Patent Publication Number: US-9846000-B2

Title: Heat exchanger

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority to Japanese Patent Application No. 2012-170953 filed in Japan on Aug. 1, 2012, the entire contents of which are incorporated herein by reference. 
     TECHNICAL FIELD 
     The present invention relates to a heat exchanger in which a first coolant and a second coolant are made to flow and exchange heat between the first coolant and the second coolant. 
     BACKGROUND ART 
     As to a conventional heat exchanger of this type, there is a heat exchanger disclosed in Patent Document 1. As illustrated in  FIG. 11  to  FIG. 13 , this heat exchanger  100  has first plates  101  and second plates  102  alternately laminated therein, and in each of the plates  101  and  102 , a pair of first communication holes  103  and a pair of second communication holes  104  are formed, respectively. Each of the plates  101  and  102  has an outer peripheral wall  105  protruding toward the same direction of a laminating direction, and the outer peripheral walls  105  adjacent to each other come into contact with each other. Furthermore, a first coolant flow path  106  and a second coolant flow path  107  are alternately provided between the adjacent plates  101  and  102 . Each of the first communication holes  103  is opened and each of the second communication holes  104  is closed, to the first coolant flow path  106 , and each of the second communication holes  104  is opened, and each of the first communication holes  103  is closed, to the second coolant flow path  107 . 
     In the configuration described above, a first coolant that flows via a coolant inlet portion  108  flows into the first coolant flow path  106  from one side of the first communication holes  103 , passes through the first coolant flow path  106 , and then, flows out of the other side of the first communication holes  103  via a coolant outlet portion  109 . A second coolant that flows via a cooling-water inlet portion  110  flows into the second coolant flow path  107  from one side of the second communication holes  104 , flows through the second coolant flow path  107 , and then, flows out of the other side of the second communication holes  104  via a cooling-water outlet portion  111 . The first coolant and the second coolant exchange heat via the first plate  101  or the second plate  102  during the process of flowing through each of the first coolant flow path  106  and the second coolant flow path  107 . 
     In the heat exchanger  100  having a laminated form as described above, the first plate  101  and the second plate  102  are fixed through brazing in a state where portions of the first plate  101  and the second plate  102  required to be joined are brought into close contact with each other by applying a load, with a jig or the like during brazing, in the laminating direction of the first plate  101  and the second plate  102 . At this time, the load applied in the laminating direction is preferably large because the degree of close contact at the potions required to be joined is increased, as long as the first plate  101  and the second plate  102  are within the range of not being deformed. 
     Furthermore, portions of the first plate  101  and the second plate  102  where the first communication hole  103  or second communication hole  104  is opened have a weaker strength than that of other portions, and it is necessary to achieve a highly airtight structure by reliably brazing the peripheries of the first communication hole  103  and second communication hole  104 , where coolant with higher pressure flows. Specifically, in the case where coolant with higher pressure flows into the first coolant flow path  106 , it is necessary to perform brazing so that the first communication hole  103  and the first coolant flow path  106  are shielded in a highly airtight manner. 
     CITATION LIST 
     Patent Literature 
     Patent Literature 1: Japanese Patent Laid-Open Publication No. 2007-205634 
     SUMMARY OF INVENTION 
     Technical Problem 
     However, in the heat exchanger  100  of the conventional example described above, when a load is applied in the laminating direction of the first plate  101  and the second plate  102  at the time of brazing, only the load corresponding to the strength of the portion where the first communication hole  103  and the second communication hole  104  are opened can be applied, namely, only a relatively small load can be applied, and thus it is difficult to sufficiently bring the joined portion into close contact. This leads to a problem in which the periphery of the communication hole  103 , where coolant with higher pressure flows, cannot be reliably blazed in a highly airtight manner. 
     In view of the facts described above, the present invention has been made in order to solve the problem described above, and an object of the present invention is to provide a heat exchanger in which the periphery of the communication hole, where coolant with higher pressure flows, can be reliably brazed in a highly airtight manner. 
