JP2004257641A

JP2004257641A - Method of manufacturing finned tube heat exchanger and air-conditioning/freezing device

Info

Publication number: JP2004257641A
Application number: JP2003048543A
Authority: JP
Inventors: Akira Ishibashi; 晃石橋; Masahiro Nakayama; 雅弘中山; Kunihiko Kaga; 邦彦加賀; Taijo Murakami; 泰城村上; Shinji Nakajima; 伸治中島; Shinji Nakadeguchi; 真治中出口
Original assignee: Mitsubishi Electric Corp
Current assignee: Mitsubishi Electric Corp
Priority date: 2003-02-26
Filing date: 2003-02-26
Publication date: 2004-09-16
Anticipated expiration: 2023-02-26
Also published as: JP4080352B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a finned tube heat exchanger capable of reducing air flow resistance and increasing heat exchange amount and having excellent heat transfer performance and assembly performance. <P>SOLUTION: This method of manufacturing a finned tube heat exchanger comprises a step for applying a brazing filler material to a heat transfer tube, a step for inserting the heat transfer tube into a sheath-like metal plate, a step for fitting a drawing tool to the end of the sheath-like metal plate, a step for inserting the heat transfer tube surrounded by the sheath-like metal plates into the fin collars of plate-like fins by pulling the drawing tool, a step for mounting a fixing tool to the lower end of the heat transfer tube, a step for pulling the sheath-like metal plates with the drawing tool while leaving the heat transfer tube left in the plate-like fins by the fixing tool, a step for mounting a header to the ends of the transfer tubes, and a step for putting the assembled heat exchanger in a furnace and brazing the heat exchanger in the furnace. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
この発明は、冷媒と気体等の流体間での熱交換を行うためのフィンチューブ型熱交換器の製造方法及び空調冷凍装置に関するものである。
【０００２】
【従来の技術】
従来の円管フィンチューブ型熱交換器は、定間隔でその間を気体（空気）が流れる板状フィンが配置され、内部に作動流体が流れる円形伝熱管が板状フィンに垂直に挿入され、その後機械拡管と呼ばれる工程により、フィンと伝熱管が固定される（例えば、特許文献１参照）。
【０００３】
また、従来の扁平管を用いたフィンチューブ型熱交換器の製造方法は、扁平管をＵ字のブレージングシート製のカバー材で包み、切り欠きを設けた積層されたフィンに対し、列方向から挿入したのち、ロウ付け工程を経て熱交換器が完成する（例えば、特許文献２参照）。
【０００４】
また、他の従来の扁平管を用いたフィンチューブ型熱交換器の製造方法は、扁平管を切り欠きを設けた積層されたフィンに対し、列方向から挿入して、熱交換器を組み立てるが、板状フィンの積層間隔を規制する切り起しを設けている（例えば、特許文献３参照）。
【０００５】
【特許文献１】
特開２００１−２２１５８７号公報（第１４頁、第１７図）
【特許文献２】
特開２０００−２３４８８３号公報（第５頁、第１図）
【特許文献３】
特開平９−３２４９９５号公報（第７頁、第１図）
【０００６】
【発明が解決しようとする課題】
従来の円管フィンチューブ型熱交換器の製造方法においては（例えば、特許文献１）、機械拡管によってフィンカラーと伝熱管の密着が行われるが、ロウ付けによるフィンカラーと伝熱管の接合と比べて、フィンカラーと伝熱管の接触熱伝達率が低くなるという問題点があった。
【０００７】
また、従来の扁平管熱交換器の製造方法においては（例えば、特許文献２）、ブレージングシート製のカバー材を被せた扁平管が列方向から挿入されるために、フィンカラーが段方向に広がりやすく、フィンカラーと伝熱管の間にロウ材が行き渡りにくいという問題点があった。
【０００８】
また、従来の扁平管熱交換器製造方法においては（例えば、特許文献３）、扁平管が列方向から挿入されるために、フィンカラーが軸方向に広がりやすく、フィンカラーと伝熱管の間にロウ材が行き渡りにくいという問題点があるのに加え、板状フィンのピッチを規制するために切り起しを設けているため、板状フィンの伝熱面積を損ない、熱交換性能を損なうという問題点があった。
【０００９】
この発明は、上記のような問題点を解決するためになされたもので、通風抵抗の減少および熱交換量の向上を図り、伝熱性能が良好で、組み立て性にも優れるフィンチューブ型熱交換器の製造方法及び空調冷凍装置を提供することを目的とする。
【００１０】
【課題を解決するための手段】
この発明に係るフィンチューブ型熱交換器の製造方法は、多数平行に配置され、その間を気体が流動する板状フィンと、この板状フィンのフィンカラーに挿入され、内部を作動流体が通過し、気体通過方向に対して直角方向の段方向へ複数段設けられる伝熱管とを接合させたフィンチューブ型熱交換器の製造方法において、伝熱管にロウ材を塗布する工程と、鞘状金属板に伝熱管を挿入する工程と、鞘状金属板の端部に引抜治具を取り付ける工程と、鞘状金属板に包まれた伝熱管を引抜治具を引っ張ることにより板状フィンのフィンカラーに挿入する工程と、伝熱管の下端部に固定治具を取り付ける工程と、鞘状金属板を引抜治具により、伝熱管を固定治具により板状フィン内に残して、引き抜く工程と、伝熱管の端部にヘッダーを取り付ける工程と、組み立てた熱交換器を炉に投入して炉中ロウ付けを行う工程と、を備えたことを特徴とする。
【００１１】
【発明の実施の形態】
以下、この発明の実施の形態を図面を参照して説明する。
実施の形態１．
図１は鞘状金属板を示す外観図と断面図である。図において、鞘状金属板１は、伝熱管を板状フィンに挿入する際に、伝熱管を包むために用いられる。鞘状金属板１は板厚が約０．１ｍｍ程度であり、断面が扁平形状の中空構造となっている。また、片方の先端部１ａは閉じられ、引抜冶具２が取り付けられる。
【００１２】
図２は伝熱管を示す部分外観図である。図に示すように、伝熱管３は扁平形状をしており、作動流体が流れるマイクロチャネル４を８個設けている。また、伝熱管３の外側にはロウ材が塗布される。ロウ材にはアルミ−シリコン系の合金を用いている。
【００１３】
図３は鞘状金属板の断面図である。図に示すように、鞘状金属板１は内部に凹凸５を設けている。これは、鞘状金属板１を引き抜く際に、伝熱管３の外側に塗布されたロウ材が剥がれるのを防ぐ役割をしている。
【００１４】
図４は板状フィン及びフィンカラーを示す外観図と断面図である。図に示すように、板状フィン６に設けられたフィンカラー７は、根元部７ａ、中間部７ｂおよび先端部７ｃで構成され、根元部７ａおよび先端部７ｃは伝熱管３に向かって凸の円弧、中間部７ｂはストレート形状となっている。ここで、中間部７ｂは伝熱管軸方向（挿入方向）に対して、伝熱管側にある角度θをなしている。伝熱管３および鞘状金属板１の挿入性を改善するために、根元部７ａ側が広がるように中間部７ｂに角度θの傾きを付けている。
【００１５】
また、フィンカラー７の短軸内径最小値ｄｍｉｎ、最大径ｄｍａｘおよび伝熱管短軸最大径Ｄａの間に、ｄｍｉｎ＜Ｄａ＜ｄｍａｘの関係が成立するようにしている。これは、鞘状金属板１を引き抜いた後、フィンカラー７を伝熱管３に密着させるためである。
なお、本実施の形態では、ｄｍａｘ＝２．５ｍｍ、ｄｍｉｎ＝１．５ｍｍ、Ｄａ＝２．０ｍｍとする。
【００１６】
図５はロウ材８を塗布した伝熱管３と伝熱管３を包んだ鞘状金属板１が板状フィン６上に設けられたフィンカラー７の穴部に挿入されている状態を示す部分断面図である。図に示すように、ロウ材８を塗布した伝熱管３および鞘状金属板１はフィンカラー７を弾性変形させながら、伝熱管３の軸方向（引き抜き方向）に引抜冶具２を引っ張ることによって、挿入される。
【００１７】
その際、伝熱管３に塗布されたロウ材８は、鞘状金属板１によって、フィンカラー７との摩擦により、剥がれ落ちることを免れる。また、鞘状金属板１の端部を閉じているため、フィンカラー７の穴よりも鞘状金属板１の外径が小さくなり、伝熱管３をフィンカラー７に滑らかに挿入することが可能となる。
【００１８】
図６は伝熱管３を包んだ鞘状金属板１が板状フィン６上に設けられたフィンカラー７の穴部から引き抜かれている状態を示す部分断面図である。図に示すように、引きぬきの際、伝熱管３の下端部に固定冶具９を付加することによって、鞘状金属板１と共に伝熱管３も引きぬかれることを防止できる。
【００１９】
この際、ロウ材８は鞘状金属板１との摩擦によって伝熱管３から剥がれ落ちる可能性があるため、図３のように鞘状金属板１の内部形状に凹凸５を設けてこれを概ね防ぐことが出来る。これは、鞘状金属板１を引き抜く工程において、ロウ材８と鞘状金属板１が凸の部分のみ接触することによる。
【００２０】
また、フィンカラー中間部７ｂは、図４のように、伝熱管軸方向（挿入方向）に対して、伝熱管側にある角度θをなしている。例えば、θ＝０°の場合、伝熱管３および鞘状金属板１は挿入の際フィンカラー７の根元部７ａに引っ掛かるため、挿入性が非常に悪い。本実施の形態のように、フィンカラー７が伝熱管側にある角度θをなしていることにより、鞘状金属板１は挿入の際フィンカラー７の中間部７ｂと接触し、挿入性が良くなる。
【００２１】
また、フィンカラー短軸内径最小値ｄｍｉｎ、最大径ｄｍａｘおよび伝熱管短軸最大径Ｄａの間に、ｄｍｉｎ＜Ｄａ＜ｄｍａｘの関係が成立するようにしているため、弾性変形領域で起きるスプリングバックと呼ばれる現象によって、鞘状金属板１を引きぬいた後、フィンカラー７がロウ材８を塗布した伝熱管３と密着する。
【００２２】
図７は板状フィン６表面をブレージングシート２０製とし、先端部にテーパ３ａを設けた伝熱管３が、板状フィン６上に設けられたフィンカラー７の穴部に挿入されている工程を示す部分断面図である。図に示すように、伝熱管３はフィンカラー７を弾性変形させながら、押し出し冶具２１によって、伝熱管３の軸方向（引き抜き方向）に挿入される。
【００２３】
その際、ロウ材の役目を果たすフィン表面のブレージングシート２０は高い強度を有し、伝熱管３との摩擦により、剥がれ落ちない。また、伝熱管３の端部に伝熱管周方向に対し内側にテーパ３ａを設けているため、伝熱管３をフィンカラー７に滑らかに挿入することが可能となり金属製の鞘で伝熱管３を包む必要がない。
【００２４】
図８は板状フィンと伝熱管からなる作動流体と空気の熱交換部とヘッダを組み合わせた状態をしめす外観図である。図に示すように、伝熱管３の端部には作動流体を各伝熱管３に分配するためのヘッダ１０を付加しており、片方のヘッダ１０には作動流体出入り口１１を設けている。この状態まで組み立てた後、炉に投入し、炉中ロウ付けを行う。
【００２５】
図９は炉中ロウ付け工程を終えた後の伝熱管３と板状フィン６上に設けられたフィンカラー７の穴部、ロウ材８を示す部分断面図である。炉中ロウ付けによって、ロウ材８はフィンカラー７の根元部７ａと先端部７ｃ付近の伝熱管３との隙間に溜まりこむため、フィンカラー７の中間部７ｂと伝熱管３の間のロウ材８は非常に薄くなっているが、フィンカラー７の中間部７ｂがスプリングバックによって伝熱管と密着したことによる。
【００２６】
このようにして、本実施の形態において、伝熱管３とフィンカラー７の隙間にロウ材８が隈なく行き渡るため、伝熱管３とフィンカラー７の間の接触熱伝達率αｃは非常に大きくなり、熱交換性能は向上する。なお接触熱伝達率αｃの定義は以下のようである。
積層された板状フィン６のピッチＦｐ内を通る熱流束をｑ（Ｗ／ｍ^２）、フィンカラー根元部７ａの温度をＴｃ、伝熱管外周の温度をＴｒとすると、
αｃ＝ｑ／｜Ｔｃ−Ｔｒ｜（Ｗ／ｍ^２Ｋ）
となる。
【００２７】
図１０は鞘状金属板を用いた場合の熱交換器を製造する工程を示すフローチャートである。
以下にその手順を示す。伝熱管３にロウ材８を塗布（Ｓ１）、鞘状金属板１に伝熱管３を挿入（Ｓ２）、鞘状金属板の端部１ａに引抜冶具２を取り付け（Ｓ３）、冶具で固定された板状フィン６に鞘状金属板１および伝熱管３を挿入（Ｓ４）、固定冶具９を伝熱管下端部に取り付け（Ｓ５）、鞘状金属板１の引き抜き（Ｓ６）、ヘッダ１０を取り付け、炉に投入（Ｓ７）、組み立てた熱交換器を乾燥炉に投入（Ｓ８）、完成となる。
【００２８】
図１１は、表面がブレージングシート製の板状フィン６、端部に伝熱管周方向に対し内側にテーパ３ａを設けた伝熱管を用いた場合（図７）の熱交換器を製造する工程を示すフローチャートである。
以下に熱交換器の製造工程を示す。押し出し冶具２１を伝熱管下部に取りつけ（Ｓ１）、冶具で固定された板状フィン６に伝熱管３を挿入（Ｓ２）、ヘッダ１０を取り付け、炉に投入（Ｓ３）、組み立てた熱交換器を乾燥炉に投入（Ｓ４）、完成となる。
【００２９】
図１２は、鞘状金属板１をブレージングシート板材とした場合、伝熱管と鞘状のブレ−ジングシート板材をフィンカラーの穴に挿入し終えた状態を示している。ここで、鞘状金属板１の先端部１ａは破線部において、切断される。このように、鞘状金属板１をブレージンブシート板材とすることで、鞘状金属板１を引き抜く必要がなくなり、鞘状金属板１の先端部１ａが切断された後、ヘッダ１０を熱交換器に取りつけ、直ちに炉中ロウ付け工程に移ることが出来る。また、鞘状金属板１を引き抜く必要がないため、伝熱管３にロウ材を塗布した場合の鞘状金属板１の引き抜き工程のロウ材の剥がれ落ちを防ぐことが出来る。
【００３０】
図１３は鞘状金属板１にブレージングシート板材を用いた場合の熱交換器を製造する工程を示すフローチャートである。
