Heat Exchanger

The present invention relates to a heat exchanger, in which a plurality of compartments is defined by dividing a header tank of the heat exchanger, in which a heat exchange medium flows, by partition walls in a first row and a second row, and communication holes, which connect the plurality of compartments, are formed in the partition walls.

An air conditioning device for a vehicle refers to an internal device for a vehicle installed for the purpose of cooling or heating a vehicle interior in the summer or winter season or ensuring front and rear visual fields for a driver by removing frost or the like formed on a windshield in rainy or cold weather. The air conditioning device typically has both a heating system and a cooling system and cools, heats, or ventilates the vehicle interior by selectively introducing outside air or inside air, heating or cooling the air, and then blowing the air into the vehicle interior.

A general refrigeration cycle of the air conditioning device includes an evaporator configured to absorb heat from the periphery, a compressor configured to compress a refrigerant, a condenser configured to discharge heat to the periphery, and an expansion valve configured to expand the refrigerant. In the cooling system, a gaseous refrigerant, which is introduced into the compressor from the evaporator, is compressed into a high-temperature, high-pressure refrigerant by the compressor, and the compressed gaseous refrigerant is liquefied while passing through the condenser, such that liquefaction heat is discharged to the periphery. The liquefied refrigerant is converted into low-temperature, low-pressure wet saturated vapor while passing through the expansion valve again. Thereafter, the refrigerant is introduced into the evaporator again and cools ambient air by absorbing vaporization heat from the periphery while being vaporized. Therefore, the vehicle interior is cooled by this process.

The condenser, the evaporator, and the like used in the cooling system are representative heat exchangers. There have been many consistent research efforts to create more effective heat exchange between the air outside the heat exchanger and a heat exchange medium in the heat exchanger, i.e., the refrigerant. The efficiency of the evaporator has the most direct effect on the cooling of the vehicle interior. Therefore, various types of structural research and development have been particularly carried out to improve the heat exchange efficiency of the evaporator.

One of the improved structures to improve the heat exchange efficiency of the evaporator is a dual evaporation structure in which cores including tubes and fins are doubly provided to define first and second rows that are spaces in which the refrigerant flows.

As the related art, Japanese Patent Laid-Open No. 2005-308384 (“Ejector Cycle,” Nov. 4, 2005) discloses a shape similar to a dual evaporator in which a refrigerant flows in first and second rows.

In this case, in the dual evaporator, a header tank disposed at an upper or lower side may be divided by a partition wall into two rows, and a communication hole may be formed in the partition wall, which separates first and second rows, to connect the first and second rows formed so that the refrigerant flows to constitute a flow path for a flow of the refrigerant.

However, because the header tank does not have a drain hole at a portion corresponding to an intermediate position between the first row and the second row, there is a problem in that condensate water, which is created on refrigerant tubes and fins that constitute the evaporator, is hardly discharged while passing through the header tank during the heat exchange.

In addition, in order to form a drain hole, through which condensate water is discharged, in the header tank, a narrow portion corresponding to the intermediate position between the first row and the second row may be formed, and the drain hole may be formed in the narrow portion. However, in this structure, it is very difficult to form the communication hole that connects the first row and the second row, and durability may be degraded because of low structural strength.

The present invention has been made in an effort to solve the above-mentioned problem, and an object of the present invention is to provide a heat exchanger, in which a through-hole, through which condensate water may be discharged, is easily formed in a widthwise center portion of a header tank without increasing the number of components in the header tank having two rows, a degree of freedom related to a forming size and position of a communication hole, which connects first and second compartments of the header tank, is high, and durability of a portion in which the communication hole is formed is high.

In order to achieve the above-mentioned object, the present invention provides a heat exchanger including: a tank having a depressed portion formed by bending a widthwise center portion concavely inward in a longitudinal direction, and partition walls disposed to be spaced apart from each other with the depressed portion interposed therebetween; and a header coupled to the tank and having a plurality of compartments separated in a width direction by the partition walls, and tube insertion holes into which tubes are inserted, in which the tank has a contact portion where the partition walls are in contact with each other in the width direction in at least a partial region in the longitudinal direction, and the tank includes a communication hole formed through the partition walls in the width direction at the contact portion to allow the plurality of compartments to communicate with one another.

In addition, the tank may further include a connection portion configured to connect the contact portion and the partition walls spaced apart from each other with the depressed portion interposed therebetween, and the connection portion may be formed such that an interval between the partition walls spaced apart from each other gradually decreases in a direction from the partition walls, which are spaced apart from each other, toward the contact portion.

In addition, a height of the contact portion of the tank may be a height from a lower end of the depressed portion to a portion that excludes a round portion where a flat portion of an upper end of the tank is connected to the contact portion.

