Heat Exchanger for Automobile and Fabricating Method Thereof

Abstract

There is provided a heat exchanger of a vehicle including a plurality of tubes spaced apart from each other by a predetermined distance and through which a heat-exchanging fluid flows, an upper header pipe unit coupled and communicated with the upper ends of the tubes, and a lower header pipe unit coupled and communicated with the lower ends of the tubes, and in which a header pipe is made by making and drawing a plate member containing a clad sheet into a pipe so that it does not need to separate and assemble a header from and with a tank and the clad sheet is not separated from the header pipe during transferring, a pair of header pipes have flat surfaces to bring into surface contact with each other such that a plurality of independent header pipes are assembled to closely contact each other, a plurality of same type and same number of communication devices are configured such that the heat-exchanging fluid flows therethrough, and an inlet and outlet end cap, an end cap, and separator are used such that the header pipes are tightly and securely assembled, and a method of manufacturing the heat exchanger.

1 - 20 . (canceled) 
   
   
       21 . A heat exchange of a vehicle comprising:
 a plurality of tubes ( 7 ), through which a heat exchanging fluid ( 90 ) flows, spaced apart from each other;   an upper header pipe unit ( 3 ) coupled with upper ends of the tubes ( 7 ) to communicate with;   a lower header pipe unit ( 6 ) coupled with lower ends of the tubes ( 7 ) to communicate with;   the upper header pipe unit ( 3 ) including:   a first header pipe ( 1 ) through which the heat exchanging fluid ( 90 ) enters;   a second header pipe ( 2 ) through which the heat exchanging fluid ( 90 ) is discharged; and   a plurality of separators to control flowing directions of the heat exchanging fluids ( 90 ) of the first and second header pipes ( 1  and  2 );   the lower header pipe unit ( 6 ) including:   a third header pipe ( 4 ) to make the heat exchanging fluid ( 90 ) flow to a side; and   a fourth header pipe ( 5 ) to make the heat exchanging fluid ( 90 ) flow in a direction opposite to the third header pipe ( 4 ); and   the upper header pipe unit ( 3 ) and the lower header pipe unit ( 6 ) to comprise a pair of header pipes in which a header and a tank are integrally formed with each other,   wherein the plurality of separators comprise:   control separator ( 32 ) and end separator ( 33 ) respectively inserted into insertion groove ( 40 ) formed in the middle and one ends of the first and second header pipes ( 1  and  2 ) to control the flowing direction of the heat exchanging fluid; and   inlet and outlet separator ( 31 ) inserted into insertion grooves ( 40 ) formed in the other ends of the first and second header pipes ( 1  and  2 ) to form an inlet ( 50 ) and an outlet ( 51 ) for the heat exchanging fluid,   wherein the first and second header pipes ( 1  and  2 ) closely contact with each other due to the control separator ( 32 ), the end separator ( 33 ) and the inlet and outlet separator ( 31 ).   
   
   
       22 . A heat exchange of a vehicle comprising:
 a plurality of tubes ( 7 ), through which a heat exchanging fluid ( 90 ) flows, spaced apart from each other;   an upper header pipe unit ( 3 ) coupled with upper ends of the tubes ( 7 ) to communicate with;   a lower header pipe unit ( 6 ) coupled with lower ends of the tubes ( 7 ) to communicate with;   the upper header pipe unit ( 3 ) including:   a first header pipe ( 1 ) through which the heat exchanging fluid ( 90 ) enters;   a second header pipe ( 2 ) through which the heat exchanging fluid ( 90 ) is discharged; and   a separator and a plurality of end caps ( 20 ) to control flowing directions of the heat exchanging fluids ( 90 ) of the first and second header pipes ( 1  and  2 );   the lower header pipe unit ( 6 ) including:   a third header pipe ( 4 ) to make the heat exchanging fluid ( 90 ) flow to a side; and   a fourth header pipe ( 5 ) to make the heat exchanging fluid ( 90 ) flow in a direction opposite to the third header pipe ( 4 ); and   the upper header pipe unit ( 3 ) and the lower header pipe unit ( 6 ) to comprise a pair of header pipes in which a header and a tank are integrally formed with each other,   wherein the end caps ( 20 ) comprise:   inlet and outlet end cap ( 21 ) to form the inlet ( 50 ) and the outlet ( 51 ) for the heat exchanging fluid ( 90 ) and coupled with one end sides of the first and second header pipes ( 1  and  2 ); and   a plurality of control end caps ( 22 ) coupled with the other end sides of the first and second header pipes ( 1  and  2 ) and both ends of the third and fourth header pipes ( 4  and  5 ) to control the flow of the heat exchanging fluid ( 90 ), wherein the first and second header pipes ( 1  and  2 ) are closely coupled with each other by control separator ( 32 ) inserted into insertion grooves ( 40 ) formed in the middle of the first and second header pipes ( 1  and  2 ) to control the flow of the heat exchanging fluid ( 90 ) and by inlet and outlet end cap ( 21 ) and control end cap ( 22 ) respectively coupled with both ends of the first and second header pipes ( 1  and  2 ).   
   