以下にその手順を示す。鞘状金属板１に伝熱管３を挿入（Ｓ１）、鞘状金属板の端部１ａに引抜冶具２取りつけ（Ｓ２）、冶具で固定された板状フィン６に鞘状金属板１および伝熱管３を挿入（Ｓ３）、鞘状金属板１の上部端部を切り取る（Ｓ４）、ヘッダ１０を取り付け、炉に投入（Ｓ５）、組み立てた熱交換器を乾燥炉に投入（Ｓ６）、完成となる。
【００３１】
図１４は板状フィン６上に設けられたフィンカラー７の形状と伝熱管３の位置関係を示している。フィンカラー７は根元部７ａ、中間部７ｂおよび先端部７ｃで構成され、根元部７ａおよび先端部７ｃは伝熱管３に向かって凸の円弧、中間部７ｂはストレート形状となっている。ここで、中間部７ｂは伝熱管軸方向（挿入方向）に対して、平行に設けられている。
【００３２】
また、フィンカラー７の短軸内径最小値ｄｍｉｎおよび伝熱管短軸最大径Ｄａの間に、ｄｍｉｎ＞Ｄａの関係が成立するようにしており、伝熱管挿入工程後、フィンカラー７を伝熱管周方向より押し込み冶具１９でかしめることにより（図１５）、フィンカラー７とロウ材８を塗布した伝熱管３を密着させることが可能となる。なお、本実施の形態では、ｄｍｉｎ＝２．２ｍｍ、Ｄａ＝２．０ｍｍとした。
【００３３】
図１６は、図１４に示した熱交換器を製造する工程を示すフローチャートである。
以下にその手順を示す。冶具で固定された板状フィン６に伝熱管３を挿入（Ｓ１）、フィンカラー７をかしめる（Ｓ２）、ヘッダを取り付け、炉に投入（Ｓ３）、組み立てた熱交換器を乾燥炉に投入（Ｓ４）、完成となる。
【００３４】
図１７は伝熱管に円管を用いた場合の板状フィン６とフィンカラーの断面図である。この場合も、図１０、１１および１３の工程を用いて、同様に熱交換器を製造できることは言うまでもない。
【００３５】
実施の形態２．
図１８および図１９は実施の形態２による伝熱管の形状を示す外観図と断面図である。図に示すように、伝熱管３は、扁平形状をしており、作動流体が流れるマイクロチャネル４を８個設けている。また、伝熱管３の外側には、図１８は伝熱管周方向、図１９は軸方向に、溝が設けられ、その溝にロウ材８が塗布される。ロウ材８にはアルミ−シリコン系の合金を用いている。
【００３６】
図２０は板状フィン６と板状フィン６上に設けられるスリット１２およびフィンカラー７を示す部分外観図および断面図である。図に示すように、スリット１２は伝熱管軸（挿入）方向に対し上下に切り起されている。また、フィンカラー７は先端部に曲面部が無く、図４のフィンカラー７よりも伝熱管軸方向に短い。このため、図４のフィンカラー７を成形するときのように、しごき加工を用いて、フィンカラー７の軸方向高さを稼ぐ必要が無く、成形が容易となる利点がある。この場合、フィンカラー７の長さＬは板状フィン６のピッチＦｐよりも小さくなる。また、フィンカラー７は穴全体に渡って設けられていない。これは、しごき加工無しで穴のＲの小さい部分にフィンカラー７を設ける場合割れを生じやすいためである。
【００３７】
図２１は板状フィン６上に設けられたフィンカラー７の形状と伝熱管３の位置関係を示している。フィンカラー７は根元部７ａおよび中間部７ｂで構成され、根元部７ａは伝熱管３に向かって凸の円弧、中間部７ｂはストレート形状となっている。ここで、中間部７ｂは伝熱管軸方向（挿入方向）に対して、伝熱管側にある角度θをなしている。また、フィンカラー７の短軸内径最小値ｄｍｉｎ、最大径ｄｍａｘおよび伝熱管短軸最大径Ｄａの間に、ｄｍｉｎ＜Ｄａ＜ｄｍａｘの関係が成立するようにしている。なお、本実施の形態では、ｄｍａｘ＝２．５ｍｍ、ｄｍｉｎ＝１．７ｍｍ、Ｄａ＝２．０ｍｍとする。
【００３８】
図２２はロウ材８を溝に塗布した伝熱管３と伝熱管３を包んだ鞘状金属板１（図１）が板状フィン６上に設けられたフィンカラー７の穴部に挿入されている工程を示す部分断面図である。図に示すように、ロウ材８を溝に塗布した伝熱管３および鞘状金属板１はフィンカラー７を弾性変形させながら、伝熱管３の軸方向（鞘状金属板１と伝熱管３挿入方向）に引抜冶具２を引っ張ることによって、挿入される。
【００３９】
その際、スリット１２は管軸方向の積層された板状フィン６のピッチＦｐを規制するように、その片面を異なる板状フィン６から切起こされたスリット１２の片面と接触させている。また、伝熱管３に塗布されたロウ材８は、鞘状金属板１によって、フィンカラー７との摩擦により、剥がれ落ちることを免れる。また、鞘状金属板１の端部を閉じているため、フィンカラー７の穴よりも鞘状金属板１の外径が小さくなり、フィンカラー７に滑らかに挿入することが可能となる。
【００４０】
図２３は伝熱管３を包んだ鞘状金属板１が板状フィン６上に設けられたフィンカラー７の穴部から引き抜かれている工程を示す部分断面図である。図に示すように、鞘状金属板１の引きぬきの際、伝熱管３の下端部に固定冶具９を付加することによって、鞘状金属板１と共に伝熱管３も引きぬかれることを防止できる。
【００４１】
また、伝熱管挿入工程が終了した際、フィンカラー７が伝熱管３に設けられたロウ材８を塗布した溝と一致するようにする。この際、ロウ材８は鞘状金属板１との摩擦によって伝熱管３から剥がれ落ちる可能性があるが、図１８および図１９のよう伝熱管３の外周に設けてある溝にロウ材８が入り込んでいるためにロウ材８の剥がれを概ね防ぐことが出来る。
【００４２】
また、外周の溝を伝熱管軸方向に対し、斜めに設けても同様な効果を奏する。
【００４３】
また、フィンカラー７は図２１のように、伝熱管軸方向（挿入方向）に対して、伝熱管側にある角度θをなしている。例えば、θ＝０°の場合、伝熱管３および鞘状金属板１は挿入の際フィンカラー根元部７ａに引っ掛かるため、挿入性が非常に悪い。本実施の形態のように、フィンカラー７が伝熱管側にある角度θをなしていることにより、鞘状金属板１は挿入の際フィンカラー７の中間部７ｂと接触し、挿入性が良くなる。
【００４４】
また、フィンカラー７の短軸内径最小値ｄｍｉｎ、最大径ｄｍａｘおよび伝熱管短軸最大径Ｄａの間に、ｄｍｉｎ＜Ｄａ＜ｄｍａｘの関係が成立するようにしているため、弾性変形領域で起きるスプリングバックと呼ばれる現象によって、鞘状金属板１を引きぬいた後、フィンカラー７とロウ材を塗布した伝熱管３が密着する。
【００４５】
また、本実施の形態のフィンカラー７（図２１）のように、フィンカラー７の伝熱管軸方向長さが短い場合、フィンカラー７にしごき加工を加える必要がほとんど無いため、フィンカラー７の加工硬化を防ぐことが出来、スプリングバックが起きやすい。よって、鞘状金属板１を引き抜いた後にスプリングバックによる伝熱管３とフィンカラー７の密着をより円滑に行うことが出来る。さらに、ヘッダ１０を付加した後、炉に投入し、炉中ロウ付けを行う。
【００４６】
図２４は炉中ロウ付け工程を終えた後の伝熱管３と板状フィン６上に設けられたフィンカラー７、ロウ材８を示す部分断面図である。炉中ロウ付けによってロウ材８は溶けだすが、溝の中に留まり、フィンカラー７はスプリングバックによって溝の中に折り込まれる。よってフィンカラー７は全体に渡って伝熱管３と密着する。
【００４７】
このようにして、本実施の形態において伝熱管３とフィンカラー７の隙間にロウ材８が隈なく行き渡るため、伝熱管３とフィンカラー７の間の接触熱伝達率αｃは非常に大きくなり、熱交換性能が向上する。
【００４８】
また、本実施の形態の製造方法においては、余分なロウ材８を伝熱管３に取りつける必要が無く、ロウ材８の節約にもなる。製造工程は図１０のフロ−チャートと同様に行われることはいうまでも無い。
【００４９】
図２５（ａ）はフィンカラーに設けられた穴を長方形とした場合の部分外観図、図２５（ｂ）は伝熱管形状を長方形とした場合の断面図である。図のように、フィンカラー形状および伝熱管形状を長方形とした場合、図２０のフィンカラー７ようにＲの小さい部分が無く、フィンカラー７を全周に設けることが可能となる。よって、ロウ付け工程後伝熱管３とフィンカラー７の間の接触熱伝達率αｃは非常に大きくなり、熱交換性能は向上する。
【００５０】
図２６は伝熱管に円管を用いた場合の板状フィンとフィンカラーの断面図である。この場合も、図１８および図１９のように伝熱管３に周方向もしくは軸方向にロウ材８を塗布する溝を設け、図１０の工程を用いて、熱交換器を製造できることは言うまでもない。
【００５１】
尚、本実施の形態では、図２２に示すように、ロウ材８を溝に塗布した伝熱管３および鞘状金属板１はフィンカラー７を弾性変形させながら、伝熱管３の軸方向（鞘状金属板１と伝熱管３挿入方向）に引抜冶具２を引っ張ることによって、挿入されるものを示したが、鞘状金属板１を用いずに、図７に示した板状フィン６表面をブレージングシート２０製とし、先端部にテーパ３ａを設けた伝熱管３が、板状フィン６上に設けられたフィンカラー７の穴部に挿入されるようにしてもよい。
【００５２】
実施の形態３．
図２７は実施の形態３を示す図で、空気調和機の冷媒回路図である。図に示す冷媒回路は、圧縮機１３、凝縮熱交換器１４、絞り装置１５、蒸発熱交換器１６、送風機１７により構成されている。上述の実施の形態１、２による熱交換器を凝縮熱交換器１４または蒸発熱交換器１６、もしくは両方に用いることにより、エネルギ効率の高い空気調和機を実現することが出来る。
ここで、エネルギ効率は、次式で定義されるものである。
暖房エネルギ効率＝室内熱交換器（凝縮器）能力／全入力
冷房エネルギ効率＝室内熱交換器（蒸発器）能力／全入力
また、空気調和機に限らず、冷凍装置においても、有効であることは言うまでもない。
【００５３】
なお、上述の実施の形態１〜３で述べた熱交換器およびそれを用いた空調冷凍装置については、ＨＣＦＣ（Ｒ２２）やＨＦＣ（Ｒ１１６、Ｒ１２５、Ｒ１３４ａ、Ｒ１４、Ｒ１４３ａ、Ｒ１５２ａ、Ｒ２２７ｅａ、Ｒ２３、Ｒ２３６ｅａ、Ｒ２３６ｆａ、Ｒ２４５ｃａ、Ｒ２４５ｆａ、Ｒ３２、Ｒ４１，ＲＣ３１８などや、これら冷媒の数種の混合冷媒Ｒ４０７Ａ、Ｒ４０７Ｂ、Ｒ４０７Ｃ、Ｒ４０７Ｄ、Ｒ４０７Ｅ、Ｒ４１０Ａ、Ｒ４１０Ｂ、Ｒ４０４Ａ、Ｒ５０７Ａ、Ｒ５０８Ａ、Ｒ５０８Ｂなど）、ＨＣ（ブタン、イソブタン、エタン、プロパン、プロピレンなどや、これら冷媒の数種混合冷媒）、自然冷媒（空気、炭酸ガス、アンモニアなどや、これら冷媒の数種の混合冷媒）、またこれら冷媒の数種の混合冷媒など、どんな種類の冷媒を用いても、その効果を達成することが出来る。
【００５４】
また、作動流体として、空気と冷媒や、他の気体、液体、気液混合流体を用いても、同様の効果を奏する。
【００５５】
また、伝熱管とフィンは異なった材料を用いていることが多いが、伝熱管とフィンに銅、アルミ等の同じ材料を用いることで、フィンと伝熱管のロウ付けが可能となり、フィンと伝熱管の接触熱伝達率が飛躍的に向上し、熱交換能力が大幅に向上する。また、リサイクル性も向上させることができる。
【００５６】
また、伝熱管とフィンを密着させる方法として、炉中ロウ付けを行う場合、フィンへの親水材の塗布を後処理で行うことで、前処理の場合のロウ付け中の親水材の焼け落ちを防ぐことができる。
【００５７】
なお、上述の実施の形態１〜３で述べた熱交換器およびそれを用いた空調冷凍装置については、鉱油系、アルキルベンゼン油系、エステル油系、エーテル油系、フッ素油系など、冷媒と油が溶ける溶けないにかかわらず、どんな冷凍機油についても、その効果を達成することができる。
【００５８】
【発明の効果】
この発明に係るフィンチューブ型熱交換器の製造方法は、鞘状金属板に包まれた伝熱管を引抜治具を引っ張ることにより板状フィンのフィンカラーに挿入し、鞘状金属板を引抜治具により、伝熱管を固定治具により板状フィン内に残して、引き抜くようにしたので、熱交換効率が良いフィンチューブ型熱交換器が得られると共に、製造工程が容易となる効果がある。
【図面の簡単な説明】
【図１】実施の形態１を示す図で、鞘状金属板を示す外観図および断面図である。
【図２】実施の形態１を示す図で、伝熱管を示す部分外観図である。
【図３】実施の形態１を示す図で、鞘状金属板を示す断面図である。
【図４】実施の形態１を示す図で、板状フィンおよびフィンカラーを示す外観図および断面図である。
【図５】実施の形態１を示す図で、鞘状金属板および伝熱管挿入工程を示す断面図である。
【図６】実施の形態１を示す図で、鞘状金属板の引き抜き工程を示す断面図である。
【図７】実施の形態１を示す図で、伝熱管挿入工程を示す断面図である。
【図８】実施の形態１を示す図で、熱交換器組み立て状態を示す外観図である。
【図９】実施の形態１を示す図で、ロウ付け後の状態を示す断面図である。
【図１０】実施の形態１を示す図で、製造工程を示すフローチャート図である。
【図１１】実施の形態１を示す図で、製造工程を示すフローチャート図である。
【図１２】実施の形態１を示す図で、鞘状のブレージングシート板材および伝熱管を板状フィンに挿入した状態を示す断面図である。
【図１３】実施の形態１を示す図で、製造工程を示すフローチャート図である。
【図１４】実施の形態１を示す図で、板状フィンおよびフィンカラーを示す外観図および断面図である。
【図１５】実施の形態１を示す図で、フィンカラーを冶具により伝熱管にかしめる工程を示す外観図および断面図である。
【図１６】実施の形態１を示す図で、製造工程を示すフローチャート図である。
【図１７】実施の形態１を示す図で、円管を用いた場合のフィンカラー形状を示す外観図および断面図である。
【図１８】実施の形態２を示す図で、伝熱管の形状を表す外観図および断面図である。
【図１９】実施の形態２を示す図で、伝熱管の形状を表す外観図および断面図である。
【図２０】実施の形態２を示す図で、板状フィン形状およびフィンカラー形状を示す外観図および断面図である。
【図２１】実施の形態２を示す図で、フィンカラー形状および伝熱管の関係を示す断面図である。
【図２２】実施の形態２を示す図で、鞘状金属板および伝熱管挿入工程を示す断面図である。
【図２３】実施の形態２を示す図で、鞘状金属板の引き抜き工程を示す断面図である。
【図２４】実施の形態２を示す図で、ロウ付け後の状態を示す断面図である。
【図２５】実施の形態２を示す図で、板状フィン形状および伝熱管形状を示す外観図および断面図である。
【図２６】実施の形態２を示す図で、円管を用いた場合のフィンカラー形状を示す外観図および断面図である。
【図２７】実施の形態３を示す図で、空気調和機構成を表す平面断面図である。
【符号の説明】
１鞘状金属板、２引抜冶具、３伝熱管、４マイクロチャネル、５凹凸、６板状フィン、７フィンカラー、８ロウ材、９固定冶具、１０ヘッダ、１１作動流体出入り口、１２スリット、１３圧縮機、１４凝縮熱交換器、１５絞り装置、１６蒸発熱交換器、１７送風機、１８モータ、１９押し込み冶具、２０ブレージングシート、２１押し出し冶具。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a fin tube type heat exchanger for performing heat exchange between a refrigerant and a fluid such as a gas, and an air conditioning refrigeration apparatus.
[0002]
[Prior art]
