Heat Exchanger And Method For Manufacturing The Same

• US 20070251091A1
• Filed: 12/24/2004
• Published: 11/01/2007
• Est. Priority Date: 12/24/2003
• Status: Abandoned Application

• Current Assignee: Showa Denko KK (Resonac Holdings Corp.)
• Original Assignee: Showa Denko KK (Resonac Holdings Corp.)
• Inventors: Minami, Kazuhiko, Yamanoi, Tomoaki
• Application Number:
  US10/584,197
• Publication Number:
  US 20070251091A1
• Time in Patent Office: Days
• US Class Current: 29/890.54
• CPC Class Codes: B23K 1/0012 Brazing heat exchangers
• CPC Class Codes: B23K 2101/14 Heat exchangers
• CPC Class Codes: F28D 1/05391 with multiple rows of conduits or with multi-channel conduits combined with a particular flow pattern, e.g. multi-row multi-stage radiators
• CPC Class Codes: F28F 1/126 consisting of zig-zag shaped fins F28F1/105 takes precedence
• CPC Class Codes: F28F 19/02 by using coatings, e.g. vitreous or enamel coatings
• CPC Class Codes: F28F 2275/04 by brazing
• CPC Class Codes: Y10T 29/49393 with metallurgical bonding

Abstract

A method for manufacturing a heat exchanger according to the present invention includes the steps of forming a thermally sprayed layer on a surface of an aluminum tube core by thermally spraying Al—Si series alloy brazing material onto the surface of the aluminum tube core to obtain a tube 2, applying flux composite containing non-corrosive flux showing zinc substitution reaction onto a surface of the tube 2, combining the tube 2 with the fin 3, and brazing the tube 2 and the fin 3 in an combined state.

Claims

1. A method for manufacturing a heat exchanger, the method comprising the steps of:

forming a thermally sprayed layer on a surface of an aluminum tube core by thermally spraying Al—

Si series alloy brazing material onto the surface of the aluminum tube core to obtain a tube;

applying flux composite containing non-corrosive flux showing zinc substitution reaction onto a surface of the tube;

combining the tube with the fin; and

brazing the tube and the fin in an combined state.

10. The method for manufacturing a heat exchanger as recited in any one of claims 1 to 9, wherein KZnF₃ is used as the flux component containing the non-corrosive flux showing zinc substitution reaction.

11. The method for manufacturing a heat exchanger as recited in any one of claims 1 to 10, wherein the flux component containing the non-corrosive flux showing zinc substitution reaction is applied by 5 to 20 g/m².

12. The method for manufacturing a heat exchanger as recited in any one of claims 1 to 11, wherein alloy brazing material containing Si:

6 to 15 mass % and the balance being Al and inevitable impurities is used as the Al—

Si series alloy brazing material.

13. The method for manufacturing a heat exchanger as recited in any one of claims 1 to 11, wherein alloy brazing material containing Si:

6 to 15 mass %, at least either Cu;

0.3 to 0.6 mass % or Mn;

0.3 to 1.5 mass %, and the balance being Al and inevitable impurities is used as the Al—

Si series alloy brazing material.

14. The method for manufacturing a heat exchanger as recited in any one of claims 1 to 11, wherein alloy brazing material containing Si:

6 to 15 mass %, at least either Cu;

0.35 to 0.55 mass % or Mn;

0.4 to 1.0 mass %, and the balance being Al and inevitable impurities is used as the Al—

Si series alloy brazing material.

15. The method for manufacturing a heat exchanger as recited in any one of claims 1 to 14, wherein a fin with no brazing material clad is used as the fin.

16. The method for manufacturing a heat exchanger as recited in any one of claims 1 to 15, wherein a flat tube formed by an extrusion is used as the tube.

17. The method for manufacturing a heat exchanger as recited in any one of claims 1 to 16, wherein the brazing is performed at a heating temperature of 550 to 620°

C.

18. A heat exchanger manufactured by the method as recited in any one of claims 1 to 17.

2. A method for manufacturing a heat exchanger, the method comprising the steps of:

forming a thermally sprayed layer on a surface of an aluminum tube core by thermally spraying Al—

Si series alloy brazing material onto the surface of the aluminum tube core to obtain a tube;

applying flux composite onto a surface of the tube, wherein the flux composite contains non-corrosive flux showing zinc substitution reaction and binder, the binder being resin having a property in which 90 mass % or more of the resin evaporates at a temperature of 350°

C. when a differential thermal analysis is performed under a condition of a temperature rising rate of 20°

C./minute;

combining the tube with the fin; and

brazing the tube and the fin in a combined state.

3. The method for manufacturing a heat exchanger as recited in claim 2, wherein butyl series resin is used as the resin.

9. The method for manufacturing a heat exchanger as recited in any one of claims 2 to 8, wherein a mixed mass ratio in the flux composite is set so as to fall within the range of:

the binder material/the flux component containing the non-corrosive flux showing zinc substitution reaction=20/80 to 80/20.

4. A method for manufacturing a heat exchanger, the method comprising the steps of:

forming a thermally sprayed layer on a surface of an aluminum tube core by thermally spraying Al—

Si series alloy brazing material onto the surface of the aluminum tube core to obtain a tube;

applying flux composite onto a surface of the tube, wherein the flux composite contains non-corrosive flux showing zinc substitution reaction and binder, the binder being polyethylene oxide having a property in which 90 mass % or more of the polyethylene oxide evaporates at a temperature of 350°

C. when a differential thermal analysis is performed under a condition of a temperature rising rate of 20°

C./minute;

combining the tube with the fin; and

brazing the tube and the fin in an combined state.

5. The method for manufacturing a heat exchanger as recited in claim 4, wherein a molecular weight of the polyethylene oxide is 10,000 to 1,500,000.

6. A method for manufacturing a heat exchanger, the method comprising the steps of:

forming a thermally sprayed layer on a surface of an aluminum tube core by thermally spraying Al—

Si series alloy brazing material onto the surface of the aluminum tube core to obtain a tube;

applying flux composite onto a surface of the tube, wherein the flux composite contains non-corrosive flux showing zinc substitution reaction and binder, the binder being paraffin having a property in which 90 mass % or more of the paraffin evaporates at a temperature of 350°

C. when a differential thermal analysis is performed under a condition of a temperature rising rate of 20°

C./minute;

combining the tube with the fin; and

brazing the tube and the fin in an combined state.

7. The method for manufacturing a heat exchanger as recited in claim 6, wherein a molecular weight of the paraffin is 200 to 600.

8. The method for manufacturing a heat exchanger as recited in claim 6, wherein one of elements selected from the group consisting of paraffin wax, isoparaffin and cycloparaffin is used as the paraffin.