     Solution to Problem 
     The present invention provides a heat exchanger in which: a first plate having a pair of first communication holes and a pair of second communication holes, and a second plate having a pair of first communication holes and a pair of second communication holes are alternately laminated to alternately form, between the first plate and the second plate adjacent to each other, a first coolant flow path and a second coolant flow path; each of the first communication holes is opened, and each of the second communication holes is closed, to the first coolant flow path; each of the second communication holes is opened, and each of the first communication holes is closed, to the second coolant flow path; the first coolant having a pressure higher than the second coolant flows into the first coolant flow path from one side of the first communication holes, and the first coolant that has passed through the first coolant flow path flows out of the other side of the first communication holes; and the second coolant having a pressure lower than the first coolant flows into the second coolant flow path from one side of the second communication holes, and the second coolant that has passed through the second coolant flow path flows out of the other side of the second communication holes, wherein a first spacer is interposed around each of the first communication holes within the first coolant flow path, and a second spacer is interposed within the second coolant flow path and at a position corresponding to a periphery of each of the first communication holes. 
     The first spacer preferably allows the first coolant to flow between the first communication hole and the first coolant flow path. The first spacer preferably blocks a flow of the first coolant from positions of the first communication holes toward both ends. The first spacer is preferably interposed also around the second communication hole. It is preferable that an inner fin is disposed within the first coolant flow path, and the first spacer surrounds an outer, periphery of the inner fin. It is preferable that the first plate and the second plate each include an outer peripheral wall protruding toward the same direction of a laminating direction, the outer peripheral wall is provided with a step portion, and the first plate and the second plate located adjacent to each other come into contact with each other at the step portion. It is preferable that, when the first plate and the second plate come into contact with each other, a space is formed between the outer peripheral wall of the first plate and the outer peripheral wall of the second plate. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  illustrates an embodiment according to the present invention, and is a partially exploded perspective view of a heat exchanger. 
         FIG. 2  illustrates an embodiment according to the present invention, and is a configuration view of a vehicle heat-exchanging system to which the heat exchanger is applied. 
         FIG. 3  illustrates an embodiment according to the present invention, and is an entire perspective view of the heat exchanger. 
         FIG. 4  illustrates an embodiment according to the present invention, and is an elevation view of the heat exchanger. 
         FIG. 5  illustrates an embodiment according to the present invention, and is a transverse cross-sectional view taken along line A-A in  FIG. 4 . 
         FIG. 6  illustrates an embodiment according to the present invention, and is a transverse cross-sectional view in which portion B in  FIG. 5  is enlarged. 
         FIG. 7  illustrates an embodiment according to the present invention, and is a transverse cross-sectional view in which portion C in  FIG. 6  is further enlarged. 
         FIG. 8  illustrates an embodiment according to the present invention, and is a plan view of a first spacer and an inner fin. 
         FIG. 9  illustrates an embodiment according to the present invention, and is an exploded perspective view of the first spacer and the inner fin. 
         FIG. 10  is a plan view of a first spacer and an inner fin according to a modification of an embodiment. 
         FIG. 11  is an entire perspective view of a conventional example of a heat exchanger. 
         FIG. 12  is a cross-sectional view taken along line D-D in  FIG. 11 . 
         FIG. 13  is a cross-sectional view taken along line E-E in  FIG. 11 . 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Hereinafter, an embodiment according to the present invention will be described with reference to the drawings. 
     Embodiment 
       FIG. 1  to  FIG. 9  each illustrate an embodiment according to the present invention. 
     As illustrated in  FIG. 2 , a water-cooled condenser  1  (heat exchanger) according to the present embodiment is applied to a vehicle heat-exchanging system  2 . This vehicle heat-exchanging system  2  includes the water-cooled condenser  1  according to the present embodiment, a main radiator  21  that cools cooling water for an engine  20 , a sub-radiator  23  that cools coolant for a water-cooled charge air cooler  22  (water-cooled CAC), and an air-cooled condenser  24  that cools coolant for an air conditioner for a vehicle interior. 
     The main radiator  21  is provided on the upstream side of cooling air from a motor fan  25 . The main radiator  21  includes plural tubes (not illustrated) in which cooling water for the engine  20  runs, and exchanges heat with cooling air running outside the tubes. The cooling water for the engine is circulated by a pump  26 . 