In the conventional circular tube fin tube type heat exchanger, a plate-like fin through which gas (air) flows is arranged at regular intervals, and a circular heat transfer tube through which a working fluid flows is inserted vertically into the plate-like fin. The fins and the heat transfer tubes are fixed by a process called mechanical expansion (see, for example, Patent Document 1).
[0003]
In addition, a conventional method of manufacturing a fin tube type heat exchanger using a flat tube encloses the flat tube with a cover material made of a U-shaped brazing sheet, and, from a row direction, with respect to a stacked fin having a notch. After the insertion, the heat exchanger is completed through a brazing process (for example, see Patent Document 2).
[0004]
Another conventional method of manufacturing a fin tube type heat exchanger using a flat tube is to assemble the heat exchanger by inserting the flat tube into a laminated fin having a notch in a row direction. In addition, a cut-and-raised portion for regulating the laminating interval of the plate-like fins is provided (for example, see Patent Document 3).
[0005]
[Patent Document 1]
JP 2001-221587 A (page 14, FIG. 17)
[Patent Document 2]
JP-A-2000-234883 (page 5, FIG. 1)
[Patent Document 3]
Japanese Patent Application Laid-Open No. 9-324995 (page 7, FIG. 1)
[0006]
[Problems to be solved by the invention]
In a conventional method for manufacturing a circular tube fin tube type heat exchanger (for example, Patent Document 1), the fin collar and the heat transfer tube are brought into close contact by mechanical expansion, but compared with the joining of the fin collar and the heat transfer tube by brazing. Thus, there is a problem that the contact heat transfer coefficient between the fin collar and the heat transfer tube is reduced.
[0007]
Further, in the conventional method for manufacturing a flat tube heat exchanger (for example, Patent Document 2), a flat tube covered with a brazing sheet cover material is inserted from the row direction, so that the fin collar expands in the step direction. There is a problem that the brazing material is difficult to spread between the fin collar and the heat transfer tube.
[0008]
Further, in the conventional flat tube heat exchanger manufacturing method (for example, Patent Document 3), since the flat tubes are inserted from the row direction, the fin collar tends to spread in the axial direction, and the fin collar and the heat transfer tube are located between the fin collar and the heat transfer tube. In addition to the problem that the brazing material is difficult to spread, in addition to the fact that cut and raised portions are provided to regulate the pitch of the plate-like fins, the heat transfer area of the plate-like fins is impaired and the heat exchange performance is impaired. There was a point.
[0009]
The present invention has been made in order to solve the above-mentioned problems, and aims at reducing ventilation resistance and improving the amount of heat exchange, and has a good heat transfer performance and excellent fin tube type heat exchange. It is an object of the present invention to provide a method for manufacturing a vessel and an air conditioning refrigeration apparatus.
[0010]
[Means for Solving the Problems]
The method of manufacturing a fin tube type heat exchanger according to the present invention includes a plurality of plate-like fins arranged in parallel, in which a gas flows, and a fin collar of the plate-like fin, and a working fluid passes through the inside. A method of manufacturing a fin tube type heat exchanger in which a plurality of heat transfer tubes are provided in a step direction perpendicular to a gas passage direction, wherein a brazing material is applied to the heat transfer tubes, A step of inserting a heat transfer tube into the fin, a step of attaching a drawing jig to an end of the sheathed metal plate, and a drawing tube to wrap the heat transfer tube wrapped in the sheathed metal plate into a fin collar of a plate fin. Inserting the heat transfer tube, attaching a fixing jig to the lower end of the heat transfer tube, extracting the sheath-shaped metal plate with a jig, leaving the heat transfer tube in the plate-like fin with the fixing jig, and withdrawing the heat transfer tube. Attach header to end of A step, a step of performing heat exchanger was put into a furnace furnace brazing the assembled, characterized by comprising a.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Embodiment 1 FIG.
FIG. 1 is an external view and a sectional view showing a sheath-shaped metal plate. In the figure, a sheath-shaped metal plate 1 is used for wrapping a heat transfer tube when inserting the heat transfer tube into a plate-like fin. The sheath-shaped metal plate 1 has a thickness of about 0.1 mm and a hollow structure having a flat cross section. Further, one end 1a is closed, and the drawing jig 2 is attached.
[0012]
FIG. 2 is a partial external view showing a heat transfer tube. As shown in the figure, the heat transfer tube 3 has a flat shape and is provided with eight microchannels 4 through which a working fluid flows. Further, a brazing material is applied to the outside of the heat transfer tube 3. An aluminum-silicon alloy is used for the brazing material.
[0013]
FIG. 3 is a sectional view of the sheath-shaped metal plate. As shown in the figure, the sheath-shaped metal plate 1 has unevenness 5 inside. This serves to prevent the brazing material applied to the outside of the heat transfer tube 3 from peeling when the sheath-shaped metal plate 1 is pulled out.
[0014]
FIG. 4 is an external view and a sectional view showing a plate-like fin and a fin collar. As shown in the figure, the fin collar 7 provided on the plate-like fin 6 includes a root portion 7a, an intermediate portion 7b, and a distal end portion 7c, and the root portion 7a and the distal end portion 7c are convex toward the heat transfer tube 3. The arc and the intermediate portion 7b have a straight shape. Here, the intermediate portion 7b forms an angle θ on the heat transfer tube side with respect to the heat transfer tube axial direction (insertion direction). In order to improve the insertability of the heat transfer tube 3 and the sheath-shaped metal plate 1, the intermediate portion 7b is inclined at an angle θ so that the root portion 7a is widened.
[0015]
Further, the relationship of dmin <Da <dmax is established between the minimum value dmin of the short-axis inner diameter of the fin collar 7, the maximum diameter dmax, and the maximum diameter Da of the heat transfer tube short-axis. This is for bringing the fin collar 7 into close contact with the heat transfer tube 3 after the sheath-shaped metal plate 1 is pulled out.
In this embodiment, dmax = 2.5 mm, dmin = 1.5 mm, and Da = 2.0 mm.
[0016]
