JP2007198629A - Manufacturing method of tube - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a tube capable of improving brazing and soldering property of two plate members, with respect to the tube composed of two plate members. <P>SOLUTION: This manufacturing method of the tube having a process for fitting and disposing a first plate member 111 and a second plate member 112 for the tubes 110A having the approximately U-shaped cross section, in a state of their approximate U-shaped opening side edge portions 111a, 112a are opposite to each other, and a brazing and soldering process for brazing and soldering the plate members 111, 112 by a brazing and soldering material 113, further having a caulking process for caulking the opening side end portion 111a at an outer side to the opening side edge portion 112a side as an inner side so that both opening side end portions 111a, 112a are kept into contact with each other at a fitting portion of both plate members 111, 112 after the installing process. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a tube manufacturing method suitable for use in, for example, a heat exchanger.

As a conventional heat exchanger (and a manufacturing method), for example, one disclosed in Patent Document 1 is known. That is, the tube used in this heat exchanger is formed of a first plate member and a second plate member having a substantially U-shaped cross section and a brazing material on the surface. ing. The first and second plate members are fitted and arranged so that the substantially U-shaped opening sides face each other, and the fitting is heated to melt and braze the brazing material.
JP 2005-30755 A

  However, when the first and second plate members are manufactured by press molding, the substantially U-shaped opening side is opened by the spring back, so that the gap between the fitting portions becomes larger than the target value, which causes a deterioration in brazing performance. It has become.

  In view of the above problems, an object of the present invention is to provide a method of manufacturing a tube that can improve brazing between two plate members formed from two plate members.

  In order to achieve the above object, the present invention employs the following technical means.

  According to the first aspect of the present invention, the first plate member (111) and the second plate member (112) for the tube (110A) having a substantially U-shaped cross section are arranged at the opening side end portion having a substantially U-shaped shape. (111a, 112a) A method of manufacturing a tube, which includes an arrangement step of fitting and arranging so as to oppose each other, and a brazing step of brazing both plate members (111, 112) with a brazing material (113). After the arranging step, the opening side end portion (111a) which is the outside is set to the inside so that both opening side end portions (111a, 112a) come into contact with each other in the fitting portion of both plate members (111, 112). A caulking step is provided on the opening side end (112a) side.

  Thereby, even if there is variation in the performance of the substantially U-shape of both plate members (111, 112), the gap between the fitting portions can be made appropriate by the caulking process, so both plate members (111, 112) ) Can be improved.

  The invention according to claim 2 is characterized in that a foil-like brazing material (113) is interposed between the two plate members (111, 112) as the brazing material (113) in the arranging step. .

  As a result, the brazing material (113) can be selected without being restricted by the material of both plate members (111, 112), and the brazing conditions such as the brazing temperature can be easily set. Also, by assembling the first plate member (111), the foil-like brazing material (113), and the second plate member (112) in this order, the brazing material (113) can be set and the tube can be easily operated. (110A) can be manufactured.

  In the third aspect of the present invention, the foil-shaped brazing material (113), the inner fin (114), the foil shape is formed inside the substantially U-shape of the first plate member (111) during the arranging step. The brazing material (113) is laminated in order, and the second plate member (112) is fitted and arranged on the first plate member (111).

  Thereby, the tube (110A) which has an inner fin (114) inside can be manufactured easily.

  In addition, the code | symbol in the bracket | parenthesis of each said means shows a corresponding relationship with the specific means of embodiment description mentioned later.

(First embodiment)
In the present embodiment, the tube 110A according to the present invention is applied to an air-cooled intercooler 100. Hereinafter, the configuration of the intercooler 100 will be described with reference to FIGS. 1 is a front view showing an intercooler 100 according to the present embodiment, FIG. 2 is a cross-sectional view showing an AA portion in FIG. 1, and FIG. 3 is a cross-sectional view showing a procedure for assembling the tube 110A.

