Heat exchanger and method of manufacturing the same

Abstract

A heat exchanger includes a connector for connecting a header tank to an exterior pipe. The connector includes a first member configured to define a communication path through which a tank open portion of the header tank communicates with an interior of the exterior pipe, and a second member to which the first member is fixed. The first member and the second member are fixed to each other after being separately formed by pressing, and the second member has a fastening portion through which the connector is fastened to the exterior pipe. Furthermore, the first member includes a first connection portion that is fitted into the tank open portion at one open side of the communication path, and a second connection portion fitted to an open portion of the exterior pipe at other open side of the communication path.

1 . A heat exchanger comprising:
 a plurality of tubes in which a fluid flows, the tubes being arranged in parallel with each other;   a header tank located at one end side of the plurality of tubes in a longitudinal direction of the tubes to distribute the fluid into the tubes and to join the fluid from the tubes; and   a connector that includes a first member configured to define a communication path through which a tank open portion of the header tank communicates with an interior of an exterior pipe, and a second member to which the first member is fixed, wherein:   the first member and the second member are fixed to each other after being separately formed by pressing;   the second member has a fastening portion through which the connector is fastened to the exterior pipe; and   the first member includes a first connection portion that is fitted into the tank open portion at one open side of the communication path, and a second connection portion fitted to an open portion of the exterior pipe at other open side of the communication path.   
   
   
       2 . The heat exchanger according to  claim 1 , wherein
 the second member has a through hole into which the second connection portion of the first member is fitted by expanding the second connection portion to the first member.   
   
   
       3 . The heat exchanger according to  claim 1 , wherein
 the first connection portion of the first member is brazed to the tank open portion of the header tank to be fixed to the tank open portion of the header tank.   
   
   
       4 . The heat exchanger according to  claim 1 , wherein:
 the first connection portion of the first member is a cornuted pipe; and   the second connection portion of the first member is a circular pipe.   
   
   
       5 . The heat exchanger according to  claim 1 , wherein:
 the second connection portion of the first member is located to be fitted into the open portion of the exterior pipe;   the second connection portion includes a flare portion at an end portion in an axial direction; and   the flare portion extends radially outwardly as toward to the other open side of the communication path in the axial direction.   
   
   
       6 . The heat exchanger according to  claim 5 , wherein:
 the second connection portion of the first member further includes a flange portion extending outwardly in a radial direction from the flare portion; and   the second member has a flange supporting portion configured to support the flange portion in a direction parallel to the axial direction.   
   
   
       7 . The heat exchanger according to  claim 6 , wherein:
 the flange portion has a flat surface at the other open side of the communication path in the axial direction;   the second member has a flat surface at the other open side of the communication path in the axial direction; and   the flat surface of the flange portion has a surface direction that corresponds to that of the flat surface of the flange portion.   
   
   
       8 . The heat exchanger according to  claim 7 , wherein:
 the second member has an inner peripheral end surface at the other end side in the axial direction, the inner peripheral end surface being located to enclose the flange portion of the second connection portion of the first member in a direction perpendicular to the axial direction; and   the flange portion has a radial outward end portion that is opposite to the inner peripheral end surface of the second member and is spaced from the inner peripheral end surface of the second member by a clearance.   
   
   
       9 . The heat exchanger according to  claim 1 , wherein the second member has an inner peripheral surface portion for defining the through hole, the heat exchanger further comprising:
 one of a recess portion and a protruding portion, provided at the inner peripheral surface portion of the second member;   the other one of the recess portion and the protruding portion, provided at an outer peripheral portion of the first member; and   the protruding portion is fitted into the recess portion.   
   
   
       10 . The heat exchanger according to  claim 9 , further comprising
 a seal member located at the inner peripheral surface portion of the second connection portion of the first member to seal between the inner peripheral surface portion of the second connection portion and the exterior pipe; and   the one of the recess portion and the protruding portion is located at a position shifted from the seal member in the axial direction.   
   
   
       11 . The heat exchanger according to  claim 1 , wherein:
 the exterior pipe is for supplying the fluid to the header tank or for discharging the fluid from the header tank; and   the tubes are arranged such that the fluid flowing in the tubes is heat exchanged with an exterior fluid outside the tubes.   
   
   
       12 . A method of manufacturing a heat exchanger having a connector for connecting a header tank with an exterior pipe, the method comprising:
 forming the header tank to be connected to one end side of a plurality of tubes in a longitudinal direction of the tubes; and   forming a connector, wherein the forming of the connector includes: forming a first member having a first connection portion and a second connection portion by pressing; forming a second member having a through hole by pressing; inserting the second connection portion of the first member into the through hole and expanding the second connection portion by using a jig to the first member, forming a flare portion by pressing at an end portion of the second connection portion of the first member, and forming a flange portion at a position radially outside of the flare portion by pressing; and   fitting the first connection portion of the first member to a tank open portion of the header tank.   
   
   
       13 . The method of manufacturing a heat exchanger according to  claim 12 , wherein the first connection portion of the first member is brazed to the tank open portion of the header tank to be fixed to the tank open portion of the header tank. 
   
   
       14 . The method of manufacturing a heat exchanger according to  claim 12 , wherein
 the first connection portion of the first member is formed into a cornuted pipe, and the second connection portion of the first member is formed into a circular pipe.   
   
   
       15 . The method of a heat exchanger according to  claim 12 , further comprising
 fitting the second connection portion of the first member into an open portion of the exterior pipe.   
   
   
       16 . The method of a heat exchanger according to  claim 12 , wherein:
 in the forming of the second member, a flange supporting portion is formed; and   the flange support portion supports the flange portion in a direction parallel to the axial direction when the first member is fitted into the second member.   
   
   
       17 . The method of a heat exchanger according to  claim 12 , wherein:
 the flange portion is formed by pressing to have a flat surface;   the second member is formed to have a flat surface; and   the first member is fitted to the second member such that a surface direction of the flat surface of the flange portion corresponds to a surface direction of the flat surface of the flange portion.   
   
   
       18 . The method of a heat exchanger according to  claim 12 , wherein:
 the first member is fitted to the second member such that an inner peripheral end surface of the second member encloses the flange portion of the second connection portion of the first member in a direction perpendicular to the axial direction, and the flange portion has a radial outward end portion that is opposite to the inner peripheral end surface of the second member and is spaced from the inner peripheral end surface of the second member by a clearance.