FIG. 5 is a partial cross-sectional view showing a state where the heat transfer tube 3 coated with the brazing material 8 and the sheath-shaped metal plate 1 surrounding the heat transfer tube 3 are inserted into holes of a fin collar 7 provided on the plate-like fin 6. FIG. As shown in the figure, the heat transfer tube 3 and the sheath-shaped metal plate 1 coated with the brazing material 8 pull the drawing jig 2 in the axial direction (drawing direction) of the heat transfer tube 3 while elastically deforming the fin collar 7. Inserted.
[0017]
At this time, the brazing material 8 applied to the heat transfer tube 3 is prevented from being peeled off by the friction with the fin collar 7 by the sheath-shaped metal plate 1. Further, since the end of the sheath-shaped metal plate 1 is closed, the outer diameter of the sheath-shaped metal plate 1 is smaller than the hole of the fin collar 7, and the heat transfer tube 3 can be smoothly inserted into the fin collar 7. It becomes.
[0018]
FIG. 6 is a partial sectional view showing a state in which the sheath-shaped metal plate 1 surrounding the heat transfer tube 3 is pulled out from a hole of a fin collar 7 provided on the plate-shaped fin 6. As shown in the drawing, by adding a fixing jig 9 to the lower end of the heat transfer tube 3 at the time of pulling out, it is possible to prevent the heat transfer tube 3 from being pulled out together with the sheathed metal plate 1.
[0019]
At this time, since the brazing material 8 may peel off from the heat transfer tube 3 due to friction with the sheath-shaped metal plate 1, the inner shape of the sheath-shaped metal plate 1 is provided with irregularities 5 as shown in FIG. Can be prevented. This is because the brazing material 8 and the sheath-shaped metal plate 1 come into contact with each other only in the convex portion in the step of pulling out the sheath-shaped metal plate 1.
[0020]
Further, as shown in FIG. 4, the fin collar intermediate portion 7b forms an angle θ on the heat transfer tube side with respect to the heat transfer tube axial direction (insertion direction). For example, when θ = 0 °, the heat transfer tube 3 and the sheath-shaped metal plate 1 are caught on the base 7a of the fin collar 7 during insertion, so that the insertability is very poor. Since the fin collar 7 forms an angle θ on the heat transfer tube side as in the present embodiment, the sheath-shaped metal plate 1 comes into contact with the intermediate portion 7b of the fin collar 7 at the time of insertion, and the insertability is good. Become.
[0021]
In addition, since the relationship of dmin <Da <dmax is established between the minimum value dmin, the maximum diameter dmax, and the maximum diameter Da of the heat transfer tube in the fin collar short axis inner diameter, the springback that occurs in the elastic deformation region is reduced. By the phenomenon called, after the sheath-shaped metal plate 1 is pulled out, the fin collar 7 comes into close contact with the heat transfer tube 3 coated with the brazing material 8.
[0022]
FIG. 7 shows a process in which the surface of the plate-like fin 6 is made of a brazing sheet 20 and the heat transfer tube 3 provided with a taper 3 a at the tip is inserted into a hole of a fin collar 7 provided on the plate-like fin 6. FIG. As shown in the figure, the heat transfer tube 3 is inserted in the axial direction (pull-out direction) of the heat transfer tube 3 by the extrusion jig 21 while elastically deforming the fin collar 7.
[0023]
At this time, the brazing sheet 20 on the surface of the fin serving as a brazing material has high strength and does not peel off due to friction with the heat transfer tube 3. In addition, since the end of the heat transfer tube 3 is provided with a taper 3a on the inner side in the circumferential direction of the heat transfer tube, the heat transfer tube 3 can be smoothly inserted into the fin collar 7, and the heat transfer tube 3 is formed of a metal sheath. No need to wrap.
[0024]
FIG. 8 is an external view showing a state in which a heat exchange portion of air and a working fluid including plate-like fins and heat transfer tubes and a header are combined. As shown in the figure, a header 10 for distributing a working fluid to each heat transfer tube 3 is added to an end of the heat transfer tube 3, and one of the headers 10 is provided with a working fluid inlet / outlet 11. After assembling to this state, it is put into a furnace and brazed in the furnace.
[0025]
FIG. 9 is a partial cross-sectional view showing the hole of the fin collar 7 provided on the heat transfer tube 3 and the plate-like fin 6 and the brazing material 8 after the in-furnace brazing step. By brazing in the furnace, the brazing material 8 accumulates in the gap between the heat transfer tube 3 near the root portion 7a and the tip portion 7c of the fin collar 7, so that the brazing material between the intermediate portion 7b of the fin collar 7 and the heat transfer tube 3 is formed. 8 is very thin, but because the intermediate portion 7b of the fin collar 7 is in close contact with the heat transfer tube by springback.
[0026]
In this manner, in the present embodiment, since the brazing material 8 spreads all over the gap between the heat transfer tube 3 and the fin collar 7, the contact heat transfer coefficient αc between the heat transfer tube 3 and the fin collar 7 becomes very large. , Heat exchange performance is improved. The definition of the contact heat transfer coefficient αc is as follows.
The heat flux passing through the pitch Fp of the laminated plate-like fins 6 is represented by q (W / m ² ), Assuming that the temperature of the fin collar root portion 7a is Tc and the temperature of the outer periphery of the heat transfer tube is Tr.
αc = q / | Tc−Tr | (W / m ² K)
It becomes.
[0027]
FIG. 10 is a flowchart showing the steps of manufacturing a heat exchanger using a sheath-shaped metal plate.
The procedure is described below. The brazing material 8 is applied to the heat transfer tube 3 (S1), the heat transfer tube 3 is inserted into the sheathed metal plate 1 (S2), the drawing jig 2 is attached to the end 1a of the sheathed metal plate (S3), and fixed by the jig. The sheathed metal plate 1 and the heat transfer tube 3 are inserted into the plate fins 6 (S4), the fixing jig 9 is attached to the lower end of the heat transfer tube (S5), the sheathed metal plate 1 is pulled out (S6), and the header 10 is attached. And put it in a furnace (S7), put the assembled heat exchanger in a drying furnace (S8), and it is completed.
[0028]
FIG. 11 shows a process of manufacturing a heat exchanger using a plate-like fin 6 whose surface is made of a brazing sheet and a heat transfer tube provided with a taper 3a inside at the end with respect to the circumferential direction of the heat transfer tube (FIG. 7). It is a flowchart shown.
