Header for use in heat exchanger, heat exchanger and method for manufacturing the same

Abstract

A header for use in heat exchanger includes a base wall ( 20 ) with a plurality of tube insertion apertures ( 23 ), an opposite wall ( 30 ) opposed to the base wall ( 20 ), a pair of side walls ( 40 a and 40 b ) disposed at both lateral sides of the base wall ( 20 ) and the opposite wall ( 30 ) and connecting the lateral sides and are inforcing walls ( 50 a and 50 b ) disposed betwwen the base wall ( 20 ) and the opposite wall ( 30 ) along a longitudinal direction thereof and connecting the base wall ( 20 ) with the opposite wall ( 30 ). The side walls ( 40 a and 40 b ) are integrally formed at both lateral sides of the base wall ( 20 ) be bending processing. A first half (30 a ) of the opposite wall ( 30 ) is integrally formed at a side of one of the side walls ( 40 a ) by bending processing, and a second half ( 30 b ) of the opposite wall ( 30 ) is integrally formed at a side of the other of the side walls ( 40 b ) by bending processing. Reinforcing walls ( 50 a and 50 b ) are integrally formed at sides of the first half ( 30 a ) and the second half ( 30 b ) of the opposite wall ( 30 ) by bending processing. With this header for use in heat exchanger, high pressure resistance can be obtained, and the number of parts and the manufacturing cost can be decreased.

1 . A header for use in heat exchangers, said header comprising: 
 a base wall with a plurality of tube insertion apertures for inserting heat exchanging tubes formed at predetermined intervals in a longitudinal direction of said base wall;    an opposite wall opposed to said base wall;    a pair of side walls disposed at both lateral sides of said base wall and said opposite wall and connecting said lateral sides; and    a reinforcing wall disposed between said base wall and said opposite wall along a longitudinal direction thereof and connecting said base wall to said opposite wall,    wherein said side walls are integrally formed at both lateral sides of said base wall by bending processing,    wherein a first half of said opposite wall constituting one half of said opposite wall is integrally formed at a side of one of said side walls by bending processing,    wherein a second half of said opposite wall constituting the other half of said opposite wall is integrally formed at a side of the other of said side walls by bending processing, and    wherein said reinforcing wall is integrally formed at at least one of sides of said first half of said opposite wall and said second half of said opposite wall by bending processing.    
     
     
         2 . The header for use in heat exchangers as recited in  claim 1 , wherein said reinforcing wall is integrally formed at each of said sides of said first half of said opposite wall and said second half of said opposite wall.  
     
     
         3 . The header for use in heat exchangers as recited in  claim 1  or  2 , wherein a side edge of said reinforcing wall opposed to said base wall is integrally brazed to said base wall.  
     
     
         4 . The header for use in heat exchangers as recited in  claim 2 , wherein said reinforcing walls are fitted with each other and integrally brazed with each other.  
     
     
         5 . The header for use in heat exchangers as recited in any one of  claims 1  to  4 , wherein said reinforcing wall is provided with tube engaging cut-out portions formed at positions corresponding to said plurality of tube insertion apertures, whereby each end of said plurality of heat exchanging tubes inserted into said tube insertion apertures is engaged with said tube engaging cut-out portion in a positioned manner.  
     
     
         6 . The header for use in heat exchangers as recited in any one of  claims 1  to  5 , wherein said reinforcing wall is provided with insertion ledges at a base wall side edge of said reinforcing wall opposed to said base wall, wherein said base wall is provided with insertion ledge engaging apertures at positions corresponding to said insertion ledges, and wherein said insertion ledges are inserted into said insertion ledge engaging apertures and engaged therewith, respectively.  
     
     
         7 . The header for use in heat exchangers as recited in  claim 6 , wherein said insertion ledges are integrally brazed to said base wall with said insertion ledges inserted into said insertion ledge engaging apertures.  
     
     
         8 . The header for use in heat exchangers as recited in  claim 6  or  7 , wherein said insertion ledges are intermittently formed at certain intervals in the longitudinal direction of said header.  
     
     
         9 . The header for use in heat exchangers as recited in any one of  claims 6  to  8 , wherein a tip portion of said insertion ledge is inserted into said insertion ledge engaging aperture, and wherein said tip portion of said insertion ledge is bent and engaged with an external surface of said base wall.  
     
     
         10 . The header for use in heat exchangers as recited in any one of  claims 1  to  9 , wherein a peripheral edge of said tube insertion aperture is bent inwardly.  
     