     The sub-radiator  23  is disposed on the upstream surface side of cooling air from the main radiator  21 , and is disposed in an upper-half area. The sub-radiator  23  includes plural tubes (not illustrated) in which cooling water serving as a second coolant for the water-cooled charge air cooler  22  runs, and exchanges heat with cooling air flowing outside the tubes. The cooling water for the water-cooled charge air cooler  22  is circulated by a pump  29 . As to air supplied to the engine  20 , the temperature of intake air becomes high due to compression with a turbo part  27  through the utilization of exhaust, and thus the compressed high-temperature air is cooled with the water-cooled charge air cooler  22 . With this arrangement, it is possible to enhance the density of air supplied to the engine  20  by cooling the intake air, and thereby it is possible to enhance combustion efficiency of the engine  20 . Namely, the water-cooled charge air cooler  22  exchanges heat between the compressed intake air supplied to the engine  20  and cooling water, and thus the intake air to the engine  20  is cooled. 
     The air-cooled condenser  24  is disposed on the upstream surface side of cooling air from the main radiator  21  and in a lower-half area. The air-cooled condenser  24  includes plural tubes (not illustrated) in which an air-conditioning coolant serving as a first coolant runs, and exchanges heat with cooling air running outside the tubes. 
     Next, the water-cooled condenser  1  according to the present embodiment will be described. As illustrated in  FIG. 2 , the water-cooled condenser  1  and the air-cooled condenser  24  are connected in series within a refrigeration cycle with the water-cooled condenser  1  being located on the upstream side. The air-conditioning coolant being subjected to high temperature and high pressure by a compressor  28  in the refrigeration cycle and serving as the first coolant, first flows into the water-cooled condenser  1 , and then, flows out to the air-cooled condenser  24 . The cooling water being subjected to cooling by the sub-radiator  23  and serving as the second coolant, flows into the water-cooled condenser  1  to thereby exchange heat with the air-conditioning coolant, and then, flows into the water-cooled charge air cooler  22 . 
     As illustrated in  FIG. 1 ,  FIG. 5  and the like, the water-cooled condenser  1  according to the present embodiment includes: first plates  3  and second plates  4 , which are alternately laminated; first spacers  5  and second spacers  6 , which are alternately interposed between each of the first plates  3  and each of the second plates  4 ; and inner fins  7  each having the outer periphery surrounded by each of the first spacers  5 . All of the contact surfaces between these parts are fixed through brazing. 
     As illustrated in  FIG. 5  to  FIG. 7 , the first plates  3  and the second plates  4  have, respectively, outer peripheral walls  31  and  41 , which protrude toward the same direction of the laminating direction, and the outer peripheral walls  31  and  41  are, respectively, provided with step portions  32  and  42 . At the step portions  32  and  42 , the first plate  3  and the second plate  4  located adjacent to each other come into contact with each other. Each of the plates  3  and  4  is provided with plural protrusions  33  and  43  each protruding on the side of a second coolant flow path  82  to be described later, and having top ends coming into contact with each other, and the contacting surfaces of these protrusions  33  and  43  are brazed to each other. 
     When the first plate  3  and the second plate  4 , located adjacent to each other, come into contact with each other, a space is formed between the outer peripheral wall  31  of the first plate  3  and the outer peripheral wall  41  of the second plate  4 . A brazing filler metal is accumulated in the space at the time of brazing. 
     The first plate  3  includes a pair of first communication holes  34  through which the air-conditioning coolant flows, and a pair of second communication holes  35  through which the cooling water flows. Furthermore, the second plate  4  includes a pair of first communication holes  44  through which the air-conditioning coolant flows, and a pair of second communication holes  45  through which the cooling water flows. Between the first plate  3  and the second plate  4  located adjacent to each other in a state of being alternately laminated, a first coolant flow path  81  into which the air-conditioning coolant flows as indicated by the arrow with a solid line in  FIG. 1  and the second coolant flow path  82  into which the cooling water flows as indicated by the arrow with a broken line in  FIG. 1  are alternately provided. 