The manufacturing process of the heat exchanger is described below. The extruding jig 21 is attached to the lower part of the heat transfer tube (S1), the heat transfer tube 3 is inserted into the plate-like fin 6 fixed by the jig (S2), the header 10 is attached, and the furnace is put into the furnace (S3). It is put into a drying oven (S4) and completed.
[0029]
FIG. 12 shows a state in which, when the sheath-shaped metal plate 1 is a brazing sheet plate, the heat transfer tube and the sheath-shaped brazing sheet plate have been inserted into the holes of the fin collar. Here, the distal end portion 1a of the sheath-shaped metal plate 1 is cut at a broken line portion. In this way, by making the sheath-shaped metal plate 1 a brazing sheet material, it is not necessary to pull out the sheath-shaped metal plate 1, and after the distal end portion 1a of the sheath-shaped metal plate 1 is cut, the header 10 is heated. It can be mounted on the exchanger and immediately proceed to the furnace brazing process. Further, since there is no need to pull out the sheath-shaped metal plate 1, it is possible to prevent the brazing material from peeling off in the step of drawing the sheath-shaped metal plate 1 when the brazing material is applied to the heat transfer tube 3.
[0030]
FIG. 13 is a flowchart showing a process of manufacturing a heat exchanger when a brazing sheet plate is used for the sheath-shaped metal plate 1.
The procedure is described below. The heat transfer tube 3 is inserted into the sheathed metal plate 1 (S1), the drawing jig 2 is attached to the end 1a of the sheathed metal plate (S2), and the sheathed metal plate 1 and the heat transfer tube are attached to the plate fin 6 fixed by the jig. 3 (S3), cut off the upper end of the sheath-shaped metal plate 1 (S4), attach the header 10, put it into the furnace (S5), put the assembled heat exchanger into the drying furnace (S6), and complete it. Become.
[0031]
FIG. 14 shows the positional relationship between the shape of the fin collar 7 provided on the plate-like fin 6 and the heat transfer tube 3. The fin collar 7 includes a root portion 7a, an intermediate portion 7b, and a distal end portion 7c. The root portion 7a and the distal end portion 7c have a circular arc convex toward the heat transfer tube 3, and the intermediate portion 7b has a straight shape. Here, the intermediate portion 7b is provided in parallel to the heat transfer tube axial direction (insertion direction).
[0032]
Further, a relationship of dmin> Da is established between the minimum value dmin of the short-axis inner diameter of the fin collar 7 and the maximum diameter Da of the heat-transfer tube, and after the heat-transfer tube insertion step, the fin collar 7 is moved around the heat-transfer tube. The fin collar 7 and the heat transfer tube 3 coated with the brazing material 8 can be brought into close contact with each other by caulking with the pushing jig 19 from the direction (FIG. 15). In the present embodiment, dmin = 2.2 mm and Da = 2.0 mm.
[0033]
FIG. 16 is a flowchart showing a process of manufacturing the heat exchanger shown in FIG.
The procedure is described below. The heat transfer tube 3 is inserted into the plate-like fin 6 fixed by the jig (S1), the fin collar 7 is caulked (S2), the header is attached, and the furnace is put into the furnace (S3), and the assembled heat exchanger is put into the drying furnace. (S4), it is completed.
[0034]
FIG. 17 is a cross-sectional view of the plate-like fin 6 and the fin collar when a circular tube is used as the heat transfer tube. Also in this case, it is needless to say that the heat exchanger can be similarly manufactured using the steps of FIGS.
[0035]
Embodiment 2 FIG.
18 and 19 are an external view and a sectional view showing the shape of the heat transfer tube according to the second embodiment. As shown in the figure, the heat transfer tube 3 has a flat shape and is provided with eight microchannels 4 through which a working fluid flows. Further, a groove is provided outside the heat transfer tube 3 in the circumferential direction of the heat transfer tube in FIG. 18 and in the axial direction in FIG. 19, and the brazing material 8 is applied to the groove. Aluminum-silicon alloy is used for the brazing material 8.
[0036]
FIG. 20 is a partial external view and a cross-sectional view showing the plate-like fin 6, the slit 12 provided on the plate-like fin 6, and the fin collar 7. As shown in the figure, the slit 12 is cut and raised vertically with respect to the heat transfer tube axis (insertion) direction. Further, the fin collar 7 has no curved surface portion at the tip end and is shorter in the heat transfer tube axial direction than the fin collar 7 of FIG. Therefore, unlike the case of forming the fin collar 7 in FIG. 4, there is no need to increase the height of the fin collar 7 in the axial direction by using ironing, and there is an advantage that the forming is easy. In this case, the length L of the fin collar 7 is smaller than the pitch Fp of the plate-like fins 6. Further, the fin collar 7 is not provided over the entire hole. This is because when the fin collar 7 is provided in a portion having a small R of the hole without ironing, a crack is easily generated.
[0037]
FIG. 21 shows the positional relationship between the shape of the fin collar 7 provided on the plate-like fin 6 and the heat transfer tube 3. The fin collar 7 includes a root portion 7a and an intermediate portion 7b. The root portion 7a has a circular arc protruding toward the heat transfer tube 3, and the intermediate portion 7b has a straight shape. Here, the intermediate portion 7b forms an angle θ on the heat transfer tube side with respect to the heat transfer tube axial direction (insertion direction). Further, the relationship of dmin <Da <dmax is established between the minimum value dmin of the short-axis inner diameter of the fin collar 7, the maximum diameter dmax, and the maximum diameter Da of the heat transfer tube short-axis. In this embodiment, dmax = 2.5 mm, dmin = 1.7 mm, and Da = 2.0 mm.
[0038]
FIG. 22 shows a heat transfer tube 3 in which a brazing material 8 is applied to a groove and a sheath-shaped metal plate 1 (FIG. 1) surrounding the heat transfer tube 3 inserted into a hole of a fin collar 7 provided on a plate-like fin 6. FIG. 7 is a partial cross-sectional view showing a step in which the present invention is performed. As shown in the figure, the heat transfer tube 3 and the sheathed metal plate 1 in which the brazing material 8 is applied to the grooves, while the fin collar 7 is elastically deformed, the axial direction of the heat transfer tube 3 (the insertion of the sheathed metal plate 1 and the heat transfer tube 3). (Direction) by inserting the pull-out jig 2.
