Patent Publication Number: US-2017370659-A1

Title: Air-conditioning apparatus and method of manufacturing air-conditioning apparatus

Description:
TECHNICAL FIELD 
     The present invention relates to an air-conditioning apparatus including a heat exchanger provided with side plates and a method of manufacturing the air-conditioning apparatus. 
     BACKGROUND ART 
     A heat exchanger employed in an air-conditioning apparatus is configured with, for example, a radiator fin, a tube and a side plate. There are provided multiple radiator fins and tubes, and the multiple tubes are inserted into the multiple radiator fins. The side plate is provided at end portions of the tubes, and the side plate has multiple holes formed thereon through which the multiple tubes are inserted. In the heat exchanger, connection members that connect the multiple tubes are provided on the side plate. As the connection member, for example, a U-bent tube, a three-way bent tube, a bulge three-way tube and other tubes can be provided. Moreover, when the tube is a hairpin tube, the tube and the connection member are integrally formed. 
     The connection member provided to such a heat exchanger has various kinds of connection patterns (path patterns) that are complex. Therefore, a drawing on which a path pattern is provided is separately prepared. Then, a worker who manufactures the heat exchanger attaches parts to assemble the heat exchanger while alternately comparing the heat exchanger and the drawing providing the path pattern. When the number of parts related to the path pattern is large, it exceeds 100 per a single heat exchanger. Moreover, the parts include several types in some cases. Consequently, there is a possibility that the working hours are increased and a failure caused by an attachment mistake occurs. 
     Moreover, as described above, the parts related to the path pattern are mainly four types: the hairpin tube; the U-bent tube; the three-way bent tube; and the bulge three-way tube. In these connection members, there is no limitation to functions, an outer shape, attachment number and place, and so forth. Therefore, there is a possibility of increase in working hours due to inadequate confirmation of attachment places and inadequate confirmation of the connection member itself, and occurrence of failure caused by attachment mistake due to inadequate confirmation of attachment places and inadequate confirmation of the connection member itself. 
     Note that, when these connection members are attached by brazing, it is difficult to detach the members that have been attached once. Therefore, when an attachment mistake occurs, the whole heat exchanger including the radiator fins and the side plates has to be discarded. 
     Here, in Patent Literature 1, there is disclosed a method of manufacturing a heat exchanger including multiple bent tubes. In Patent Literature 1, a heat exchanger is manufactured by attaching multiple bent tubes in advance to a support material having holes for inserting the bent tubes formed thereon, and fitting the support material to a tube inserted into a plate fin. In this manner, Patent Literature 1 employs the support material to eliminate the confirmation of attachment places of the bent tubes, thereby, intends to improve workability in assembly of the heat exchanger. 
     CITATION LIST 
     Patent Literature 
     
         
         Patent Literature 1: Japanese Unexamined Patent Application Publication No. 2009-68805 
       
    
     SUMMARY OF INVENTION 
     Technical Problem 
     However, since the heat exchanger disclosed in Patent Literature 1 requires the support material, manufacturing costs are increased. Moreover, in Patent Literature 1, attachment of bent tubes only is disclosed, and attachment workability when there are multiple connection members is not at all considered. 
     The present invention has been made in view of the above circumstances, and provides an air-conditioning apparatus and a method of manufacturing the air-conditioning apparatus that reduce manufacturing costs and improve attachment workability even when there are multiple connection members. 
     Solution to Problem 
     An air-conditioning apparatus of an embodiment of the present invention includes: a compressor, a first heat exchanger, an expansion unit and a second heat exchanger that are connected, by a pipe, in a refrigerant circuit through which refrigerant flows, wherein the first heat exchanger includes: a radiator fin, a plurality of tubes extending through the radiator fin and through which the refrigerant flows, and a side plate provided at end portions of the tubes, and having a plurality of holes formed thereon through which the tubes are extended, wherein, on the side plate, between the holes corresponding to the tubes to be connected, a marking corresponding to a type of a connection member that connects the tubes is provided. 
     Advantageous Effects of Invention 
     According to the present invention, on the side plate, between the holes corresponding to the multiple tubes to be connected, markings corresponding to the types of the connection members that connect the multiple tubes is provided. Therefore, positioning is performed with ease without any support material. Consequently, the manufacturing costs is reduced. Moreover, the markings are different by respective types of the connection members, and thereby the connection member to be attached is recognized with ease. Therefore, the attachment workability is improved even when there are multiple connection members. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a circuit diagram showing an air-conditioning apparatus  1  according to Embodiment 1 of the present invention. 
         FIG. 2A  is a side view showing a first heat exchanger  4  in Embodiment 1 of the present invention. 
         FIG. 2B  is a front view showing the first heat exchanger  4  in Embodiment 1 of the present invention. 