  The intercooler 100 is a heat exchanger that cools combustion air (hereinafter, intake air) sucked into a vehicle engine (internal combustion engine) by heat exchange with cooling air from the outside. The intercooler 100 mainly includes a core portion 110 and a pair of header tanks 120. Here, the intercooler 100 is a large intercooler 100 mounted on a large vehicle such as a truck. Therefore, each member described below is made of copper, copper alloy, or iron so that sufficient thermal conductivity and durability can be obtained, and the contact portion of each member is brazed (for brazing in the present invention). Corresponding) or welding.

  The core portion 110 is formed by alternately stacking tubes 110A having inner fins 114 inserted therein and outer fins 115, and side plates 116 disposed on both outermost sides in the stacking direction.

  The tube 110A is a tube member having a flat cross section through which intake air flows, and is formed of two tube plates 111 and 112 (corresponding to the first and second plate members in the present invention). Each of the tube plates 111 and 112 is formed by pressing so that the cross-section of the tube plate has a substantially U shape, and the ends 111a and 112a on the substantially U-shaped opening side face each other. It is fitted and brazed. The fitting state of the both ends 111a and 112a is such that the end 111a is on the outside and the end 112a is on the inside. In addition, the material of each tube plate 111,112 is taken as the red copper material in which zinc (about 15%) contains in a copper material.

  The inner fin 114 inserted into the tube 110A is formed in a wave shape from a thin flat plate made of pure copper, gives a turbulent flow effect to the flow of intake air, and improves the heat transfer coefficient on the intake side.

  Like the inner fin 114, the outer fin 115 is formed into a wave shape from a thin flat plate material made of pure copper, and a plurality of louvers 115a formed in an armor door shape by cutting and raising are provided on the flat surface, While expanding the heat radiation area to the air side, the turbulent flow effect by the louver 115a is obtained, and the heat exchange with the intake air is promoted.

  The side plate 116 is a brass reinforcing member extending in the longitudinal direction of the tube 110A. The side plate 116 has a substantially U-shaped cross-section, and a rib extending in the longitudinal direction is provided at the center of the U-shape. .

  A foil brazing material (corresponding to the foil-like brazing material in the present invention) 113 is interposed between the tube plates 111 and 112 and the inner fin 114 (FIG. 3). The tube plates 111 and 112 are brazed together to form the tube 110A, and the inner fins 114 are brazed to the inner surface of the tube 110A. The foil brazing material 113 is composed of, for example, components of 75% copper, 15% tin, 5% nickel, and 5% phosphorous, and has a low melting point (600 ° C. to 650 ° C.) and a reducing ability. .

  In addition, a paste-like brazing material in which a brazing material and a binder are mixed is applied in advance to the surface of the tube 110A, and the outer fin 115 is brazed to the tube 110A by this pasty brazing material. Further, a paste-like brazing material is applied in advance to the surface of the side plate 116 on the outer fin 115 side, and the outermost outer fin 115 is brazed to the side plate 116 with this paste-like brazing material. . The paste-like brazing material may be replaced with the foil brazing material 113 used for brazing in the tube 110A.

  A pair of header tanks 120 that extend in the stacking direction of the tubes 110A and communicate with the tubes 110A are provided on both longitudinal ends (hereinafter referred to as tube ends) of the tubes 110A. The header tank 120 includes a header plate 121, a tank body 122, and a pipe 123.

  The header plate 121 is a plate member in which an edge portion is provided on the outer peripheral portion of the elongated flat plate and a tube hole is formed in a portion corresponding to the tube end portion. The tube hole is formed so as to be slightly larger than the cross-sectional shape of the tube 110A in consideration of the fitting property of the tube 110A. Here, the material of the header plate 121 is an iron material.

  The tube end portion is inserted and fitted into the tube hole of the header plate 121, and the tube 110A and the header plate 121 are brazed to each other by a paste-like brazing material applied to the fitting portion. Note that both end portions in the longitudinal direction of the side plate 116 are brazed to the header plate 121 by a paste-like brazing material applied to a contact portion with the header plate 121.