[0039]
At this time, one side of the slit 12 is in contact with one side of the slit 12 cut and raised from a different plate-like fin 6 so as to regulate the pitch Fp of the laminated plate-like fins 6 in the tube axis direction. Further, the brazing material 8 applied to the heat transfer tube 3 is prevented from being peeled off by the friction with the fin collar 7 by the sheath-shaped metal plate 1. Further, since the end of the sheath-shaped metal plate 1 is closed, the outer diameter of the sheath-shaped metal plate 1 is smaller than the hole of the fin collar 7, and the sheath metal plate 1 can be smoothly inserted into the fin collar 7.
[0040]
FIG. 23 is a partial cross-sectional view showing a step in which the sheath-shaped metal plate 1 enclosing the heat transfer tube 3 is pulled out from the hole of the fin collar 7 provided on the plate-shaped fin 6. As shown in the figure, at the time of pulling out the sheath-shaped metal plate 1, by adding a fixing jig 9 to the lower end of the heat transfer tube 3, it is possible to prevent the heat transfer tube 3 from being pulled out together with the sheath-shaped metal plate 1. .
[0041]
Further, when the heat transfer tube insertion step is completed, the fin collar 7 is made to coincide with the groove provided on the heat transfer tube 3 to which the brazing material 8 has been applied. At this time, the brazing material 8 may peel off from the heat transfer tube 3 due to friction with the sheath-shaped metal plate 1, but the brazing material 8 is placed in a groove provided on the outer periphery of the heat transfer tube 3 as shown in FIGS. 18 and 19. Since it enters, the peeling of the brazing material 8 can be substantially prevented.
[0042]
The same effect can be obtained even if the groove on the outer periphery is provided obliquely with respect to the axial direction of the heat transfer tube.
[0043]
The fin collar 7 forms an angle θ on the heat transfer tube side with respect to the heat transfer tube axial direction (insertion direction) as shown in FIG. For example, when θ = 0 °, the heat transfer tube 3 and the sheath-shaped metal plate 1 are caught on the fin collar base portion 7a during insertion, so that the insertability is very poor. Since the fin collar 7 forms an angle θ on the heat transfer tube side as in the present embodiment, the sheath-shaped metal plate 1 comes into contact with the intermediate portion 7b of the fin collar 7 at the time of insertion, and the insertability is good. Become.
[0044]
Further, since the relationship of dmin <Da <dmax is established between the minimum value dmin, the maximum diameter dmax of the short axis inner diameter of the fin collar 7 and the maximum diameter Da of the heat transfer tube, the spring occurring in the elastic deformation region. After the sheath-shaped metal plate 1 is pulled out by a phenomenon called back, the fin collar 7 and the heat transfer tube 3 coated with the brazing material adhere to each other.
[0045]
When the length of the fin collar 7 in the axial direction of the heat transfer tube is short as in the fin collar 7 of the present embodiment (FIG. 21), it is almost unnecessary to perform ironing on the fin collar 7. Work hardening can be prevented, and springback is likely to occur. Therefore, after the sheath-shaped metal plate 1 is pulled out, the heat transfer tube 3 and the fin collar 7 can be more smoothly adhered to each other by springback. Furthermore, after adding the header 10, it is put into a furnace and brazing in the furnace is performed.
[0046]
FIG. 24 is a partial cross-sectional view showing the heat transfer tube 3 and the fin collar 7 and the brazing material 8 provided on the plate-like fin 6 after the in-furnace brazing step. The brazing material 8 melts by brazing in the furnace, but remains in the groove, and the fin collar 7 is folded into the groove by springback. Therefore, the fin collar 7 is in close contact with the heat transfer tube 3 throughout.
[0047]
In this manner, in the present embodiment, since the brazing material 8 spreads all over the gap between the heat transfer tube 3 and the fin collar 7, the contact heat transfer coefficient αc between the heat transfer tube 3 and the fin collar 7 becomes very large, Heat exchange performance is improved.
[0048]
Further, in the manufacturing method of the present embodiment, there is no need to attach extra brazing material 8 to heat transfer tube 3, and the brazing material 8 can be saved. It goes without saying that the manufacturing process is performed in the same manner as the flowchart of FIG.
[0049]
FIG. 25A is a partial external view when a hole provided in a fin collar is rectangular, and FIG. 25B is a cross-sectional view when a heat transfer tube shape is rectangular. As shown in the figure, when the fin collar shape and the heat transfer tube shape are rectangular, there is no small portion of R as in the fin collar 7 of FIG. 20, and the fin collar 7 can be provided on the entire circumference. Therefore, after the brazing step, the contact heat transfer coefficient αc between the heat transfer tube 3 and the fin collar 7 becomes very large, and the heat exchange performance is improved.
[0050]
FIG. 26 is a cross-sectional view of a plate-like fin and a fin collar when a circular tube is used as a heat transfer tube. Also in this case, it is needless to say that a heat exchanger can be manufactured using the process shown in FIG. 10 by providing grooves for applying the brazing material 8 in the circumferential direction or the axial direction in the heat transfer tube 3 as shown in FIGS. 18 and 19.
[0051]
In the present embodiment, as shown in FIG. 22, the heat transfer tube 3 and the sheath-shaped metal plate 1 having the brazing material 8 applied to the groove, while the fin collar 7 is elastically deformed, the axial direction of the heat transfer tube 3 (sheath). The drawing jig 2 is inserted by pulling the drawing jig 2 in the direction in which the plate-shaped metal plate 1 and the heat transfer tube 3 are inserted), but the surface of the plate-shaped fin 6 shown in FIG. The heat transfer tube 3 made of the brazing sheet 20 and having the tapered end 3 a at the tip may be inserted into the hole of the fin collar 7 provided on the plate-like fin 6.
[0052]
Embodiment 3 FIG.
FIG. 27 shows the third embodiment and is a refrigerant circuit diagram of the air conditioner. The refrigerant circuit shown in the figure includes a compressor 13, a condensing heat exchanger 14, a throttle device 15, an evaporating heat exchanger 16, and a blower 17. By using the heat exchangers according to the first and second embodiments for the condensing heat exchanger 14, the evaporating heat exchanger 16, or both, an air conditioner with high energy efficiency can be realized.
