Heat exchange having header tank

[0002] This application relates to and claims priority from Japanese Patent Application No. 11-20514 filed on Jan. 28, 1999.

[0003] 1. Field of the Invention

[0004] The present invention relates generally to heat exchangers, and particularly to a radiator for cooling coolant flowing from an internal combustion engine.

[0005] 2. Related Art

[0006] JP-A-10-132485 discloses a radiator having plural tubes and a header tank connected to the tubes. The header tank includes a core plate to which the plural tubes are connected, and a tank portion brazed to the core plate. The core plate and the tank portion are formed by pressing to reduce manufacturing cost.

[0007] However, the core plate and the tank portion may have a distortion such as warping or waviness during a manufacturing process. Therefore, when the core plate and the tank portion are tentatively assembled, a relatively large clearance may be formed between the core plate and the tank portion. As a result, brazing performance between the core plate and the tank portion may be compromised. Even when the core plate and the tank portion are formed by other processes such as drawing, the core plate and the tank portion may also be distorted during the manufacturing process, thereby compromising the brazing performance between the core portion and the tank portion.

[0008] The present invention is made in light of the foregoing problems, and it is an object of the present invention to provide a heat exchanger having first and second components, in which undesirable clearance is restricted from being formed between the first and second components.

[0009] According to the present invention, a heat exchanger has a plurality of tubes and a header tank disposed at a flow-path end of the tubes to communicate with each tube. The header tank has a first tank portion and a second tank portion. The first tank portion has a protruding portion protruding from a wall of the first tank portion, and the second tank portion has a hole into which the protruding portion is inserted. The protruding portion is engaged with the hole when the first tank portion is slidably moved against the second tank portion in a parallel direction with respect to a longitudinal direction of the header tank. When the protruding portion is engaged with the hole, the second tank portion is partially clamped between the wall of the first tank portion and the protruding portion.

[0010] Therefore, when the first tank portion and the second tank portion are tentatively assembled together, the first tank portion sufficiently contacts the second tank portion, and a relatively large clearance is restricted from being formed between the first and second tank portions. As a result, brazing performance between the first and second tank portions is improved.

[0011] This and other objects and features of the present invention will become more readily apparent from a better understanding of the preferred embodiment described below with reference to the accompanying drawings, in which:

[0012] FIG. 1 is a perspective view showing a radiator according to a preferred embodiment of the present invention;

[0013] FIG. 2 is a partial perspective view showing a header tank of the radiator according to the embodiment;

[0014] FIGS. 3A-3C are partial perspective views showing an assembling process of the header tank according to the embodiment;

[0015] FIG. 4 is a partial longitudinal sectional view showing the header tank according to the embodiment;

[0016] FIG. 5 is a lateral sectional view showing the header tank according to the embodiment; and

[0017] FIG. 6 is a schematic view showing a hole of a header tank of a heat exchanger according to a modification of the embodiment.

[0018] A preferred embodiment of the present invention is described hereinafter with reference to the accompanying drawings.

[0019] As shown in FIG. 1, a radiator 100 includes plural flat aluminum tubes 111 through which coolant flows, and plural aluminum corrugated fins 112 each of which is disposed between adjacent tubes 111. The tubes 111 and the fins 112 form a core portion 110 which performs heat-exchange between coolant and air passing through the core portion 110.

[0020] A first header tank 121 is disposed at one flow-path end of the tubes 111 (i.e., at a left end of the tubes 111 in FIG. 1) to extend in a direction perpendicular to a longitudinal direction of the tubes 111. The first header tank 121 communicates with the tubes 111 to distribute coolant to each tube 111. Similarly, a second header tank 122 is disposed at the other flow-path end of the tubes 111 (i.e., at a right end of the tubes 111 in FIG. 1) to extend in the direction perpendicular to the longitudinal direction of the tubes 111. The second header tank 122 communicates with the tubes 111 so that coolant from the tubes 111 is collected into the second header tank 122. Further, the radiator 100 has an inlet joint 121athrough which coolant flows into the first inlet tank 121, and an outlet joint 122athrough which coolant is discharged from the second header tank 122. The first and second header tanks 121, 122 have the same structure, and are hereinafter collectively referred to as a header tank 120.

[0021] As shown in FIG. 2, the header tank 120 is formed by a first tank portion 123 and a second tank portion 124 both having a J-shaped cross-section. The tubes 111 are inserted into and brazed to the header tank 120. As shown in FIG. 1, each longitudinal end of the header tank 120 is closed by a cap 131.

[0022] Referring to FIGS. 3A-3C, the first tank portion 123 has a first protruding portion 125 formed by cutting and raising a portion of the first tank portion 123 to protrude toward the second tank portion 124. The first protruding portion 125 is formed in a wall of the first tank portion 123 to be brazed to the second tank portion 124. The second tank portion 124 has a first hole 126 at a position corresponding to the first protruding portion 125 so that the first protruding portion 125 is inserted into the first hole 126.