  The tank body 122 is made of the same iron material as the header plate 121, and is an elongated half-container body that opens on the header plate 121 side. The opening side is welded to the edged portion of the header plate 121 to form a tank internal space. Yes.

  The pipe 123 is a pipe member made of an iron material, and is welded to one end in the longitudinal direction of the tank main body 122 so as to communicate with the space in the tank.

  The right header tank 120 in FIG. 1 distributes and supplies intake air flowing from the pipe 123 to each tube 110A, and the left header tank 120 in FIG. 1 collects and collects intake air flowing from the tube 110A. Then, it flows out from the pipe 123 to the outside.

  Next, a method for manufacturing the intercooler 100 will be described. First, the tube plates 111 and 112, the side plate 116, the header plate 121 formed by pressing the plate material, the inner fin 114 and the outer fin 115 formed by roller processing, and the foil brazing material 113 are prepared in advance.

  Then, as shown in FIG. 3A, the tube plate 111 is set on the work table so that the end portion 111a faces upward, and the foil brazing material 113 and the inner fin 114 are placed inside the substantially U-shape. The foil brazing material 113 is laminated in order. At this time, the length of the lower brazing filler metal 113 in the left-right direction in FIG. 3 is approximately equal to the overall length of the U-shape of the tube plate 111. Further, the length in the left-right direction in FIG. 3 of the upper brazing filler metal 113 is set to a dimension that allows at least contact with the entire area of the inner fin 114. Then, the tube plate 112 is set so that the end 112a faces downward from the upper side of the foil brazing material 113, the inner fin 114, and the foil brazing material 113 laminated as described above. At this time, the end portion 112a enters the inside of the end portion 111a so as to be fitted, and both the tube plates 111 and 112 are fitted and arranged. Hereinafter, what the tube plates 111 and 112 are fitted and arranged is referred to as a tube fitting body (the arrangement process in the present invention is completed).

  Then, as shown in FIG. 3B, the tube fitting body is caulked using a caulking roller 200. Here, the caulking roller 200 is a pair of rollers in which concave portions 210 that are recessed in an arc shape are formed on the peripheral surface. A tube fitting body is set with respect to the caulking roller 200 so that both end portions 111 a abut against the recess 210. Then, the caulking roller 200 is rotated while being pressed by the caulking roller 200 so that a predetermined load is applied from both sides of the tube fitting body, and further the longitudinal direction of the tube fitting body (with respect to the paper surface in FIG. 3B). To move vertically). By the operation of the caulking roller 200, as shown in FIG. 3C, the outer end 111a is deformed into an arc shape and is caulked so as to come into contact with the inner end 112a. Hereinafter, this caulked material is referred to as a tube assembly (the caulking process in the present invention is completed).

  Then, a paste-like brazing material is applied to the surface of the tube assembly and the surface of the side plate 116 on the outer fin 115 side.

  Then, using a laminating jig (not shown) as a guide, the side plate 116 is set on the lowermost side, and an outer fin 115, a tube assembly, and an outer fin 115 are alternately laminated in order on the upper side by a predetermined number, Another side plate 116 is set on the upper side of the uppermost outer fin 115 to assemble the core portion 110. Hereinafter, this assembly is referred to as a core assembly.

  And a tube end part is inserted and fitted in the tube hole of the header plate 121, and a paste-like brazing material is apply | coated to a fitting part. If necessary, a jig such as a wire is attached in the stacking direction of the tube assembly in order to maintain the assembled state of the core assembly.

  And after degreasing | defatting the said core part assembly, it puts in a brazing furnace and brazes integrally (here brazing temperature 625 degreeC). That is, in the tube assembly, the tube plates 111 and 112 are brazed at the ends 111a and 112a by the foil brazing material 113 to form the tube 110A (completion of the brazing process in the present invention). In addition, the inner fin 114 is brazed to the inner surfaces of the tube plates 111 and 112 by the foil brazing material 113. Further, the portions of the tube 110A, the outer fin 115, the side plate 116, and the header plate 121 that are in contact with each other are brazed with a paste-like brazing material.