Here, the energy efficiency is defined by the following equation.
Heating energy efficiency = indoor heat exchanger (condenser) capacity / all inputs
Cooling energy efficiency = indoor heat exchanger (evaporator) capacity / all inputs
Needless to say, the present invention is effective not only in air conditioners but also in refrigeration systems.
[0053]
Note that the heat exchangers described in the first to third embodiments and the air-conditioning refrigeration systems using the same are provided with HCFC (R22) and HFC (R116, R125, R134a, R14, R143a, R152a, R227ea, R23, R236ea, R236fa, R245ca, R245fa, R32, R41, RC318, etc., and several types of mixed refrigerants R407A, R407B, R407C, R407D, R407E, R410A, R410B, R404A, R507A, R508A, R508B, etc. Butane, isobutane, ethane, propane, propylene, etc., and some kinds of these refrigerants), natural refrigerants (air, carbon dioxide, ammonia, etc., and some kinds of these refrigerants), and some kinds of these refrigerants What kind of mixed refrigerant Also using the medium, it is possible to achieve its effect.
[0054]
Similar effects can be obtained by using air and a refrigerant or another gas, liquid, or gas-liquid mixed fluid as the working fluid.
[0055]
The heat transfer tubes and the fins are often made of different materials, but by using the same material such as copper or aluminum for the heat transfer tubes and the fins, the fins and the heat transfer tubes can be brazed. The contact heat transfer coefficient of the heat pipe is dramatically improved, and the heat exchange capacity is greatly improved. In addition, recyclability can be improved.
[0056]
When brazing in a furnace is performed as a method of bringing the heat transfer tube and the fin into close contact with each other, by applying a hydrophilic material to the fin in a post-process, the burn-off of the hydrophilic material during brazing in the pre-process is performed. Can be prevented.
[0057]
The heat exchangers described in the first to third embodiments and the air-conditioning refrigeration apparatus using the same are described as refrigerants and oils such as mineral oils, alkylbenzene oils, ester oils, ether oils, and fluorine oils. The effect can be achieved with any refrigeration oil, regardless of whether it melts.
[0058]
【The invention's effect】
In the method of manufacturing a fin tube type heat exchanger according to the present invention, the heat transfer tube wrapped in the sheathed metal plate is inserted into the fin collar of the plate-like fin by pulling the drawing jig, and the sheathing metal plate is pulled out and cured. Since the heat transfer tubes are drawn out of the plate-like fins by the fixing jig, the fin tube type heat exchanger having good heat exchange efficiency can be obtained, and the manufacturing process can be facilitated.
[Brief description of the drawings]
FIG. 1 shows the first embodiment, and is an external view and a sectional view showing a sheath-shaped metal plate.
FIG. 2 shows the first embodiment and is a partial external view showing a heat transfer tube.
FIG. 3 shows the first embodiment, and is a cross-sectional view showing a sheath-shaped metal plate.
FIG. 4 shows the first embodiment, and is an external view and a cross-sectional view showing a plate-like fin and a fin collar.
FIG. 5 is a diagram showing the first embodiment, and is a cross-sectional view showing a step of inserting a sheath-shaped metal plate and a heat transfer tube.
FIG. 6 shows the first embodiment and is a cross-sectional view showing a step of pulling out the sheath-shaped metal plate.
FIG. 7 shows the first embodiment and is a cross-sectional view showing a heat transfer tube inserting step.
FIG. 8 shows the first embodiment, and is an external view showing a heat exchanger assembled state.
FIG. 9 shows the first embodiment, and is a cross-sectional view showing a state after brazing.
FIG. 10 is a view showing the first embodiment and is a flowchart showing a manufacturing process.
FIG. 11 is a view showing the first embodiment and is a flow chart showing a manufacturing process.
FIG. 12 shows the first embodiment, and is a cross-sectional view showing a state in which a sheath-shaped brazing sheet plate and heat transfer tubes are inserted into plate-like fins.
FIG. 13 shows the first embodiment, and is a flowchart showing the manufacturing steps.
FIG. 14 shows the first embodiment, and is an external view and a sectional view showing a plate-like fin and a fin collar.
FIG. 15 is a view showing the first embodiment, and is an external view and a sectional view showing a step of caulking the fin collar to the heat transfer tube with a jig.
FIG. 16 shows the first embodiment, and is a flowchart showing the manufacturing process.
FIG. 17 shows the first embodiment, and is an external view and a sectional view showing a fin collar shape when a circular tube is used.
FIG. 18 shows the second embodiment, and is an external view and a sectional view showing the shape of a heat transfer tube.
FIG. 19 shows the second embodiment, and is an external view and a sectional view showing the shape of a heat transfer tube.
FIG. 20 shows the second embodiment, and is an external view and a cross-sectional view showing a plate-like fin shape and a fin collar shape.
FIG. 21 shows the second embodiment, and is a cross-sectional view showing a relationship between a fin collar shape and a heat transfer tube.
FIG. 22 shows the second embodiment, and is a cross-sectional view showing a step of inserting a sheath-shaped metal plate and a heat transfer tube.
FIG. 23 shows the second embodiment, and is a cross-sectional view showing a step of extracting the sheath-shaped metal plate.
FIG. 24 shows the second embodiment, and is a cross-sectional view showing a state after brazing.
FIG. 25 shows the second embodiment, and is an external view and a sectional view showing a plate-like fin shape and a heat transfer tube shape.
FIG. 26 shows the second embodiment, and is an external view and a sectional view showing a fin collar shape when a circular tube is used.
FIG. 27 shows the third embodiment, and is a plan sectional view illustrating the configuration of an air conditioner.
[Explanation of symbols]
Reference Signs List 1 sheathed metal plate, 2 drawing jig, 3 heat transfer tube, 4 microchannel, 5 irregularities, 6 plate fin, 7 fin color, 8 brazing material, 9 fixing jig, 10 header, 11 working fluid inlet / outlet, 12 slit, 13 Compressor, 14 condensation heat exchanger, 15 expansion device, 16 evaporative heat exchanger, 17 blower, 18 motor, 19 indentation jig, 20 brazing sheet, 21 extrusion jig.