     Annular-shaped protruding edge portions  34   a  and  44   a  around the first communication holes  34  and  44  of the first plate  3  and the second plate  4  protrude into the second coolant flow path  82 , and are brazed and joined to each other in a state of overlapping with each other within this second coolant flow path  82 . In the same way, annular-shaped protruding edge portions  35   a  and  45   a  around the second communication holes  35  and  45  protrude into the first coolant flow path  81 , and are brazed and joined to each other in a state of overlapping with each other within this first coolant flow path  81 . 
     With the configuration described above, each of the first communication holes  34  and  44  is opened, and each of the second communication holes  35  and  45  is closed, to the first coolant flow path  81 . Furthermore, the air-conditioning coolant having a pressure higher than the cooling water flows into each first coolant flow path  81  from one side of the first communication holes  34  and  44 , and the air-conditioning coolant having flowed through each first coolant flow path  81  flows out of the other side of the first communication holes  34  and  44 . In contrast, each of the second communication holes  35  and  45  is opened, and each of the first communication holes  34  and  44  is closed, for the second coolant flow path  82 . Furthermore, the cooling water having a pressure lower than the air-conditioning coolant flows into each second coolant flow path  82  from one side of the second communication holes  35  and  45 , and the cooling water having flowed through each second coolant flow path  82  flows out of the other side of the second communication holes  35  and  45 . 
     At one end (lower end in  FIG. 5 ) of the first plates  3  and the second plates  4  in the laminating direction, there are protrusively provided, respectively, a coolant inlet portion  81   a  and a coolant outlet portion  81   b  through which the air-conditioning coolant flows into or flows out, and a cooling-water inlet portion  82   a  and a cooling-water outlet portion  82   b  through which the cooling water flows into or flows out. At the other end (upper end in  FIG. 5 ) of the first plates  3  and the second plates  4  in the laminating direction, there are provided a patch end  83  and a flange portion  84  that close each of the end portions of the pair of first communication holes  34  and  44  and a pair of second communication holes  55 . 
     The inner fin  7  is disposed within the first coolant flow path  81 . The contact surface of the inner fin  7  and each of the plates  3  and  4  is also brazed. 
     The first spacer  5  is disposed within the first coolant flow path  81 . The first spacer  5  includes a fin-accommodating opening portion  53  that accommodates the inner fin  7 , a pair of first communication holes  54  provided at positions corresponding to the pair of first communication holes  34  and  44  of each of the plates  3  and  4 , and the pair of second communication holes  55  provided at positions corresponding to the pair of second communication holes  35  and  45  of each of the plates  3  and  4 . The first spacer  5  is disposed so as to surround the entire periphery of the inner fin  7 . Each of the first communication holes  54  is opened to the fin-accommodating opening portion  53 . With this arrangement, it becomes possible for the air-conditioning coolant to flow into or out of the first coolant flow path  81 , and the air-conditioning coolant does not flow from the position of each of the first communication holes  34  and  44  toward both ends. Each of the second communication holes  55  has a diameter larger than that of each of the protruding edge portions  35   a  and  45   a  around each of the second communication holes  35  and  45  of each of the plates  3  and  4 . With this arrangement, the first spacer  5  is disposed so as to surround the protruding edge portions  35   a  and  45   a  of the second communication holes  35  and  45 . 
     The second spacer  6  is disposed within the second coolant flow path  82 . As illustrated in  FIG. 1 , the second spacer  6  has an annular shape. The second spacer  6  is provided at a position corresponding to the periphery of the pair of first communication holes  34  and  44  of each of the plates  3  and  4 . The second spacer  6  has an internal diameter larger than each of the protruding edge portions  34   a  and  44   a  around the first communication holes  34  and  44  of the plates  3  and  4 . With this arrangement, each of the second spacers  6  is disposed so as to surround the protruding edge portion  34   a  and  44   a  of the first communication holes  34  and  44 . 
