first hole 62 communicates with the plurality of second holes 90. Therefore, compared with a case in which the tank side holes 62 and the communication holes 90 have the same shape, it becomes possible to suppress the narrowing of the communication passage that is formed by the communication between the tank side holes 62 and the communication holes 90 even when the displacement is caused for the passage forming member 28 to be provided for the respective header tanks 24.

In addition, the first header tank 24 and the second header tank 24 can be allowed to communicate with each other by the passage forming member 28. Therefore, compared with a case in which the first header tank 24 and the second header tank 24 are communicated by using the distribution portion communication portion, the intermediate tank portion, and the collection portion communication portion, it is possible to reduce the number of components.

Furthermore, compared with a case in which the first header tank 24 and the second header tank 24 are communicated by sequentially connecting the first header tank 24, the distribution portion communication portion, the intermediate tank portion, the collection portion communication portion, and the second header tank 24, it is possible to reduce the number of connection points. With such a configuration, it is possible to reduce the cost for the management of connection accuracy that is to be performed for every connection points in order to suppress leakage of the heat transfer medium.

As a result, t becomes possible to suppress the manufacturing cost.

In addition, the header tanks 24 have the plurality of the tube insertion ports 66 into which the tubes 26 are respectively inserted, and the header tanks 24 are formed to have a tubular shape elongated in the arrangement direction of the tubes 26. When the imaginary region 68 extending in the circumferential direction of the header tanks 24 through the connecting portion 64 provided between the adjacent tank side holes 62 is assumed, the tube insertion ports 66 include the tube insertion ports 66 opening in the imaginary region 68.

According to such a configuration, compared with a case in which all of the tube insertion ports 66 open at portions offset from the tank side holes 62 in the circumferential direction, it is possible to reduce the area that divides the header tanks 24 in the length direction on the circumferential line where the tube insertion ports 66 are provided.

With such a configuration, because a decrease in the rigidity of the header tanks 24 can be suppressed, it is possible to suppress the deformation of the header tanks 24 at the time of insertion of the tubes 26 without separately providing a reinforcing structure.

In addition, the length dimension L1 of the first hole 62 is longer than the length dimension L2 from the first end 92 to the second end 94 of the second holes 90 in adjacent positions as the pair.

According to such a configuration, even in a case in which the passage forming member 28 is arranged so as to be displaced along the length direction of the first hole 62, the narrowing of the communication passage that is formed by the communication between the tank side holes 62 and the communication holes 90 is suppressed. As a result, it is possible secure a flow passage area formed by the communication holes 90 without increasing a mounting accuracy of the passage forming member 28 more than necessary.

In addition, with the passage forming member 28, it is possible to reduce void portions formed by the communication holes 90. Therefore, it is possible to suppress the decrease in the rigidity of the passage forming member 28 due to the presence of the communication holes 90.

In addition, the first core portion 20 and the second core portion 22, which are arranged so as to be overlapped, each has the plurality of divided core portions 30, 32, 34, 36, the divided core portions 30, 32, 34, 36 being formed by being divided in the arrangement direction of the tubes 26 and each having independent flow path of the heat transfer medium. The passage forming member 28 is provided between the respective upper header tanks 40, 42, 50, 52 of the respective divided core portions 30, 32, 34, 36, which are arranged so as to be overlapped.

According to such a configuration, the first core portion 20 and the second core portion 22 are formed of the divided core portions 30, 32, 34, 36 each having independent flow path of the heat transfer medium, and it becomes possible to perform the heat exchange in the respective divided core portion 30, 32, 34, 36 in an independent manner.

Therefore, by using the heat exchanger 10, for example, it becomes possible to perform an appropriate temperature control for each location in a space in a vehicle cabin according to the presence or absence of occupants or the the preference of the occupants.

Although the embodiment of the present invention has been described in the above, the above-mentioned embodiment merely illustrates a part of application examples of the present invention, and the technical scope of the present invention is not intended to be limited to the specific configurations of the above-described embodiment.

The present application claims a priority based on Japanese Patent Application No. 2022-118938 filed with the Japan Patent Office on Jul. 26, 2022, the entire content of which are incorporated into this specification by reference.