     
         11 . The header for use in heat exchangers as recited in claim  1  or  2 , wherein said reinforcing wall has a side edge opposed to said base wall, and wherein said side edge is abutted against an inner surface of said base wall.  
     
     
         12 . The header for use in heat exchangers as recited in  claim 11 , wherein said side edge of said reinforcing wall is integrally brazed to said base wall.  
     
     
         13 . The header for use in heat exchangers as recited in  claim 11  or  12 , wherein said side edge of said reinforcing wall is abutted against said base wall continuously along a longitudinal direction of said header.  
     
     
         14 . The header for use in heat exchangers as recited in  claim 1  or  2 , wherein a side edge portion of said reinforcing wall opposed to said base wall is bent outwardly to form a bent portion, and wherein said bent portion is secured to an inner surface of said base wall.  
     
     
         15 . The header for use in heat exchangers as recited in  claim 14 , wherein said bent portion of said reinforcing wall is integrally brazed to said base wall.  
     
     
         16 . The header for use in heat exchangers as recited in  claim 14  or  15 , wherein said bent portion of said reinforcing wall is continuously formed along a longitudinal direction of said header.  
     
     
         17 . The header for use in heat exchangers as recited in  claim 14  or  15 , wherein said bent portion of said reinforcing wall is intermittently formed at certain intervals along a longitudinal direction of said header.  
     
     
         18 . The header for use in heat exchangers as recited in  claim 17 , wherein said side edge of said reinforcing wall between said bent portions adjacent in a longitudinal direction of said header is abutted against said base wall.  
     
     
         19 . The header for use in heat exchangers as recited in  claim 17 , wherein said reinforcing wall has insertion ledges at said side edge of said reinforcing wall opposed to said base wall between said bent portions adjacent in a longitudinal direction of said header, wherein said base wall is provided with insertion ledge engaging apertures at positions corresponding to said insertion ledges, and wherein said insertion ledges are inserted into said insertion ledge engaging apertures and engaged therewith.  
     
     
         20 . The header for use in heat exchangers as recited in  claim 2 , wherein one of said reinforcing walls is provided with insertion ledges at a side edge opposed to said base wall, wherein said base wall is provided with insertion ledge engaging apertures at positions corresponding to said insertion ledges, wherein said insertion ledges are inserted into said insertion ledge engaging apertures and engaged therewith, and wherein a side edge of the other of said reinforcing walls opposed to said base wall is abutted against an inner surface of said base wall.  
     
     
         21 . The header for use in heat exchangers as recited in  claim 2 , wherein one of said reinforcing walls is provided with insertion ledges at a side edge opposed to said base wall, wherein said base wall is provided with insertion ledge engaging apertures at positions corresponding to said insertion ledges, wherein said insertion ledges are inserted into said insertion ledge engaging apertures and engaged therewith, and wherein a side edge portion of the other of said reinforcing walls opposed to said base wall has an outwardly bent portion and said bent portion is secured to an inner surface of said base wall.  
     
     
         22 . The header for use in heat exchangers as recited in  claim 21 , wherein said insertion ledges of said one of reinforcing walls are formed at certain intervals in a longitudinal direction of said header.  
     
     
         23 . The header for use in heat exchangers as recited in  claim 21 , wherein said bent portions of said the other reinforcing wall are formed at certain intervals in a longitudinal direction of said header.  
     
     
         24 . The header for use in heat exchangers as recited in  claim 2 , wherein said one of said reinforcing walls is disposed such that a side edge of said one of said reinforcing walls opposed to said base wall is abutted against said base wall, and wherein said the other of said reinforcing walls is disposed such that a side edge portion of said the other of said reinforcing walls is bent outwardly to form a bent portion and said bent portion is secured to an inner surface of said base wall.  
     
     
         25 . The header for use in heat exchangers as recited in  claim 24 , wherein said bent portion of said the other of said reinforcing walls is formed at certain intervals in a longitudinal direction of said header.  
     