     In the configuration described above, the air-conditioning coolant made into a state of gas having a high temperature and high pressure through the compressor  28  in the refrigeration cycle, first flows into the water-cooled condenser  1 , and flows into one side of the first communication holes  34 ,  44 , and  54  of the water-cooled condenser  1  via the coolant inlet portion  81   a . Then, the air-conditioning coolant passes through the first coolant flow path  81  between the first plate  3  and the second plate  4 , and flows out to the air-cooled condenser  24  from the other side of the first communication holes  34 ,  44 , and  54  via the coolant outlet portion  81   b.    
     On the other hand, the cooling water cooled by the sub-radiator  23  flows into the second communication holes  35 ,  45 , and  55  of the water-cooled condenser  1  via the cooling-water inlet portion  82   a . Then, the cooling water passes through the second coolant flow path  82  between the first plate  3  and the second plate  4 , flows out of the other side of the second communication holes  35 ,  45 , and  55  via the cooling-water outlet portion  82   b , and flows into the water-cooled charge air cooler  22  via the pump  29 . With this arrangement, the air-conditioning coolant and the cooling water exchange heat via the first plate  3  or the second plate  4  during processes of passing through each of the first coolant flow path  81  and the second coolant flow path  82  of the water-cooled condenser  1 . 
     Next, manufacturing of the water-cooled condenser  1  will be briefly described. A brazing filler material is basically applied to a portion of each of the parts coming into contact with each other, and each of the parts having the brazing filler material applied thereto is set as a predetermined position, and is disposed in a laminated state. The brazing filler material joined portions are sufficiently brought into close contact with each other by applying a relatively large load in the laminating direction of the plates  3  and  4 , with a jig or the like. 
     Here, the first spacer  5  or the second spacer  6  is interposed between the plates  3  and  4  throughout the entire laminating direction. Specifically, the first spacer  5  is interposed around each of the first communication holes  34  and  44  within the first coolant flow path  81 , and the second spacer  6  is interposed within the second coolant flow path  82  and at a position corresponding to the periphery of each of the first communication holes  34  and  44 , whereby it is possible to reinforce portions of the plates  3  and  4  where the first communication holes  34  and  44  are opened. Therefore, even if large force is applied in the laminating direction of the plates  3  and  4 , it is possible to prevent buckling of the periphery of each of the first communication holes  34  and  44  of the plates  3  and  4 . Furthermore, since the first spacer  5  is interposed around each of the second communication holes  35  and  45  of the plates  3  and  4 , it is possible to reinforce portions of the plates  3  and  4  where each of the second communication holes  35  and  45  is opened. 
     With these configurations as described above, at the time of laminating the plates  3  and  4  to thereby braze them, it is possible to sufficiently bring the joined portions into close contact with each other by applying relatively a large load in the laminating direction of the plates  3  and  4 , and thus the peripheries of the first communication holes  34  and  44  and the first coolant flow path  81 , where coolant with high pressure flows, can be reliably brazed in a highly airtight manner. 
     Furthermore, permissible ranges of a load applied in the laminating direction of the plates  3  and  4  at the time of brazing are widened, and thus manufacturing of the water-cooled condenser  1  is easy. 
     The first spacer  5  allows the air-conditioning coolant to flow between the first communication holes  34  and  44  of the plates  3  and  4  and the first coolant flow path  81 , and does not prevent the air-conditioning coolant from flowing into or out of the first coolant flow path  81 . Therefore, the air-conditioning coolant smoothly flows within the first coolant flow path  81 . 
     The flow of the air-conditioning coolant going from the positions of the first communication holes  34  and  44  toward both ends is blocked at end surfaces of the first communication holes  54  and the fin-accommodating opening portion  53  of the first spacer  5 . Therefore, it is possible to prevent the air-conditioning coolant from staying in the vicinity of both ends of the first coolant flow path  81 , and thus it is possible to prevent the reduction in efficiency of heat exchange. 