In addition, the header and the tank may include through-holes formed through the depressed portion and a portion of the header facing the depressed portion so that an external space of the header and a concave space of the depressed portion of the tank communicate with each other.

In addition, the header may have a concave portion formed concavely inward in a longitudinal direction of a widthwise center portion, and the concave portion of the header may be in contact with and correspond to the depressed portion of the tank.

In addition, the header and the tank may include through-holes formed through the concave portion and the depressed portion so that a concave space of the concave portion of the header and a concave space of the depressed portion of the tank communicate with each other.

In addition, a first fixing portion may protrude toward the tank from a periphery of the through-hole formed in the concave portion of the header, and the first fixing portion of the header may pass through the through-hole formed in the depressed portion of the tank and be bent in the longitudinal direction such that the concave portion of the header and the depressed portion of the tank are tightly attached to each other.

In addition, a second fixing portion may extend from any one of the partition walls of the tank toward the inside of the communication hole, and the second fixing portion may pass through the communication hole and be bent toward the other partition wall to surround the other partition wall such that the partition walls are tightly attached to each other in the width direction in which the partition walls face each other.

In addition, any one of the communication holes formed in the partition walls of the tank may be formed to be smaller in size than the other communication hole, and a caulking portion may pass from any one communication hole to the other communication hole among the communication holes and be bent to the outside of the communication hole, such that the partition walls are tightly attached to each other in the width direction in which the partition walls face each other.

In addition, the communication hole formed in the partition wall of the tank may have a shape surrounded by the partition wall in all directions.

In addition, the communication hole formed in the partition wall of the tank may be surrounded by the partition wall in three direction and opened at one side adjacent to the header.

In addition, the heat exchanger may further include: a baffle interposed between the header and the tank and configured to separate the plurality of compartments, which are internal spaces, in the longitudinal direction.

In addition, the contact portion where the partition walls are in contact with each other in the width direction may be sealed as surfaces, which are in contact with each other while facing each other, are joined.

In addition, the present invention provides a heat exchanger including: a first header tank having two rows formed by dividing an internal space into first and second compartments by coupling the header and the tank; a second header tank disposed to be spaced apart from the first header tank and having two rows formed by dividing an internal space in the width direction; a plurality of tubes each having two opposite ends connected and fixed to the first header tank and the second header tank; and heat radiating fins interposed between the tubes.

In addition, an inlet port for a heat exchange medium, which communicates with the first compartment, may be formed in a first row of the first header tank, a discharge port, which communicates with the second compartment, may be formed in a second row of the first header tank, the first and second compartments, which are the internal spaces of the first header tank, may be separated in longitudinal direction by a baffle interposed between the header and the tank, a first throttle, which decreases a cross-sectional area of the internal space, may be formed in a first row of the second header tank at one longitudinal side based on the baffle, and a second throttle, which decreases a cross-sectional area of the internal space, may be formed in a second row of the second header tank at the other longitudinal side based on the baffle.

In addition, flow paths for the heat exchange medium, through which the heat exchange medium introduced through the inlet port of the first header tank is discharged to the discharge port of the first header tank, may include: a first path through which the heat exchange medium flows from the first row of the first header tank to the first row of the second header tank; a second path through which the heat exchange medium having passed through the first path flows from the first row of the second header tank to the first row of the first header tank; a third path through which the heat exchange medium having passed through the second path flows from the second row of the first header tank to the second row of the second header tank while passing through the communication hole that connects the first and second rows of the first header tank; and a fourth path through which the heat exchange medium having passed through the third path flows from the second row of the second header tank to the second row of the first header tank.

In the heat exchanger of the present invention, the through-hole, through which condensate water may be discharged, may be easily formed in the widthwise center portion of the header tank without increasing the number of components in the header tank having the two rows, which may reduce manufacturing costs.

Further, a degree of freedom related to a forming size and position of the communication hole, which connects the first and second compartments separated in the width direction of the header tank, is high, and the durability of the portion where the communication hole of the header tank is formed is high.

Hereinafter, a header tank and an evaporator including the same according to the present invention configured as described above will be described in detail with reference to the accompanying drawings.

are an exploded perspective view and an assembled perspective view illustrating a heat exchanger according to an embodiment of the present invention,is a cross-sectional view taken by cutting a portion where a pair of partition walls is spaced apart from each other in the heat exchanger according to the embodiment of the present invention,is a cross-sectional view taken by cutting a contact portion where the pair of partition walls is in contact with each other in the heat exchanger according to the embodiment of the present invention, andis a perspective view illustrating a tank of the heat exchanger according to the embodiment of the present invention when viewed from below.

