Method of manufacturing header tank for heat exchanger and heat exchanger having the header tank

Abstract

A method of manufacturing a header tank for a heat exchanger includes forming a first engagement portion in a core plate, placing a tank body relative to a base portion of the core plate, and moving a first wall portion toward the tank body such that the first engagement portion is engaged with the tank body. In the forming, a portion of the core plate is bent, the portion extending from the first wall portion. In the placing, the tank body is placed such that an opening of the tank body is covered by the base portion such that a tank inner space is defined. The first engagement portion is engaged with the tank body by moving the first wall portion toward the tank body.

1 . A method of manufacturing a header tank for a heat exchanger in which tubes are coupled to the header tank, the method comprising:
 forming a first engagement portion in a core plate by bending a portion of the core plate, the portion extending from a first wall portion of the core plate;   placing a tank body, which has a substantially semi-tubular shape and an opening, relative to a base portion of the core plate such that the opening is covered by the base portion and a tank inner space is provided between the tank body and the base portion; and   moving the first wall portion toward the tank body such that the first engagement portion is engaged with the tank body.   
   
   
       2 . The method according to  claim 1 , further comprising:
 pre-bending the first wall portion relative to a plane of the base portion by a predetermined angle, before the placing of the tank body, wherein   in the moving of the first wall portion, the first wall portion is moved toward the tank body from a pre-bent condition formed by the pre-bending.   
   
   
       3 . The method according to  claim 1 , wherein
 in the moving of the first wall portion, an engagement portion-side section of the first wall portion is moved toward the tank body about a bending axis, the bending axis being included within the first wall portion, the engagement portion-side section being a portion of the first wall portion between the bending axis and the first engagement portion.   
   
   
       4 . The method according to  claim 3 , further comprising:
 pre-bending the engagement portion-side section relative to a remaining section of the first wall portion along the bending axis in an outward direction before the placing of the tank body, wherein   in the moving of the first wall portion, the engagement portion-side section is moved from a pre-bent condition formed by the pre-bending toward the tank body.   
   
   
       5 . The method according to  claim 1 , wherein
 in the moving of the first wall portion, the first wall portion is moved up to a position where an outer surface of the first wall portion forms an angle equal to or greater than 90 degrees relative to a plane of the base portion.   
   
   
       6 . The method according to  claim 1 , wherein the moving of the first wall portion includes engaging the first engagement portion with the tank body such that the first engagement portion forms an acute angle with the first wall portion. 
   
   
       7 . The method according to  claim 1 , further comprising:
 setting a sealing member to at least one of the core plate and the tank body before the placing of the tank body, wherein   the placing of the tank body includes arranging the tank body relative to the core plate such that the sealing member is disposed between the tank body and the core plate.   
   
   
       8 . The method according to  claim 7 , wherein
 the setting of the sealing member includes applying a sealing material in a state of at least one of gel and liquid to at least one of the core plate and the tank body and hardening the sealing material thereon.   
   
   
       9 . The method according to  claim 1 , wherein
 in the moving of the first wall portion, the first wall portion is moved about a bending axis, the bending axis being parallel to a longitudinal axis of the tank body.   
   
   
       10 . The method according to  claim 9 , further comprising:
 bending a second wall portion of the core plate across the longitudinal axis of the tank body before the placing of the tank body, the second wall portion being separated from the first wall portion; and   bending a second engagement portion that extends from the second wall portion toward the tank body to engage with the tank body after the placing of the tank body.   
   
   
       11 . A heat exchanger comprising:
 a plurality of tubes; and   the header tank manufactured by the method according to  claim 1 , wherein the plurality of tubes are coupled to the core plate.   
   
   
       12 . The heat exchanger according to  claim 11 , wherein
 the core plate includes weak portions, at which strength of the core plate is reduced less than other portions, along a bending axis of the first wall portion along which the first wall portion is moved.   
   
   
       13 . The heat exchanger according to  claim 12 , wherein the bending axis is included within the first wall portion. 
   
   
       14 . The heat exchanger according to  claim 12 , wherein the weak portion is provided by a groove. 
   
   
       15 . The heat exchanger according to  claim 12 , wherein the weak portion is provided by one of a plurality of openings and a plurality of recesses disposed along the bending axis. 
   
   
       16 . The heat exchanger according to  claim 11 , wherein
 the first wall portion extends from a lengthwise edge of the base portion and the first engagement portion extends from the first wall portion, the lengthwise edge being parallel to a longitudinal axis of the tank body, and   the core plate further includes a second wall portion and a second engagement portion, the second wall portion extending from a widthwise edge of the base portion, the widthwise edge being across the longitudinal axis of the tank body, the second engagement portion extending from the second wall portion and is engaged with the tank body.   
   
   
       17 . The heat exchanger according to  claim 16 , wherein
 the core plate further includes a support wall portion that extends from the lengthwise edge of the base portion,   the support wall portion is separated from the first wall portion and is configured to support the second wall portion.   
   
   
       18 . The heat exchanger according to  claim 16 , wherein
 the first engagement portion extends over a lengthwise end of the first wall portion, the lengthwise edge being parallel to the longitudinal axis of the tank body.   
   
   
       19 . The heat exchanger according to  claim 13 , wherein
 the tank body includes a contact portion that contacts the bending axis of the core plate from an inner side of the core plate.   
   
   
       20 . The heat exchanger according to  claim 19 , wherein
 the contact portion projects toward the bending axis and has a surface opposed to the base portion, and   the surface of the contact portion partly protrudes toward the base portion.   
   
   
       21 . The heat exchanger according to  claim 11 , wherein
 the base portion includes a plurality of holes to which the tubes are coupled, and   the base portion further includes a plurality of projections projecting in a direction opposite to the tank body, the plurality of projections are disposed between the adjacent holes.   
   
   
       22 . The heat exchanger according to  claim 21 , wherein
 each of the projections has a width greater than a width of the tubes with respect to a direction perpendicular to a longitudinal axis of the tank body.   
   
   
       23 . The heat exchanger according to  claim 11 , further comprising:
 a sealing member disposed between the tank body and the base portion of the core plate in an elastically deformed condition to seal between the tank body and the core plate.   
   
   
       24 . The heat exchanger according to  claim 23 , wherein
 the tank body includes a projected end on a perimeter of the opening,   the core plate includes a sealing surface on the periphery of the tubes, and   the sealing member is disposed between the projected end of the tank body and the sealing surface of the core plate.   
   
   
       25 . The heat exchanger according to  claim 24 , wherein
 the core plate includes a sealing groove, and the sealing surface is provided by a bottom of the sealing groove, and   the sealing member is disposed in the sealing groove.