     
         26 . A header for use in heat exchangers, said header comprising: 
 a base wall with a plurality of tube insertion apertures for inserting heat exchanging tubes formed at predetermined intervals in a longitudinal direction of said base wall;    an opposite wall opposed to said base wall;    a pair of side walls disposed at both lateral sides of said base wall and said opposite wall and connecting said lateral sides; and    a reinforcing wall disposed between said base wall and said opposite wall along a longitudinal direction thereof and connecting said base wall to said opposite wall,    wherein said side walls are integrally formed at both lateral sides of said base wall by bending processing,    wherein a first half of said opposite wall constituting one half of said opposite wall is integrally formed at a side of one of said side walls by bending processing,    wherein a second half of said opposite wall constituting the other half of said opposite wall is integrally formed at a side of the other of said side walls by bending processing, and    wherein said reinforcing wall is integrally formed at respective sides of said first half of said opposite wall and said second half of said opposite wall by bending processing,    wherein insertion ledges are formed at certain intervals in a longitudinal direction of said header at side edges of said reinforcing walls opposed to said base wall,    wherein said insertion ledges of said one of said reinforcing walls and said insertion ledges of said the other of said reinforcing walls are disposed alternatively along said longitudinal direction of said header,    wherein said base wall is provided with insertion ledge engaging apertures at positions corresponding to said insertion ledges, and    wherein said insertion ledges are inserted into corresponding insertion ledge engaging apertures and engaged therewith.    
     
     
         27 . The header for use in heat exchangers as recited in  claim 26 , wherein said insertion ledge engaging apertures are formed along said longitudinal direction of said header in a zigzag manner.  
     
     
         28 . The header for use in heat exchangers as recited in  claim 26  or  27 , wherein said tip portion of said insertion ledge is bent to form a bent portion with said insertion ledge inserted into said insertion ledge engaging aperture and said bent portion is engaged with an external surface of said base wall.  
     
     
         29 . The header for use in heat exchangers as recited in  claim 28 , wherein said bent portion is formed by bending said tip portion of said insertion ledge by caulking processing.  
     
     
         30 . A method for manufacturing a header for use in heat exchangers, said header including a base wall with a plurality of tube insertion apertures for inserting heat exchanging tubes formed at predetermined intervals in a longitudinal direction of said base wall, an opposite wall opposed to said base wall, a pair of side walls disposed at both lateral sides of said base wall and said opposite wall and connecting said lateral sides, and a reinforcing wall disposed between said base wall and said opposite wall along a longitudinal direction thereof and connecting said base wall with said opposite wall, said method comprising: 
 a step for preparing a formed plate, said formed plate including a base wall region having said plurality of tube insertion apertures and extending in a longitudinal direction of said formed plate, a pair of side wall regions formed at both lateral sides of said base wall region and extending in said longitudinal direction, a first half region of an opposite wall formed at one of lateral sides of said base wall  1  region and extending in said longitudinal direction, a second half region of an opposite wall formed at the other of lateral sides of said base wall region and extending in said longitudinal direction, and a reinforcing wall region formed at at least one of said first half and second half regions of said opposite wall and extending in said longitudinal direction;    a step for bending said reinforcing wall region relative to said first half region of said opposite wall and/or said second half region of said opposite wall;    a step for bending said first half region of said opposite wall and/or said second half region of said opposite wall relative to said side wall regions; and    a step for bending said side wall regions relative to said base wall region, to thereby obtain said header in which said base wall, said side walls, said opposite wall and said reinforcing wall are constituted by said base wall region, said side wall regions, said opposite wall region and said reinforcing wall region, respectively.    
     
     
         31 . The method for manufacturing a header for use in heat exchangers as recited in  claim 30 , wherein, in said step for preparing said formed plate, said reinforcing wall region is formed at each side of said first half region and said second half region of said opposite wall.  
     
     
         32 . The method for manufacturing a header for use in heat exchangers as recited in  claim 30 , wherein, in said step for preparing said formed plate, tube engaging cut-out portions are formed at portions of said reinforcing wall corresponding to said plurality of tube insertion apertures such that ends of said heat exchanging tubes inserted in said tube insertion apertures are engaged with said engaging cut-out portions in a positioned manner.  
     
     
         33 . The method for manufacturing a header for use in heat exchangers as recited in any one of  claims 30  to  32 , wherein, in said step for preparing said formed plate, insertion ledges are formed at a base wall side edge of said reinforcing wall and insertion ledge engaging apertures are formed at positions of said base wall corresponding to said insertion ledges, further comprising a step of inserting said insertion ledges into said insertion ledge engaging apertures.  
     
     
         34 . The method for manufacturing a header for use in heat exchangers as recited in any one of  claims 30  to  33 , wherein, in said step for preparing said formed plate, said formed plate is formed by die-cutting and pressing a brazing sheet with a brazing layer clad on at least one surface thereof.  
     
     
         35 . The method for manufacturing a header for use in heat exchangers as recited in  claim 34 , further comprising a step of brazing an assembly obtained by said bending steps in a furnace.  
     