         FIG. 3  is a front view showing a side plate  13  of the first heat exchanger  4  in Embodiment 1 of the present invention. 
         FIG. 4  is a diagram showing types of markings  15  in Embodiment 1 of the present invention. 
         FIG. 5  is a flowchart showing a method of manufacturing the air-conditioning apparatus  1  according to Embodiment 1 of the present invention. 
         FIG. 6  is a front view showing the side plate  13  of the first heat exchanger  4  in Embodiment 1 of the present invention. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Hereinafter, an embodiment of an air-conditioning apparatus  1  and a method of manufacturing the air-conditioning apparatus  1  according to the present invention will be described with reference to drawings. Note that the embodiment to be described below does not limit the present invention. Moreover, including  FIG. 1 , relations between sizes of respective components in the following drawings are different from those in actuality in some cases. 
     Embodiment 1 
       FIG. 1  is a circuit diagram showing an air-conditioning apparatus  1  according to Embodiment 1 of the present invention. The air-conditioning apparatus  1  will be described based on  FIG. 1 . As shown in  FIG. 1 , the air-conditioning apparatus  1  includes a refrigerant circuit  2 . In the refrigerant circuit  2 , a compressor  3 , a first heat exchanger  4 , an expansion unit  5  and a second heat exchanger  6  are connected by a pipe  7  to allow a flow of refrigerant. 
     The compressor  3  compresses the refrigerant. The first heat exchanger  4  is provided, for example, outdoor, and exchanges heat between outdoor air and the refrigerant. The first heat exchanger  4  is provided with an inflow header  4   a  on an inflow side of the refrigerant, and the inflow header  4   a  distributes the refrigerant discharged from the compressor  3  to each of tubes  12  of the first heat exchanger  4 . Moreover, the first heat exchanger  4  is provided with a first outflow header  4   b  on an outflow side of the refrigerant, and the first outflow header  4   b  collects the refrigerant flowing out of each tube  12  to allow the refrigerant to flow out to the expansion unit  5 . 
     The expansion unit  5  expands the refrigerant and reduces the pressure of the refrigerant. The second heat exchanger  6  is provided, for example, indoor, and exchanges heat between indoor air and the refrigerant. The second heat exchanger  6  is provided with a distributor  6   a  on an inflow side of the refrigerant, and the distributor  6   a  distributes the refrigerant flowing out of the expansion unit  5  to each of tubes  12  of the second heat exchanger  6 . Moreover, the second heat exchanger  6  is provided with a second outflow header  6   b  on an outflow side of the refrigerant, and the second outflow header  6   b  collects the refrigerant flowing out of each tube  12  to allow the refrigerant to flow out to the compressor  3 . 
       FIG. 2A  is a side view showing the first heat exchanger  4  in Embodiment 1 of the present invention, and  FIG. 2B  is a front view showing the first heat exchanger  4  in Embodiment 1 of the present invention. Next, the first heat exchanger  4  will be described. As shown in  FIG. 2A  and  FIG. 2B , the first heat exchanger  4  includes a radiator fin  11 , multiple tubes  12  and side plates  13 . For example, multiple radiator fins  11  are provided and the multiple radiator fins  11  are disposed at intervals mutually. The outdoor air flows through the multiple radiator fins  11 . 
     The multiple tubes  12  are inserted through the radiator fins  11  and allows the refrigerant to flow therethrough. 
     The side plate  13  is provided at end portions of the tubes  12 , and has multiple holes  13   a  formed thereon through which the multiple tubes  12  are inserted. The side plates  13  are provided, for example, at both end portions of the tubes  12  to sandwich the radiator fins  11 . An upper end portion and a lower end portion of the side plate  13  are bent 90 degrees in the direction opposite to the radiator fins  11 . 
       FIG. 3  is a front view showing the side plate  13  of the first heat exchanger  4  in Embodiment 1 of the present invention. Next, the side plate  13  of the first heat exchanger  4  will be described. As shown in  FIG. 3 , on the side plate  13 , between the holes  13   a  corresponding to the multiple tubes  12  to be connected, markings  15  corresponding to the types of the connection members  14  that connect the multiple tubes  12  are provided. 
     As the connection member  14 , for example, a U-bent tube  14 A in a U shape, a three-way bent tube  14   b  in a T shape, a bulge three-way tube  14   c  in a non-T shape, and other tubes can be provided. Moreover, in Embodiment 1, the tube  12  is a hairpin tube, and the tube  12  and the connection member  14  are integrally formed. 
