Header Tank for Heat Exchanger

Abstract

A header tank for a heat exchanger includes tank forming sections that are joined into a tubular shape with a substantially square cross-section. The header tank has a refrigerant low path formed inside the tank forming sections include a tank upper section ( 31 ) in which tube insertion holes ( 31 a ) for connecting tubes of a heat exchanger core are formed. The tank lower section ( 33 ) having a substantially U-shaped refrigerant split-flow groove ( 33 A) that has, in its longitudinal direction, communication holes ( 33 a, 33 b ) for the refrigerant. The tank forming sections include a plate section ( 35 ) for closing an opening of the refrigerant split-flow groove ( 33 A) to form a refrigerant split-flow path ( 37 ) inside the tank lower section.

1 . A header tank for a heat exchanger, comprising: 
 a plurality of tank constituent portions joined into a cylindrical shape with a substantially square cross-section; and    a refrigerant passage formed within the plurality of tank constituent portions; wherein    the plurality of tank constituent portions include: 
 a tank upper portion with a plurality of tube insertion holes for connection of tubes of the heat exchanger core formed;  
 a tank lower portion including a refrigerant distribution groove with a substantially U-shaped section which has a plurality of refrigerant communication holes in a longitudinal direction;  
 a plate portion closing an opening of the refrigerant distribution groove to form a refrigerant distribution passage within the tank lower portion.  
   
   
   
       2 . A header tank for a heat exchanger, comprising: 
 a plurality of tank constituent portions joined into a cylindrical shape with a substantially square section; wherein    the plurality of tank constituent portions include: 
 a tank upper portion with a plurality of tube insertion holes for connection of tubes of the heat exchanger core formed;  
 a tank lower portion including a refrigerant distribution portion with a substantially circular section integrally formed with a body of the lower portion, the refrigerant distribution portion having a plurality of refrigerant communication holes in a longitudinal direction.  
   
   
   
       3 . A header tank of a heat exchanger, comprising: 
 a header tank formed of a single constituent material into a tubular shape with a substantially square section, wherein    an upper face of the header tank includes a plurality of tube insertion holes for connection of tubes of the heat exchanger core; and    a lower face of the header tank integrally includes a refrigerant distribution portion with a substantially circular section with a tank body, the refrigerant distribution portion includes a plurality of refrigerant communication holes along a longitudinal direction.    
   
   
       4 . The header tank according to  claim 2 , wherein 
 the refrigerant distribution portion includes a part of a plate material as a tank constituent member which is shaped to have a substantially Ω-shaped section; and    the tank includes a plurality of joints in a portion where portions of the plate material are laid on each other in the substantially Ω-shaped section.    
   
   
       5 . The header tank for a heat exchanger according to  claim 1 , wherein 
 the refrigerant communication holes include: 
 first communication holes through which refrigerant in gas phase passes; and  
 second communication holes through which refrigerant in liquid phase passes, and  
   the refrigerant distribution groove includes: 
 the first communication holes in upper part in a direction of gravity when the refrigerant flows within the header tank; and  
 the second communication holes in lower part in the direction of gravity.  
   
   
   
       6 . The header tank for a heat exchanger according to  claim 1 , wherein 
 each of the refrigerant communication holes is positioned to have half or more of a sectional area overlapped on a range of thickness of the tubes.    
   
   
       7 . The header tank for a heat exchanger according to  claim 1 , wherein 
 the communication holes and the tubes match each other in terms of longitudinal positions in the header tank.    
   
   
       8 . The header tank for a heat exchanger according to  claim 4 , wherein the joint portions are caulked.  
   
   
       9 . The header tank for a heat exchanger according to  claim 4 , wherein each of the joint portions includes a hole; and a protrusion fit in the hole.  
   
   
       10 . The header tank for a heat exchanger according to  claim 4 , wherein each of the joint portions includes a hole; and a protrusion which pierces the hole and has a crushed tip.  
   
   
       11 . The header tank for a heat exchanger according to  claim 2 , wherein 
 the refrigerant distribution portion includes: 
 a refrigerant distribution pipe;  
 a support portion supporting the refrigerant distribution pipe; and  
 communication holes which communicates with refrigerant passages on both sides of the support portion.  
   
   
   
       12 . The header tank for a heat exchanger according to  claim 9 , wherein the communication holes have an equivalent diameter of 1.0 mm or more.  
   
   
       13 . The header tank for a heat exchanger according to  claim 2 , wherein 
 the refrigerant distribution portion includes: 
 a refrigerant distribution pipe including a refrigerant distribution passage defined inside;  
 a support portion supporting the refrigerant distribution pipe; and  
   a communication holes allowing refrigerant passages on both sides of the support portion and the refrigerant distribution passage to communicate with each other.    
   
   
       14 . A method of manufacturing a header tank for a heat exchanger, comprising the steps of: 
 opening a hole in a first portion of a sheet;    forming a protrusion in a second portion of the sheet;    winding a third portion between the first and second portions of the sheet to bring the first and second portions close to each other to form a refrigerant distribution passage;    piercing the hole with the protrusion;    crushing a tip of the protrusion piercing the hole; and    bending fourth and fifth portions outside of the first and second portions in the sheet toward the wound third portion to form a refrigerant passage.    
   
   
       15 . The method of manufacturing a header tank for a heat exchanger according to  claim 14 , wherein communication holes are opened in the third portion of the sheet.