     
         36 . A heat exchanger, comprising: 
 a pair of headers for use in heat exchangers; and    a plurality of heat exchanging tubes disposed in parallel with each other between said pair of headers with opposite ends thereof communicated with said headers,    wherein at least one of said pair of headers includes:    a base wall with a plurality of tube insertion apertures for inserting said heat exchanging tubes formed at predetermined intervals in a longitudinal direction of said base wall;    an opposite wall opposed to said base wall;    a pair of side walls disposed at both lateral sides of said base wall and said opposite wall and connecting said lateral sides; and    a reinforcing wall disposed between said base wall and said opposite wall along a longitudinal direction thereof and connecting said base wall to said opposite wall,    wherein said side walls are integrally formed at both lateral sides of said base wall by bending processing,    wherein a first half of said opposite wall constituting one half of said opposite wall is integrally formed at a side of one of said side walls by bending processing,    wherein a second half of said opposite wall constituting the other half of said opposite wall is integrally formed at a side of the other of said side walls by bending processing, and    wherein said reinforcing wall is integrally formed at at least one of sides of said first half of said opposite wall and said second half of said opposite wall by bending processing.    
     
     
         37 . The exchanger as recited in  claim 36 , wherein said reinforcing wall is provided with tube engaging cut-out portions formed at positions corresponding to said plurality of tube insertion apertures, whereby each end of said plurality of heat exchanging tubes inserted into said tube insertion apertures is engaged with said tube engaging cut-out portion in a positioned manner.  
     
     
         38 . The exchanger as recited in  claim 36  or  37 , wherein said each end of said plurality of heat exchanging tubes is brazed to said header.  
     
     
         39 . A heat exchanger, comprising: 
 a pair of headers for use in heat exchangers; and    a plurality of heat exchanging tubes disposed in parallel with each other between said pair of headers with opposite ends thereof communicated with said headers,    wherein at least one of said pair of headers includes:    a base wall with a plurality of tube insertion apertures for inserting said heat exchanging tubes formed at predetermined intervals in a longitudinal direction of said base wall;    an opposite wall opposed to said base wall;    a pair of side walls disposed at both lateral sides of said base wall and said opposite wall and connecting said lateral sides; and    reinforcing walls disposed between said base wall and said opposite wall along a longitudinal direction thereof and connecting said base wall to said opposite wall,    wherein said side walls are integrally formed at both lateral sides of said base wall by bending processing,    wherein a first half of said opposite wall constituting one half of said opposite wall is integrally formed at a side of one of said side walls by bending processing,    wherein a second half of said opposite wall constituting the other half of said opposite wall is integrally formed at a side of the other of said side walls by bending processing,    wherein each of said reinforcing walls is integrally formed at each of sides of said first half of said opposite wall and said second half of said opposite wall by bending processing,    wherein each of said reinforcing walls is provided with insertion ledges at a base wall side edge of said reinforcing wall opposed to said base wall at predetermined intervals in a longitudinal direction of said header,    wherein said insertion ledges of one of said reinforcing walls and said insertion ledges of the other of said reinforcing walls are disposed alternatively in said longitudinal direction of said header,    wherein said base wall is provided with insertion ledge engaging apertures at positions corresponding to said insertion ledges, and    wherein said insertion ledges are inserted into said insertion ledge engaging apertures and engaged therewith, respectively.    
     
     
         40 . The exchanger as recited in  claim 39 , wherein said reinforcing wall is provided with tube engaging cut-out portions formed at positions corresponding to said plurality of tube insertion apertures, whereby each end of said plurality of heat exchanging tubes inserted into said tube insertion apertures is engaged with said tube engaging cut-out portion in a positioned manner.  
     
     
         41 . The exchanger as recited in  claim 39  or  40 , wherein said each end of said plurality of heat exchanging tubes is brazed to said header.  
     
     
         42 . The exchanger as recited in any one of  claims 39  to  41 , wherein said insertion ledge engaging apertures are formed in a zigzag manner in said longitudinal direction of said header.  
     
     
         43 . A manufacturing method of a heat exchanger, the method comprising: 
 a step for preparing a pair of headers for use in heat exchangers;    a step for preparing a plurality of heat exchanging tubes; and    a step for disposing said plurality of heat exchanging tubes in parallel with each other between said pair of headers with opposite ends thereof communicated with said headers,    wherein at least one of said pair of headers includes:    a base wall with a plurality of tube insertion apertures for inserting heat exchanging tubes formed at predetermined intervals in a longitudinal direction of said base wall;    an opposite wall opposed to said base wall;    a pair of side walls disposed at both lateral sides of said base wall and said opposite wall and connecting said lateral sides; and    a reinforcing wall disposed between said base wall and said opposite wall along a longitudinal direction thereof and connecting said base wall to said opposite wall,    wherein said side walls are integrally formed at both lateral sides of said base wall by bending processing,    wherein a first half of said opposite wall constituting one half of said opposite wall is integrally formed at a side of one of said side walls by bending processing,    wherein a second half of said opposite wall constituting the other half of said opposite wall is integrally formed at a side of the other of said side walls by bending processing, and    wherein said reinforcing wall is integrally formed at at least one of sides of said first half of said opposite wall and said second half of said opposite wall by bending processing.    
     