[0023] Similarly, as shown in FIGS. 3A and 4, the second tank portion 124 has a second protruding portion 127 formed by cutting and raising a portion of the second tank portion 124 to protrude toward the first tank portion 123, in a wall of the second tank portion 124 to be brazed to the first tank portion 123. The first tank portion 123 has a second hole 128 into which the second protruding portion is inserted, at a position corresponding to the second protruding portion 127.

[0024] As shown in FIG. 3A, a width L1 of the first hole 126 in a direction perpendicular to a longitudinal direction of the header tank 120, at one end (i.e., at a left end in FIG. 3A) of the first hole 126 adjacent to one longitudinal end of the header tank 120 is smaller than a width L2 of the first hole 126 in the direction perpendicular to the longitudinal direction of the header tank 120, at the other end (i.e., at a right end in FIG. 3A) of the first hole 126. Thus, the first hole 126 is formed into a substantial trapezoid having a width decreased toward the one longitudinal end of the header tank 120. The second hole 128 has the similar shape as the first hole 126. However, as shown in FIG. 3A, the second hole 128 has the width L2 at one end (i.e., at a left end in FIG. 3A) of the second hole 128 adjacent to the one longitudinal end of the header tank 120, and has the width L1 at the other end (i.e., at a right end in FIG. 3A) of the second hole 128. Therefore, the second hole 128 is formed into a substantial trapezoid having a width decreased toward the other longitudinal end of the header tank 120. The width L1 is set equal to a width L3 of the first and second protruding portions 125, 127 in the direction perpendicular to the longitudinal direction of the header tank 120. The width L2 is set larger than the width L3.

[0025] Next, a manufacturing method of the header tank 120 will be described with respect to FIGS. 3A-3C. First, as shown in FIGS. 3A and 3B, the first and second protruding portions 125, 127 are respectively inserted into the first and second holes 126, 128. Next, as shown in FIG. 3B, the first tank portion 123 is slidably moved against the second tank portion in a parallel direction with respect to the longitudinal direction of the header tank 120, in a direction indicated by an arrow in FIG. 3B. As a result, as shown in FIG. 3C, the first and second protruding portions 125, 127 are respectively engaged with the first and second holes 126, 128. As shown in FIGS. 4 and 5, when the first protruding portion 125 is engaged with the first hole 126, the second tank portion 124 is partially clamped between the wall of the first tank portion 123 and the first protruding portion 125. When the second protruding portion 127 is engaged with the second hole 128, the first tank portion 123 is partially clamped between the wall of the second tank portion 124 and the second protruding portion 127.

[0026] In the present embodiment, the first and second tank portions 123, 124 are formed by pressing a clad metal plate clad with brazing material on both side surfaces. After the first and second tank portions 123, 124 are assembled together, other parts such as the caps 131 and the tubes 111 are attached to the assembled first and second tank portions 123, 124. Then, the whole assembled parts are heated in a furnace to be brazed to each other.

[0027] According to the present embodiment, during an assembly process for assembling the first tank portion 123 and the second tank portion 124, when the first protruding portion 125 is engaged with the first hole 126, the second tank portion 124 is partially clamped between the wall of the first tank portion 123 and the first protruding portion 125. When the second protruding portion 127 is engaged with the second hole 128, the first tank portion 123 is partially clamped between the wall of the second tank portion 124 and the second protruding portion 127. As a result, the first and second tank portions 123, 124 sufficiently contact each other. Therefore, when the first and second tank portions 123, 124 are tentatively assembled together, a relatively large clearance is restricted from being formed between the first and second tank portions 123, 124. As a result, brazing performance between the first and second tank portions 123, 124 is improved.

[0028] Further, in the present embodiment, the first and second tank portions 123, 124 are assembled together by respectively engaging the first and second protruding portions 125, 127 with the first and second holes 126, 128. Therefore, a jig for holding the assembled first and second tank portions 123, 124 is not required. As a result, the header tank 120 is assembled more efficiently, and the number of manufacturing processes and manufacturing cost of the radiator 100 are reduced.

[0029] Furthermore, the first and second protruding portions 125, 127 are respectively engaged with the first and second holes 126, 128 by slidably moving the first tank portion 123 against the second tank portion in a parallel direction with respect to the longitudinal direction of the header tank 120. Therefore, when the first and second tank portions 123, 124 are assembled together, each distortion of the first and second tank portions 123, 124 such as warping or waviness is substantially straighten by each other. As a result, accuracy in a finished size of the radiator 100 is improved.

[0030] In the above-mentioned embodiment, the first and second protruding portions 125, 127 may protrude toward an inside of the header tank 120. In this case, since flow resistance of coolant in the header tank 120 may be increased, each position and protruding length of the first and second protruding portions 125, 127 needs to be appropriately determined. Further, the present invention is not limited to the radiator, but may be applied to any other heat exchangers such as an indoor heat exchanger or an outdoor heat exchanger of an air conditioner. Also, as shown in FIG. 6, the first and second holes 126, 128 may be respectively holes 129, 130 formed by partially cutting out the first and second tank portions 123, 124.

[0031] Although the present invention has been fully described in connection with a preferred embodiment thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being within the scope of the present invention as defined by the appended claims.