Heat exchanger

Abstract

A heat exchanger having an improved structure which allows refrigerant tubes to be firmly bonded to heat exchange fins. The heat exchanger includes a plurality of refrigerant tubes spaced apart from each other, headers coupled to both end portions of the refrigerant tubes, and heat exchange fins coupled to the refrigerant tubes and disposed spaced apart from each other. Each of the heat exchange fins includes insertion grooves allowing the refrigerant tubes to be inserted thereinto, and bonding plates bonded to the refrigerant tubes. Each of the bonding plates includes a first bonding portion curved from one end portion thereof in a first direction and bonded to one surface of a corresponding one of the refrigerant tubes, and a second bonding portion curved from the other end portion thereof in a second direction and bonded to the other surface of the corresponding one of the refrigerant tubes.

What is claimed is: 
     
         1 . A heat exchanger comprising:
 a plurality of refrigerant tubes spaced apart from each other;   a plurality of headers coupled to both end portions of the refrigerant tubes; and   a plurality of heat exchange fins coupled to outer surfaces of the refrigerant tubes and disposed spaced apart from each other in a direction perpendicular to a direction in which the refrigerant tubes extend,   wherein each of the heat exchange fins comprises:   a plurality of insertion grooves to allow the refrigerant tubes to be inserted thereinto; and   a plurality of bonding plates bonded to the refrigerant tubes when the refrigerant tubes are inserted into the insertion grooves,   wherein each of the bonding plates comprises:   a first bonding portion curved from one end portion thereof in a first direction and bonded to a corresponding one of the refrigerant tubes; and   a second bonding portion curved from the other end portion thereof in a second direction opposite to the first direction and bonded to a corresponding one of the refrigerant tubes.   
     
     
         2 . The heat exchanger according to  claim 1 , wherein the first direction is parallel with the direction in which the refrigerant tubes extend. 
     
     
         3 . The heat exchanger according to  claim 1 , wherein the first direction is perpendicular to a direction in which the refrigerant tubes are inserted into the heat exchange fins. 
     
     
         4 . The heat exchanger according to  claim 1 , wherein the heat exchange fins are formed of a plurality of layers of aluminum alloys having different melting points. 
     
     
         5 . The heat exchanger according to  claim 1 , wherein a bonding member melting at a temperature over a predetermined temperature to bond the heat exchange fins to the refrigerant tubes is provided on both surfaces of each of the heat exchange fins. 
     
     
         6 . The heat exchanger according to  claim 5 , wherein the bonding member comprises:
 a first bonding member provided on one surface of each of the heat exchange fins, and melting at a temperature over a first predetermined temperature to flow into a gap formed between the one surface of the corresponding one of the refrigerant tubes and the first bonding portion; and   a second bonding member provided on the other surface of each of the heat exchange fins opposite the one surface, and melting at a temperature over a second predetermined temperature to flow into a gap formed between the other surface of the corresponding one of the refrigerant tubes and the second bonding portion.   
     
     
         7 . The heat exchanger according to  claim 6 , wherein:
 the first bonding portion comprises a first guide surface to guide the melted first bonding member into the gap formed between the one surface of the corresponding one of the refrigerant tubes and the first bonding portion; and   the second bonding portion comprises a second guide surface to guide the melted second bonding member into the gap formed between the other surface of the corresponding one of the refrigerant tubes and the second bonding portion.   
     
     
         8 . The heat exchanger according to  claim 1 , wherein each of the bonding plates comprises a louver formed between the first bonding portion and the second bonding portion,
 wherein the louver comprises:   a plurality of guide holes formed by cutting at least one portion of the bonding plate; and   a plurality of guide plates to guide air to pass through the guide holes.   
     
     
         9 . A heat exchanger comprising:
 a plurality of refrigerant tubes provided with a channel to allow a refrigerant to flow therethrough; and   a plurality of heat exchange fins to contact the refrigerant tubes to mediate heat exchange between the refrigerant and external air,   wherein each of the heat exchange fins comprises:   a plurality of insertion grooves to allow the refrigerant tubes to be inserted thereinto; and   a bonding plate disposed between the refrigerant tubes when the refrigerant tubes are inserted into the insertion grooves,   wherein one surface of the bonding plate is bonded to a first refrigerant tube neighboring one end portion of the bonding plate, and the other surface of the bonding plate opposite to the one surface of the bonding plate is bonded to a second refrigerant tube neighboring the other end portion of the bonding plate opposite to the one end portion of the bonding plate.   
     
     
         10 . The heat exchanger according to  claim 9 , further comprising:
 a first bonding member combined to the one surface of the bonding plate and melting at a temperature over a first predetermined temperature to flow into a gap formed between the one surface of the bonding plate and the first refrigerant tube; and   a second bonding member combined to the other surface of the bonding plate and melting at a temperature over a second predetermined temperature to flow into a gap formed between the other surface of the bonding plate and the second refrigerant tube.   
     
     
         11 . The heat exchanger according to  claim 10 , wherein the first bonding member and the second bonding member are formed of an aluminum alloy. 
     
     
         12 . The heat exchanger according to  claim 9 , further comprising a first header and a second header respectively coupled to both end portions of the refrigerant tubes and to communicate with the refrigerant tubes. 
     
     
         13 . The heat exchanger according to  claim 12 , wherein:
 one end portion of the bonding plate neighboring the first refrigerant tube is curved toward the first header; and   the other end portion of the bonding plate neighboring the second refrigerant tube is curved toward the second header.   
     
     
         14 . A method of manufacturing of a heat exchanger, the method comprising:
 arranging a plurality of refrigerant tubes in parallel;   arranging a plurality of heat exchange fins in parallel, the heat exchange fins including a plurality of insertion grooves into which the refrigerant tubes are inserted into and a plurality of bonding plates to be bonded to the refrigerant tubes;   inserting the refrigerant tubes into the insertion grooves of the heat exchange fins, the refrigerant tubes and the heat exchange fins are perpendicular to each other;   melting a bonding member, which is provided on both surfaces of each of the heat exchange fins, at a predetermined temperature to bond the heat exchange fins to the refrigerant tubes,   bonding the refrigerant tubes and the heat exchange fins, one end portion of the bonding plates being curved or slanted toward one end portion of the refrigerant tubes and the other end portion of the bonding plate being curved or slanted toward the other end portion of the refrigerant tubes so that a gap is formed to receive the melted bonding member, respectively, and the melted bonding member flowing to each gap by a capillary force to bond the end portions of the bonding plates with a corresponding one of the refrigerant tubes.