     
         44 . The manufacturing method of a heat exchanger method as recited in  claim 43 , wherein said step for preparing said header comprises: 
 a step for preparing a formed plate, said formed plate including a base wall region having said plurality of tube insertion apertures and extending in a longitudinal direction of said formed plate, a pair of side wall regions formed at both lateral sides of said base wall region and extending in said longitudinal direction, a first half region of an opposite wall formed at one of lateral sides of said base wall  1  region and extending in said longitudinal direction, a second half region of an opposite wall formed at the other of lateral sides of said base wall region and extending in said longitudinal direction, and a reinforcing wall region formed at at least one of said first half and second half regions of said opposite wall and extending in said longitudinal direction;    a step for bending said reinforcing wall region relative to said first half region of said opposite wall and/or said second half region of said opposite wall;    a step for bending said first half region of said opposite wall and/or said second half region of said opposite wall relative to said side wall regions; and    a step for bending said side wall regions relative to said base wall region.    
     
     
         45 . The manufacturing method of a heat exchanger as recited in  claim 43  or  44 , wherein said each end of said plurality of heat exchanging tubes is brazed to said header.  
     
     
         46 . A manufacturing method of a heat exchanger, the method comprising: 
 a step for preparing a pair of headers for use in heat exchangers;    a step for preparing a plurality of heat exchanging tubes; and    a step for disposing said plurality of heat exchanging tubes in parallel with each other between said pair of headers with opposite ends thereof communicated with said headers,    wherein at least one of said pair of headers includes:    a base wall with a plurality of tube insertion apertures for inserting heat exchanging tubes formed at predetermined intervals in a longitudinal direction of said base wall;    an opposite wall opposed to said base wall;    a pair of side walls disposed at both lateral sides of said base wall and said opposite wall and connecting said lateral sides; and    reinforcing walls disposed between said base wall and said opposite wall along a longitudinal direction thereof and connecting said base wall to said opposite wall,    wherein said side walls are integrally formed at both lateral sides of said base wall by bending processing,    wherein a first half of said opposite wall constituting one half of said opposite wall is integrally formed at a side of one of said side walls by bending processing,    wherein a second half of said opposite wall constituting the other half of said opposite wall is integrally formed at a side of the other of said side walls by bending processing,    wherein each of said reinforcing walls is integrally formed at each of sides of said first half of said opposite wall and said second half of said opposite wall by bending processing,    wherein each of said reinforcing walls is provided with insertion ledges at a base wall side edge of said reinforcing wall opposed to said base wall at predetermined intervals in a longitudinal direction of said header,    wherein said insertion ledges of one of said reinforcing walls and said insertion ledges of the other of said reinforcing walls are disposed alternatively in said longitudinal direction of said header,    wherein said base wall is provided with insertion ledge engaging apertures at positions corresponding to said insertion ledges, and    wherein said insertion ledges are inserted into said insertion ledge engaging apertures and engaged therewith, respectively.    
     
     
         47 . The manufacturing method of a heat exchanger method as recited in  claim 46 , wherein said step for preparing said header comprises: 
 a step for preparing a formed plate, said formed plate including a base wall region having said plurality of tube insertion apertures and extending in a longitudinal direction of said formed plate, a pair of side wall regions formed at both lateral sides of said base wall region and extending in said longitudinal direction, a first half region of an opposite wall formed at one of lateral sides of said base wall  1  region and extending in said longitudinal direction, a second half region of an opposite wall formed at the other of lateral sides of said base wall region and extending in said longitudinal direction, and a reinforcing wall region formed at at least one of said first half and second half regions of said opposite wall and extending in said longitudinal direction;    a step for bending said reinforcing wall region relative to said first half region of said opposite wall and/or said second half region of said opposite wall;    a step for bending said first half region of said opposite wall and/or said second half region of said opposite wall relative to said side wall regions; and    a step for bending said side wall regions relative to said base wall region.    
     
     
         48 . The manufacturing method of a heat exchanger as recited in  claim 46  or  47 , wherein said each end of said plurality of heat exchanging tubes is brazed to said header.