  Then, the pipe 123 is welded to the tank main body 122 formed by press working, and the opening side of the tank main body 122 is fitted to the rim portion of the header plate 121 so that the tank main body 122 and the header plate 121 are connected. Weld.

  Thereafter, predetermined inspections such as leakage inspection (check for brazing defects and welding defects) and dimensional inspection are performed, and the manufacture of the intercooler 100 is completed.

  In the present embodiment, the end 111a is caulked to the end 112a side using the caulking roller 200 with respect to the tube fitting body, so that the substantially U-shaped of the tube plates 111 and 112 are formed. Even if the quality varies, the gap between the fitting portions can be made appropriate, and the brazing performance between the tube plates 111 and 112 can be improved.

  In addition, since the foil brazing material 113 is used for brazing the tube plates 111 and 112, the brazing material can be selected without being restricted by the material of both the tube plates 111 and 112. It is easy to set the brazing conditions such as the brazing temperature. Further, by assembling the tube plate 111, the foil brazing material 113, and the tube plate 112 in this order, the foil brazing material 113 can be set, and the tube 110A can be manufactured by an easy operation.

  Since the tube plate 112 is arranged and fitted from the upper side after the inner fin 114 is set on the tube plate 111 side, the tube 110A having the inner fin 114 inside can be easily manufactured.

(Other embodiments)
In the said 1st Embodiment, although the basic material of the member which comprises a heat exchanger was made into copper or a copper alloy, it is applicable not only to this but what uses other materials, such as aluminum or an aluminum alloy.

  Further, the brazing material for brazing the tube 110 </ b> A is not limited to the foil brazing material 113 but may be a paste brazing material. Further, a clad brazing material in which a brazing material layer is formed on the surfaces of the tube plates 111 and 112 may be used.

  Further, depending on the material of the constituent member to be selected, the brazing material may be solder, and the soldering material may be targeted.

  In the first embodiment, the tube 110A of the present invention has been described as applied to the intercooler 100. However, the tube 110A may be applied to other heat exchanger tubes such as a radiator and a condenser.

  Further, the caulking roller 200 for caulking the tube fitting body is not limited to a pair, and may be a single roller. Or it is good also as crimping by a press.

  Further, the inner fin 114 in the tube 110A may be eliminated depending on the heat exchange performance.

It is a front view which shows the intercooler which concerns on this embodiment. It is sectional drawing which shows the AA part in FIG. It is sectional drawing which shows the assembly | attachment point of a tube.

Explanation of symbols

100 intercooler (heat exchanger)
110A tube 111 tube plate (first tube member)
111a end (opening side end)
112 Tube plate (second tube member)
112a end (opening side end)
113 Foil brazing material (brazing material, foil-shaped brazing material)

Claims (3)

The first plate member (111) and the second plate member (112) for the tube (110A) having a substantially U-shaped cross section are opposed to the substantially U-shaped opening side end portions (111a, 112a). An arrangement step of fitting and arranging so as to
A method for producing a tube, comprising: a brazing process for brazing the two plate members (111, 112) with a brazing material (113),
After the arrangement step, the opening-side end portion (111a) which becomes the outside so that the opening-side end portions (111a, 112a) come into contact with each other in the fitting portions of the plate members (111, 112). A method of manufacturing a tube, characterized in that a caulking step for caulking is provided on the opening side end (112a) side which is the inner side.   The foil brazing material (113) is interposed between the plate members (111, 112) as the brazing material (113) during the placement step. Tube manufacturing method.   During the placement step, the foil-shaped brazing material (113), the inner fin (114), and the foil-shaped brazing material are disposed inside the substantially U-shape of the first plate member (111). (113) is laminated | stacked in order, The said 2nd plate member (112) is fittingly arranged by the said 1st plate member (111), The manufacturing method of the tube of Claim 2 characterized by the above-mentioned.

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