As illustrated, the heat exchanger of the present invention may broadly include a tankand a header, and the tankand the headermay be coupled to define a space in which a heat exchange medium may flow. Further, partition wallsare formed at a widthwise center of the tankin a longitudinal direction, such that an internal space of a header tankmay be divided by the partition wallsinto a first compartmentand a second compartmentin the width direction. In addition, the heat exchanger of the present invention may further include bafflesand an end cap.

The tankmay have a depressed portionformed as a widthwise center portion bent concavely inward in the longitudinal direction, and a portion where the depressed portionis formed may protrude convexly toward the inside of the tank. For example, a side of the tank, which faces the header, may be formed concavely, and the tankmay have a shape in which the depressed portionprotrudes concavely inward from the widthwise center portion. Therefore, a pair of partition walls, which constitutes two opposite widthwise surfaces of the depressed portion, may be disposed to be spaced apart from each other. Further, the tankmay have a contact portionwhere the pair of partition wallsare in contact with each other in the width direction in at least a partial longitudinal region. A communication holemay be formed in the contact portionwhile penetrating the pair of partition wallsin the width direction to allow the first compartmentand the second compartmentto communicate with each other. In this case, regions corresponding to the contact portionmay be sealed as surfaces of the regions, which face each other, are joined by brazing later. In addition, the contact portionand the communication holemay be provided as one or more contact portionsand one or more communication holes. For example, as illustrated, a first contact portion-and a second contact portion-may be formed at positions spaced apart from each other. A first communication hole-having a relatively large size may be formed in the first contact portion-, and a second communication hole-having a relatively small size may be formed in the second contact portion-.

The headermay have a concave portionformed as a widthwise center portion is formed concavely inward in the longitudinal direction, and a portion where the concave portionis formed may protrude convexly toward the inside of the header. For example, a side of the header, which faces the tank, may be formed concavely, and the headermay have a shape in which the concave portionprotrudes concavely inward from the widthwise center portion. Further, the headermay have a plurality of tube insertion holesinto which tubes may be inserted. The plurality of tube insertion holesmay be arranged and spaced apart from one another in the longitudinal direction.

The bafflemay be formed in a plate shape and interposed and coupled between the tankand the header. Coupling holes may be formed in the tankand the headerwhile penetrating inner and outer surfaces of the tankand the header, and the bafflehas coupling protrusions protruding from portions corresponding to the coupling holes, such that the bafflemay be assembled in a shape in which the coupling protrusions are inserted into the coupling holes. Holes may be formed through two opposite surfaces of the end cap, and a manifold or inlet and outlet pipes may be coupled and connected to the end cap.

Therefore, the tankand the headerare coupled so that concave inner sides thereof face each other, and the bafflemay be interposed and coupled between the tankand the header. After the tankand the headerare coupled, the surfaces, which are in contact with one another, may be joined by brazing, and the tankand the headerare sealed by the joined portion, such that the heat exchange medium may not leak.

Therefore, in the heat exchanger of the present invention, the through-hole, through which condensate water may be discharged, may be easily formed in the widthwise center portion of the header tank without increasing the number of components in the header tank having the two rows, which may reduce manufacturing costs. That is, in the related art, in order to connect a first compartment and a second compartment in a state in which a pair of partition walls is spaced apart from each other, holes need to be formed in the pair of partition walls, and then a separate communication pipe needs to be coupled. Alternatively, holes need to be formed in the pair of partition walls, and then a separate insert member having holes needs to be inserted between the pair of partition walls and then joined. For this reason, additional components are required, the configuration is complicated, and manufacturing costs are increased. In contrast, in the present invention, the contact portion, in which the pair of partition wallsis in contact with each other, may be formed by plastic processing without an additional constituent component, and the communication hole, which allows the two opposite spaces of the contact portionto communicate with each other, is formed by punching, such that the separated spaces of the header tank may simply communicate with each other. In addition, a degree of freedom related to a forming size and position of the communication hole, which connects the first and second compartments separated in the width direction of the header tank, is high, and the durability of the portion where the communication hole of the header tank is formed is high. In addition, because a separate communication pipe is not used, it is possible to ensure a maximum area (height) of the communication hole.

are partial perspective views illustrating the contact portion according to the embodiment of the present invention.