   
       23 . A heat exchange of a vehicle comprising:
 a plurality of tubes ( 7 ), through which a heat exchanging fluid ( 90 ) flows, spaced apart from each other;   an upper header pipe unit ( 3 ) coupled with upper ends of the tubes ( 7 ) to communicate with;   a lower header pipe unit ( 6 ) coupled with lower ends of the tubes ( 7 ) to communicate with;   the upper header pipe unit ( 3 ) including:   a first header pipe ( 1 ) coupled with an inlet manifold ( 11 ) through which the heat exchanging fluid ( 90 ) enters;   a second header pipe ( 2 ) coupled with an outlet manifold ( 12 ) through which the heat exchanging fluid ( 90 ) is discharged; and   a separator and a plurality of end caps ( 20 ′) to control flowing directions of the heat exchanging fluids ( 90 ) of the first and second header pipes ( 1  and  2 ); the lower header pipe unit ( 6 ) including:   a third header pipe ( 4 ) to make the heat exchanging fluid ( 90 ) flow to a side; and   a fourth header pipe ( 5 ) to make the heat exchanging fluid ( 90 ) flow in a direction opposite to the third header pipe ( 4 ); and   the upper header pipe unit ( 3 ) and the lower header pipe unit ( 6 ) to comprise a pair of header pipes in which a header and a tank are integrally formed with each other,   wherein the first and second header pipes ( 1  and  2 ) are closely coupled with each other by control separator ( 32 ) inserted into insertion grooves ( 40 ) formed in the middle of the first and second header pipes ( 1  and  2 ) to control the flow of the heat exchanging fluid ( 90 ) and by inlet end cap ( 23 ) and control end cap ( 22 ) respectively coupled with both ends of the first and second header pipes ( 1  and  2 ).   
   
   
       24 . The heat exchange of a vehicle according to  claim 21 , wherein end separators ( 33 ) are inserted into respective insertion grooves ( 40 ) formed in both ends of the third and fourth header pipes ( 4  and  5 ) such that the third and fourth header pipes ( 4  and  5 ) closely contact each other and the both ends of the third and fourth header pipes ( 4  and  5 ) are closed. 
   
   
       25 . The heat exchange of a vehicle according to  claim 23 , wherein the end caps ( 20 ′) comprise:
 inlet end cap ( 23 ) coupled with one end sides of the first and second header pipes ( 1  and  2 ) to form an inlet ( 50 ) for the heat exchanging fluid ( 90 ); and   a plurality of control end caps ( 22 ) coupled with the other end sides of the first and second header pipes ( 1  and  2 ) and both ends of the third and fourth header pipes ( 4  and  5 ) to control the flow of the heat exchanging fluid ( 90 ).   
   
   
       26 . The heat exchange of a vehicle according to  claim 25 , wherein the inlet manifold ( 11 ) forms an inlet hole ( 81 ) communicated with the inlet ( 50 ), and is coupled with an inlet end cap ( 23 ) such that the heat exchanging fluid ( 90 ) enters. 
   
   
       27 . The heat exchange of a vehicle according to  claim 23 , wherein the outlet manifold ( 12 ) is inserted into a coupling hole ( 80 ) formed in a side opposite to communication means ( 41 ) about control separator ( 32 ) such that the heat exchanging fluid ( 90 ) is discharged out. 
   
   
       28 . The heat exchange of a vehicle according to  claim 22 , wherein the third and fourth header pipes ( 4  and  5 ) closely contact each other and the both ends of the third and fourth header pipes ( 4  and  5 ) are closed by a plurality of control end caps ( 22 ) coupled with both ends of the third and fourth header pipes ( 4  and  5 ). 
   