       FIG. 4  is a diagram showing types of the markings  15  in Embodiment 1 of the present invention. As shown in  FIG. 4 , in the case of the hairpin tube, the marking  15  is a single straight line. In the case of the U-bent tube  14 A, the marking  15  is two parallel straight lines. In the case of the three-way bent tube  14   b , the marking  15  is two straight lines that are orthogonally crossed. In the case of the bulge three-way tube  14   c , the marking  15  is two straight lines that are crossed non-orthogonally, and an attachment direction is also indicated. Note that the sizes of the markings  15  are appropriately determined. 
     In Embodiment 1, the markings  15  are provided by a marking jig, and the marking jig is made of metal. On the marking jig, a shape corresponding to the type of the marking  15  is formed. Note that the marking  15  may be provided by a writing material, or may be provided by a sticker. Further, the marking  15  may be provided to cover the multiple holes  13   a.    
       FIG. 5  is a flowchart showing a method of manufacturing the air-conditioning apparatus  1  according to Embodiment 1 of the present invention. Next, the method of manufacturing the air-conditioning apparatus  1  will be described. First, on the side plate  13 , the multiple holes  13   a , through which the multiple tubes  12  are inserted, are formed. Specifically, on a metal plate in a flat-plate shape to serve as the side plate  13  of the first heat exchanger  4 , the multiple holes  13   a  are formed by, for example, burring processing (step ST 1 ). 
     Next, on the side plate  13 , the markings  15  corresponding to the type of the connection member  14  that connects the multiple tubes  12  are provided between the holes  13   a  corresponding to the multiple tubes  12  to be connected. Specifically, between the multiple holes  13   a , the markings  15  are inscribed by a marking jig (step ST 2 ). Then, the upper end portion and the lower end portion of the metal plate are bent 90 degrees. Accordingly, the side plate  13  of the first heat exchanger  4  is manufactured (step ST 3 ). Thereafter, the first heat exchanger  4  is manufactured by employing the side plates  13 , and the air-conditioning apparatus  1  is manufactured by incorporating the first heat exchanger  4  thereinto. 
     Next, an operation state of the air-conditioning apparatus  1  according to Embodiment 1 will be described. The compressor  3  sucks the refrigerant and compresses the refrigerant to discharge the refrigerant in a gas state of high temperature and high pressure. The discharged refrigerant flows into the first heat exchanger  4 , and the first heat exchanger  4  condenses the refrigerant by heat exchange with the outdoor air. The condensed refrigerant flows into the expansion unit  5 , and the expansion unit  5  expands the condensed refrigerant and reduces the pressure thereof. Then, the refrigerant reduced in pressure flows into the second heat exchanger  6 , and the second heat exchanger  6  evaporates the refrigerant by heat exchange with the indoor air. At this time, the indoor air is cooled, and thereby cooling of the indoor space is performed. Then, the refrigerant evaporated and brought into a gas state of high temperature and low pressure is sucked by the compressor  3 . 
     The air-conditioning apparatus  1  according to Embodiment 1 is used in performing the cooling operation in this manner; however, the air-conditioning apparatus  1  may be configured to make it possible to perform, not only the cooling operation, but also the heating operation by providing a flow switching unit in the refrigerant circuit  2 . 
       FIG. 6  is a front view showing the side plate  13  of the first heat exchanger  4  in Embodiment 1 of the present invention. Next, action of the air-conditioning apparatus  1  according to Embodiment 1 will be described. In  FIG. 6 , solid-line arrows indicate attachment positions of the connection members  14  that are attached to the side plate  13  on one end portion of the first heat exchanger  4  and flow directions of the refrigerant. Further, in  FIG. 6 , broken lines indicate attachment positions of the connection members  14  that are attached to the side plate  13  on the other end portion of the first heat exchanger  4 . In this manner, in the first heat exchanger  4 , since the connection members  14  attached to the side plates  13  on both end portions are different, different markings  15  are provided to the side plate  13  on each of the both end portions. 
     As shown in  FIG. 6 , each connection member  14  is attached in accordance with the types of the markings  15 . For example, at the portion where the marking  15  of two parallel straight lines is provided, the U-bent tube  14 A is attached. Meanwhile, at the portion where the marking  15  of two straight lines that are orthogonally crossed is provided, the three-way bent tube  14   b  is attached. Further, on the broken line, although the marking  15  is not shown, the hairpin tube (the tube  12 ) is attached. Then, the refrigerant flowing in from the inflow header  4   a  flows through the hairpin tube (the tube  12 ), the U-bent tube  14 A, the hairpin tube (the tube  12 ), and the three-way bent tube  14   b  in this order. 
     One of the refrigerant branched at the three-way bent tube  14   b  flows through the hairpin tube (the tube  12 ), the U-bent tube  14 A, the hairpin tube (the tube  12 ), the U-bent tube  14 A and the hairpin tube (the tube  12 ) in this order, and flows out to the first outflow header  4   b . Meanwhile, the other one of the refrigerant branched at the three-way bent tube  14   b  flows through the hairpin tube (the tube  12 ), the U-bent tube  14 A, the hairpin tube (the tube  12 ), the U-bent tube  14 A and the hairpin tube (the tube  12 ) in this order, and flows out to the first outflow header  4   b.    