As illustrated, the tankmay further include connection portionsconfigured to connect the contact portionand the pair of partition wallsspaced apart from each other with the depressed portioninterposed therebetween. In this case, a length corresponding to the connection portionis indicated by A. The connection portionmay be gently formed in a shape in which an interval between the pair of partition wallsspaced apart from each other gradually decreases in a direction from the pair of partition wallstoward the contact portion. That is, the connection portionmay define a shape in which cross-sectional areas of the first and second compartmentsandgradually increase in the direction from the pair of partition wallstoward the contact portion. Therefore, the contact portionmay be more stably formed by the connection portion without a crack or the like at the time of forming the contact portionby plastic processing. Further, a length of the connection portion may increase or decrease in consideration of formability.

is a cross-sectional view illustrating the through-holes and the structure in which the tank and the widthwise center portion of the header are coupled in the heat exchanger according to the embodiment of the present invention.

As illustrated, the tankand the headermay have through-holesandprovided in the depressed portionand formed through the tankand the headerso that an external space of the headerand a concave space of the depressed portionof the tankcommunicate with each other. Therefore, condensate water formed on a surface of the heat exchanger may be discharged through the through-holesandformed in the widthwise center portion of the header tank. In this case, the through-holesandmay be provided as a plurality of through-holesand, and the plurality of through-holesandmay be arranged to be spaced apart from one another in the longitudinal direction. In addition, the through-holesandmay be formed through the portion where the depressed portionof the tankand the concave portionof the headerare adjacent to each other, such that a concave space of the depressed portionand a concave space of the concave portionmay communicate with each other.

In addition, in the header tankof the present invention, the depressed portionof the tankand the concave portionof the headermay be formed at the positions corresponding to each other, such that the depressed portionand the concave portionmay be in contact with each other when the tankand the headerare coupled. In this case, because the depressed portionof the tankand the concave portionof the headerare portions having high structural strength implemented by curved shapes, the depressed portionof the tankand the concave portionof the headermay be joined by brazing in a state of being securely coupled and supported on each other, such that the durability of the header tank may be improved, and a leak of heat exchange medium from the joined portion may be suppressed.

In addition, a first fixing portionmay protrude toward the tankfrom a periphery of the through-holeformed in the concave portionof the header. The first fixing portionmay pass through the through-holeformed in the depressed portionof the tank, and a free end portion of the first fixing portionis bent in the longitudinal direction. Therefore, the concave portionof the headerand the depressed portionof the tankmay be tightly attached and fixed to each other, and a leak of the heat exchange medium may be suppressed at the peripheries of the through-holesandjoined by brazing later.

are a cross-sectional view and a perspective view illustrating one embodiment of a coupling structure for tightly attaching the contact portion of the portion where the communication hole is formed in the tank of the heat exchanger according to the embodiment of the present invention.

As illustrated, a height H of the contact portionof the tankmay be a height from a lower end of the depressed portionto a portion that excludes a round portionwhere a flat portionof an upper end of the tankis connected to the contact portion. In this case, because the communication holemay be formed by cutting and removing the contact portion, it is possible to ensure a maximum area of the communication hole.

In addition, in the contact portionof the tank, a second fixing portionmay extend from any one of the pair of partition wallstoward the inside of the communication hole. The second fixing portionmay pass through the communication holeand be bent toward the other partition wall, such that the pair of partition wallsmay be tightly attached to each other in the width direction, and a leak of the heat exchange medium from the contact portionmay be suppressed at the peripheries of the communication holejoined by brazing later.

are a cross-sectional view and a perspective view illustrating another embodiment of the coupling structure for tightly attaching the contact portion of the portion where the communication hole is formed in the tank of the heat exchanger according to the embodiment of the present invention.

As illustrated, among the communication holesformed in the pair of partition wallsof the tank, any one hole is formed to be smaller in size than another hole. A material of the partition wall, which has the relatively small hole, passes from any one communication hole to another communication hole among the communication holesand is bent to the outside of the communication hole by caulking, such that a caulking portionmay be formed. For example, the caulking portionmay be formed in a shape that surrounds the entire communication hole. Therefore, the pair of partition wallsmay be easily joined by brazing at the contact portionhaving the communication hole, such that a leak of the heat exchange medium may be suppressed. Further, the structural strength of the portion of the communication holemay be increased by the caulking portion, which may further improve the durability.

In addition, the communication holeformed in the pair of partition wallsof the tankmay be formed in a shape surrounded by the partition wallin all directions. Therefore, it is possible to prevent structural deformation of the partition wallat the periphery of the communication holeand reduce the deterioration in structural strength when the tankand the headerare joined.

Alternatively, the communication holeformed in the pair of partition wallsof the tankmay be formed in a shape surrounded by the partition wallin three directions and opened at one side adjacent to the header. Therefore, a length, which is to be cut at the time of forming the communication holein the contact portionof the partition wall, is relatively short, such that the cutting may be performed with a low force, which may make it easy to form the communication hole.