Claims

A large number of plate-like fins are arranged in parallel and gas flows between them, and a fin collar of the plate-like fin is inserted into the fin collar, a working fluid passes through the inside, and a plurality of steps are formed in a step direction perpendicular to the gas passing direction. In a method of manufacturing a fin tube type heat exchanger in which a provided heat transfer tube is joined,
Applying a brazing material to the heat transfer tube;
Inserting the heat transfer tube into a sheathed metal plate;
Attaching a drawing jig to the end of the sheath-shaped metal plate,
Inserting the heat transfer tube wrapped in the sheath-shaped metal plate into the fin collar of the plate-like fin by pulling the drawing jig;
Attaching a fixing jig to the lower end of the heat transfer tube;
A step of extracting the sheath-shaped metal plate with the extraction jig, leaving the heat transfer tube in the plate-shaped fin by the fixing jig,
Attaching a header to the end of the heat transfer tube;
A step of charging the assembled heat exchanger into a furnace and performing brazing in the furnace,
A method for manufacturing a fin tube type heat exchanger, comprising:

A large number of plate-like fins are arranged in parallel and gas flows between them, and a fin collar of the plate-like fin is inserted into the fin collar, a working fluid passes through the inside, and a plurality of steps are formed in a step direction perpendicular to the gas passing direction. In a method of manufacturing a fin tube type heat exchanger in which a provided heat transfer tube is joined,
A step of inserting the heat transfer tube into a sheath-shaped metal plate using a brazing sheet plate,
Attaching a drawing jig to the end of the sheath-shaped metal plate,
Inserting the heat transfer tube wrapped in the sheath-shaped metal plate into the fin collar of the plate-like fin by pulling the drawing jig;
Cutting off a tip of the sheath-shaped metal plate that does not overlap with the heat transfer tube;
Attaching a header to the end of the heat transfer tube;
A step of charging the assembled heat exchanger into a furnace and performing brazing in the furnace,
A method for manufacturing a fin tube type heat exchanger, comprising:

Many are arranged in parallel, gas flows between them, and a plate-like fin whose surface is made of a brazing sheet, and inserted into the fin collar of this plate-like fin, the working fluid passes through the inside, and in the gas passing direction In a method for manufacturing a fin tube type heat exchanger in which a plurality of stages are provided in a direction perpendicular to each other, and a heat transfer tube provided with a tapered end portion is joined.
Attaching a pushing jig to the lower end of the heat transfer tube;
Inserting the heat transfer tube into the plate-shaped fin fixed by a jig by the extrusion jig;
Attaching a header to the end of the heat transfer tube;
A step of charging the assembled heat exchanger into a furnace and performing brazing in the furnace,
A method for manufacturing a fin tube type heat exchanger, comprising:

The fin collar provided on the plate-like fin includes a root portion, a middle portion, and a tip portion, and the root portion and the tip portion are formed in a convex arc toward the heat transfer tube, and the middle portion has a straight shape. The fin according to claim 1, wherein the fin has a certain angle on the heat transfer tube side with respect to the heat transfer tube insertion direction so that the root portion is widened. 5. Manufacturing method of tube type heat exchanger.

A large number of plate-like fins are arranged in parallel and gas flows between them, and a fin collar of the plate-like fin is inserted into the fin collar, a working fluid passes through the inside, and a plurality of steps are formed in a step direction perpendicular to the gas passing direction. In a method of manufacturing a fin tube type heat exchanger in which a provided heat transfer tube is joined,
Applying a brazing material to the heat transfer tube;
Inserting the heat transfer tube into a fin collar of the plate-like fin fixed with a jig,
Crimping the fin collar from the heat transfer tube circumferential direction by a pushing jig, and bringing the fin collar and the heat transfer tube into close contact with each other;
Attaching a header to the end of the heat transfer tube;
A step of charging the assembled heat exchanger into a furnace and performing brazing in the furnace,
A method for manufacturing a fin tube type heat exchanger, comprising:

The fin collar provided on the plate-like fin includes a root portion, a middle portion, and a tip portion, and the root portion and the tip portion are formed in a convex arc toward the heat transfer tube, and the middle portion has a straight shape. The method for manufacturing a fin tube type heat exchanger according to claim 5, wherein the intermediate portion is provided in parallel with the axial direction of the heat transfer tube.

7. The relationship of dmin> Da is established between a minimum value dmin of the minor axis diameter of the fin collar provided on the plate-shaped fin and a maximum diameter Da of the minor axis of the heat transfer tube. Of manufacturing a fin tube type heat exchanger.

A large number of plate-like fins are arranged in parallel and gas flows between them, and a fin collar of the plate-like fin is inserted into the fin collar, a working fluid passes through the inside, and a plurality of steps are formed in a step direction perpendicular to the gas passing direction. In a method of manufacturing a fin tube type heat exchanger in which a provided heat transfer tube is joined,
A step of applying a brazing material to grooves on the outer peripheral surface of the heat transfer tube,
Inserting the heat transfer tube into a sheathed metal plate;
Attaching a drawing jig to the end of the sheath-shaped metal plate,
Inserting the heat transfer tube wrapped in the sheath-shaped metal plate into the fin collar of the plate-like fin by pulling the drawing jig;
Attaching a fixing jig to the lower end of the heat transfer tube;
A step of extracting the sheath-shaped metal plate with the extraction jig, leaving the heat transfer tube in the plate-shaped fin by the fixing jig,
Attaching a header to the end of the heat transfer tube;
A step of charging the assembled heat exchanger into a furnace and performing brazing in the furnace,
A method for manufacturing a fin tube type heat exchanger, comprising:

The method for manufacturing a fin tube type heat exchanger according to claim 8, wherein a groove is provided in a circumferential direction of an outer peripheral surface of the heat transfer tube.

The method for manufacturing a fin tube type heat exchanger according to claim 8, wherein a groove is provided in an axial direction of an outer peripheral surface of the heat transfer tube.

The method for manufacturing a fin tube type heat exchanger according to claim 8, wherein a groove is provided obliquely to an axial direction of an outer peripheral surface of the heat transfer tube.

The method for manufacturing a fin tube type heat exchanger according to claim 1 or 8, wherein an irregular shape is provided on an inner peripheral surface of the sheath-shaped metal plate.

The method for manufacturing a fin tube type heat exchanger according to claim 1, wherein an end of the sheath-shaped metal plate on a side to which the drawing jig is attached is closed.

A large number of plate-like fins are arranged in parallel and gas flows between them, and a fin collar of the plate-like fin is inserted into the fin collar, a working fluid passes through the inside, and a plurality of steps are formed in a step direction perpendicular to the gas passing direction. In a method of manufacturing a fin tube type heat exchanger in which a provided heat transfer tube is joined,
The length L in the axial direction of the fin collar provided on the fin is set to be L <Fp with respect to the pitch Fp of the plate-like fins to be laminated, and the length of the fin collar is set up and down on the plate-like fin in the heat transfer tube insertion direction. A method for manufacturing a fin tube type heat exchanger, wherein a slit is provided, and when the plate-like fins are stacked, the slit surfaces of the adjacent plate-like fins match to regulate a pitch Fp of the plate-like fins. .

The fin collar provided on the plate-shaped fin includes a root portion and an intermediate portion, the root portion is formed in a convex arc toward the heat transfer tube, the intermediate portion has a straight shape, and the root portion has The method for manufacturing a fin tube type heat exchanger according to claim 14, wherein the heat transfer tube side has a certain angle with respect to the heat transfer tube insertion direction so as to spread.

The method for manufacturing a fin tube type heat exchanger according to claim 15, wherein the fin collar on the fin is provided at an arbitrary portion except for a portion having a small R of the opening.

The length L in the axial direction of the fin collar provided on the fin is set to be L <Fp with respect to the pitch Fp of the plate-like fins to be laminated, and the length of the fin collar is vertically above the plate-like fin with respect to the heat transfer tube insertion direction. When the slits are provided and the plate-like fins are stacked, the slit surfaces of the adjacent plate-like fins coincide with each other to regulate the pitch Fp of the plate-like fins. The method for manufacturing a fin tube type heat exchanger according to claim 9, wherein the heat pipe is folded into a groove coated with a brazing material.

The fin according to claim 14, wherein the shape of the heat transfer tube is rectangular, the four corners of the flat tube are acute, and the hole shape of the fin collar provided on the plate-like fin is rectangular. Manufacturing method of tube type heat exchanger.

The method for manufacturing a fin tube type heat exchanger according to claim 18, wherein the fin collar on the fin is provided on the entire circumference of the opening.

The length L in the axial direction of the fin collar provided on the fin is set to be L <Fp with respect to the pitch Fp of the plate-like fins to be laminated, and the length of the fin collar is vertically above the plate-like fin with respect to the heat transfer tube insertion direction. The fin tube type according to claim 5, wherein when the slits are provided and the plate-like fins are stacked, the slit surfaces of the adjacent plate-like fins match to regulate the pitch Fp of the plate-like fins. Manufacturing method of heat exchanger.

The relation of dmin <Da <dmax is established between the minimum value dmin, the maximum diameter dmax, and the maximum diameter Da of the short axis of the heat transfer tube of the fin collar provided on the plate-shaped fin. The method for manufacturing a fin tube type heat exchanger according to claim 1, claim 2, claim 3, claim 8, or claim 14.

The method for manufacturing a finned tube heat exchanger according to claim 1, wherein the heat transfer tube has a flat shape.

The method for manufacturing a fin tube type heat exchanger according to claim 1, wherein the heat transfer tube has a circular shape.

An air conditioning refrigeration system using a fin tube type heat exchanger manufactured by the method for manufacturing a fin tube type heat exchanger according to any one of claims 1 to 23.

The air conditioning refrigeration apparatus according to claim 24, wherein any one of HCFC, HFC, HC, natural refrigerant, and a mixture of several kinds of these refrigerants is used as the refrigerant.