     The heat transfer area of the first coolant flow path  81  in which the air-conditioning coolant flows is increased through the use of the inner fin  7 , and thus it is possible to more effectively enhance efficiency of heat exchange of the air-conditioning coolant. Furthermore, by appropriately setting the height of the inner fin  7  and the thickness of the first spacer  5  surrounding the outer periphery of this inner fin  7 , it is possible to prevent buckling of the inner fin  7  due to a load acting in the laminating direction at the time of brazing, and thus, by applying a sufficient load in the laminating direction of the plates  3  and  4 , it is possible to bring the inner fins  7  and the plates  3  and  4  into close contact with each other, and to reliably perform brazing. Alternatively, by reducing the thickness of each of the plates  3  and  4  according to the degree of enhancement in the strength of the inner fin  7  against the load described above, it is also possible to reduce the weight. 
     The first plate  3  and the second plate  4  located adjacent to each other come into contact with each other at the step portions  32  and  42  provided at the outer peripheral wall  31  on the outer periphery of the first plate  3  and the outer peripheral wall  41  provided on the outer periphery of the second plate  4 , respectively. The relative positional relationship between the first plate  3  and the second plate  4  is fixed by the contact at the step portion  32  and  42 , when relatively a large load is applied in the laminating direction of the plates  3  and  4 . Therefore, it is possible to appropriately keep a fitting margin (overlapping length of outer peripheral walls) between the first plate  3  and the second plate  4  to be laminated, and thus accuracy of assembly of the plates  3  and  4  is enhanced. Furthermore, since the space for accumulating the brazing filler metal is formed between the outer peripheral walls  31  and  41  of the plates  3  and  4 , it is possible to enhance a brazing property. 
     Meanwhile, through the use of a three-layered member having the brazing filler material on both sides for the first spacer  5  and the second spacer  6  each having a relatively large thickness, it is possible to resolve a shortage of the brazing filler material, particularly on the coolant side on which strong pressure resistance is required. 
     (Modification) 
       FIG. 10  illustrates a first spacer  5 A and an inner fin  7  according to a modification of the embodiment described above. As illustrated in  FIG. 10 , the first spacer  5 A according to the modification includes: a frame body  56  that surrounds the inner fin  7 ; a pair of annular portions  57  each linked to the frame body  56  and surrounding the entire periphery of each of the second communication holes  55 ; and linking portions  58  that link the frame body  56  with the pair of annular portions  57 . Within the frame body  56 , a pair of first communication holes  54  is provided, and the flow of the first coolant going from the positions of the first communication holes  34  and  44  toward both ends is blocked by the frame body  56 . 
     Configurations other than those described above are the same as those in the above-described embodiment, and thus explanation thereof will be omitted in order to avoid repeated explanation. Furthermore, in the drawing, the same reference signs are attached to the configuration portions same as those in the above-described embodiment in order to make clarification. 
     Through the use of the first spacer  5 A according to this modification, it is possible to reduce the weight as compared with the spacer in the above-described embodiment. Moreover, the frame body  56  and the pair of annular portions  57  are structured to be linked with the narrow linking portion  58 , and thus it is possible to improve a yield of materials. 
     INDUSTRIAL APPLICABILITY 
     According to the present invention, the first spacer is interposed around each of the first communication holes in the first coolant flow path in which high-pressured coolant flows and the second spacer is interposed within the second coolant flow path and at the position corresponding to the periphery of each of the first communication holes, whereby it is possible to reinforce the portions of the first plate and the second plate where each of the first communication holes is opened. Therefore, in the case where a load acts in the laminating direction of the plates, it is possible to prevent the buckling of the periphery of each of the first communication holes of the first plate and the second plate. This makes it possible to sufficiently bring the joined portions into close contact with each other by applying relatively a large load in the laminating direction of the plates, at the time of laminating the plates to thereby braze them, and thus the peripheries of the first communication holes and the first coolant flow path, where coolant with high pressure flows, can be reliably brazed in a highly airtight manner. 
     REFERENCE SIGNS LIST 
     
         
         
           
               1  water-cooled condenser (heat exchanger) 
               3  first plate 
               4  second plate 
               5 ,  5 A first spacer 
               6  second spacer 
               7  inner fin 
               31 ,  41  outer peripheral wall 
               32 ,  42  step portion 
               34 ,  44  first communication hole 
               35 ,  45  second communication hole 
               81  first coolant flow path 
               82  second coolant flow path