   
       29 . The heat exchange of a vehicle according to  claim 23 , wherein the third and fourth header pipes ( 4  and  5 ) closely contact each other and the both ends of the third and fourth header pipes ( 4  and  5 ) are closed by a plurality of control end caps ( 22 ) coupled with both ends of the third and fourth header pipes ( 4  and  5 ). 
   
   
       30 . The heat exchange of a vehicle according to  claim 21 , wherein the first and second header pipes ( 1  and  2 ) have the same shape and number of a plurality of communication means ( 41 ) to face each other from opposite sides through which the heat exchanging fluid ( 90 ) enters and is discharged in order to communicate the heat exchanging fluid ( 90 ) between the first and second header pipes ( 1  and  2 ),
 wherein the communication means ( 41 ) have a communication area gradually increased or decreased in the direction where a refrigerant flows.   
   
   
       31 . The heat exchange of a vehicle according to  claim 22 , wherein the first and second header pipes ( 1  and  2 ) have the same shape and number of a plurality of communication means ( 41 ) to face each other from opposite sides through which the heat exchanging fluid ( 90 ) enters and is discharged in order to communicate the heat exchanging fluid ( 90 ) between the first and second header pipes ( 1  and  2 ),
 wherein the communication means ( 41 ) have a communication area gradually increased or decreased in the direction where a refrigerant flows.   
   
   
       32 . The heat exchange of a vehicle according to  claim 23 , wherein the first and second header pipes ( 1  and  2 ) have the same shape and number of a plurality of communication means ( 41 ) to face each other from opposite sides through which the heat exchanging fluid ( 90 ) enters and is discharged in order to communicate the heat exchanging fluid ( 90 ) between the first and second header pipes ( 1  and  2 ),
 wherein the communication means ( 41 ) have a communication area gradually increased or decreased in the direction where a refrigerant flows.   
   
   
       33 . The heat exchange of a vehicle according to  claim 21 , wherein the first and second header pipes ( 1  and  2 ) and the third and fourth header pipes ( 4  and  5 ) respectively have flat surfaces to bring into surface contact with each other in the longitudinal direction. 
   
   
       34 . The heat exchange of a vehicle according to  claim 22 , wherein the first and second header pipes ( 1  and  2 ) and the third and fourth header pipes ( 4  and  5 ) respectively have flat surfaces to bring into surface contact with each other in the longitudinal direction. 
   
   
       35 . The heat exchange of a vehicle according to  claim 23 , wherein the first and second header pipes ( 1  and  2 ) and the third and fourth header pipes ( 4  and  5 ) respectively have flat surfaces to bring into surface contact with each other in the longitudinal direction. 
   
   
       36 . The heat exchange of a vehicle according to  claim 30 , wherein the communication means ( 41 ) are concentrated to end separator ( 33 ) or a side of the upper header pipe unit ( 3 ). 
   
   
       37 . The heat exchange of a vehicle according to  claim 31 , wherein the communication means ( 41 ) are concentrated to end separator ( 33 ) or a side of the upper header pipe unit ( 3 ). 
   
   
       38 . The heat exchange of a vehicle according to  claim 32 , wherein the communication means ( 41 ) are concentrated to end separator ( 33 ) or a side of the upper header pipe unit ( 3 ). 
   
   
       39 . The heat exchange of a vehicle according to  claim 21 , wherein the upper header pipe unit ( 3 ) and the lower header pipe unit ( 6 ) are made by making a plate member into a circular shape pipe and drawing the circular plat member proper to shapes of the header pipes,
 wherein the upper header pipe unit ( 3 ) and the lower header pipe unit ( 6 ) are made of a plate member containing a clad sheet.   
   
   
       40 . The heat exchange of a vehicle according to  claim 22 , wherein the upper header pipe unit ( 3 ) and the lower header pipe unit ( 6 ) are made by making a plate member into a circular shape pipe and drawing the circular plat member proper to shapes of the header pipes,
 wherein the upper header pipe unit ( 3 ) and the lower header pipe unit ( 6 ) are made of a plate member containing a clad sheet.   
   
   
       41 . The heat exchange of a vehicle according to  claim 23 , wherein the upper header pipe unit ( 3 ) and the lower header pipe unit ( 6 ) are made by making a plate member into a circular shape pipe and drawing the circular plat member proper to shapes of the header pipes,
 wherein the upper header pipe unit ( 3 ) and the lower header pipe unit ( 6 ) are made of a plate member containing a clad sheet.