     As described above, on the side plate  13 , between the holes  13   a  corresponding to the multiple tubes  12  to be connected, markings  15  corresponding to the types of the connection members  14  that connect the multiple tubes  12  are provided. Therefore, positioning is performed with ease without any support material. Consequently, the manufacturing costs are reduced. Further, the markings  15  are different by respective types of the connection members  14 , and thereby the connection members  14  to be attached are recognized with ease. Therefore, the attachment workability is improved even when there are multiple connection members  14 . 
     Moreover, this configuration reduces time for attaching the connection members  14  to the first heat exchanger  4 . Moreover, since the attachment workability is improved, quality of the first heat exchanger  4  is improved. Further, even when the connection member  14  is attached by brazing, since occurrence of attachment mistake is suppressed, the risk of discarding the whole first heat exchanger  4  including the radiator fins  11  and the side plates  13  is reduced. This contributes to energy saving. 
     Note that, in Embodiment 1, the markings  15  are provided on the side plates  13  of the first heat exchanger  4 , however, the markings  15  may be provided on the side plates  13  of the second heat exchanger  6 . In this case, the refrigerant flowing in from the expansion unit  5  flows through the hairpin tube, the U-bent tube  14 A, the three-way bent tube  14   b  and others, to flow out to the second outflow header  6   b . Further, in Embodiment 1, the markings  15  are provided on the side plates  13  of the first heat exchanger  4 , however, the markings  15  may be provided on the side plates  13  of the second heat exchanger  6 . 
     Further, the tube  12  is a hairpin tube, and the tube  12  and the connection member  14  are integrally formed. This configuration improves attachment workability of the hairpin tube. 
     Even further, as the connection member  14 , the U-bent tube  14 A in the U shape is used. This configuration improves attachment workability of the U-bent tube  14 A. 
     Still further, as the connection member  14 , the three-way bent tube  14   b  in the T shape is used. This configuration improves attachment workability of the three-way bent tube  14   b.    
     Then, as the connection member  14 , the bulge three-way tube  14   c  in a non-T shape is used, and the marking  15  indicating the attachment direction of the connection member  14  is provided on the side plate  13 . This configuration improves attachment workability of the bulge three-way tube  14   c , and the attachment direction thereof is recognized with ease. 
     Further, on the side plate  13 , the markings  15  are provided by the marking jigs. This improves workability in providing the markings  15 . 
     Even further, on the side plate  13 , the markings  15  are provided by the writing material. This improves workability in providing the markings  15 . 
     Still further, on the side plate  13 , the markings  15  are provided by the stickers. This improves workability in providing the markings  15 . 
     Then, on the side plate  13 , the marking  15  is provided to cover the multiple holes  13   a . This improves workability in providing the marking  15 . 
     Moreover, in a method of manufacturing an air-conditioning apparatus  1  having a refrigerant circuit  2  through which refrigerant flows, the refrigerant circuit  2  including a compressor  3 , a first heat exchanger  4 , an expansion unit  5  and a second heat exchanger  6  that are connected by a pipe  7 , the first heat exchanger  4  including a radiator fin  11 , multiple tubes  12  that are inserted through the radiator fin  11  and allows the refrigerant to flow therethrough, and a side plate  13  that is provided at end portions of the multiple tubes  12 , the method includes: a step of forming multiple holes  13   a , through which the multiple tubes  12  are inserted, on the side plate  13 ; and a step of providing, on the side plate  13 , between the holes  13   a  corresponding to the multiple tubes  12  to be connected, a marking  15  corresponding to a type of a connection member  14  connecting the multiple tubes  12 . Therefore, positioning is performed with ease without any support material. Consequently, manufacturing costs are reduced. Moreover, the markings  15  are different by respective types of the connection members  14 , and thereby the connection members  14  to be attached are recognized with ease. Therefore, the attachment workability is improved even when there are multiple connection members  14 . 
     REFERENCE SIGNS LIST 
     
         
         
           
               1  air-conditioning apparatus 
               2  refrigerant circuit 
               3  compressor 
               4  first heat exchanger 
               4   a  inflow header 
               4   b  first outflow header  5  expansion unit 
               6  second heat exchanger 
               6   a  distributor 
               6   b  second outflow header 
               7  pipe 
               11  radiator fin 
               12  tube 
               13  side plate 
               13   a  hole 
               14  connection member 
               14   a  U-bent tube 
               14   b  three-way bent tube 
               14   c  bulge three-way tube 
               15  marking