APPARATUS AND METHOD FOR MANUFACTURING HEAT EXCHANGER

Abstract

An apparatus for manufacturing a heat exchanger including a refrigerant tube, the apparatus including a moving rod movable along a first direction; and a tube expansion body connected to the moving rod to be linearly movable along the first direction, the tube expansion body insertable into a tube base material of the refrigerant tub such that the tube base material is expanded outward when the tube expansion body is inserted into the tube base material of the refrigerant tube, wherein the tube expansion body includes a plurality of groove forming protrusions formed on an outer surface of the tube expansion body so as to extend along a direction inclined with respect to the first direction, the groove forming protrusions form a plurality of grooves on an inner surface of the tube base material, when the tube expansion body is moved to be inserted into the tube base material.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation application, under 35 U.S.C. § 111(a), of international application No. PCT/KR2023/008162, filed on Jun. 14, 2023, which claims priority to Korean Patent Application No. 10-2022-0115947, filed on Sep. 14, 2022 in the Korean Intellectual Property Office, the disclosures of which are incorporated by reference herein in their entireties.

BACKGROUND

1. Field

The present disclosure relates to an apparatus and method for manufacturing a heat exchanger.

2. Description of the Related Art

A heat exchanger is an apparatus that is built-in and used in a device that uses a refrigerating cycle, such as an air conditioner or a refrigerator, and includes a plurality of heat exchange fins and a refrigerant tube installed to pass through the plurality of heat exchange fins while guiding a refrigerant. The heat exchange fin increases a contact area with air introduced into the heat exchanger from the outside to increases the heat exchange efficiency between the refrigerant flowing through the refrigerant tube and the outside air.

In a process of manufacturing the heat exchanger, a tube base material of the refrigerant tube may be disposed to pass through an installation hole provided in the heat exchange fin, and in this case, there may be a gap between the tube base material and the installation hole of the heat exchange fin. The heat exchanger may be manufactured by expanding the inner diameter of the tube base material by a tube expansion mandrel and coupling the tube base material and the heat exchange fins to each other through pressure welding.

SUMMARY

Aspects of embodiments of the disclosure will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the presented embodiments.

According to an embodiment of the disclosure, an apparatus for manufacturing a heat exchanger including a refrigerant tube, the apparatus including a moving rod configured to be linearly movable along a first direction; and a tube expansion body connected to the moving rod so as to be linearly movable along the first direction, the tube expansion body configured to be insertable into a tube base material of the refrigerant tub such that the tube base material is expanded outward by the tube expansion body when the tube expansion body is moved by the moving rod to be inserted into the tube base material of the refrigerant tube. The tube expansion body may include, a plurality of groove forming protrusions formed on an outer surface of the tube expansion body so as to extend along a direction inclined with respect to the first direction, the plurality of groove forming protrusions form a plurality of grooves on an inner surface of the tube base material, when the tube expansion body is moved by the moving rod to be inserted into the tube base material of the refrigerant tube.

According to an embodiment of the disclosure, the tube expansion body may be configured to be rotatable about the longitudinal axis of the moving rod.

According to an embodiment of the disclosure, the tube expansion body may be configured to rotate in a first rotational direction when inserted into the tube base material. Each groove forming protrusion of the plurality of groove forming protrusions may include a first end oriented toward a direction of insertion into the tube base material and a second end opposite to the first end. Each groove forming protrusion of the plurality of groove forming protrusions may be extended to slope with respect to the first direction from the first end to the second end along the first rotational direction.

According to an embodiment of the disclosure, the moving rod may be elongated along the first direction, and may have at least a portion disposed inside the tube expansion body. The tube expansion body may be configured to be rotatable around the moving rod.

According to an embodiment of the disclosure, the apparatus may further include a bearing configured between the tube expansion body and the moving rod.

According to an embodiment of the disclosure, the bearing may include a plurality of rolling elements disposed between an inner circumferential surface of the tube expansion body and an outer circumferential surface of the moving rod. The plurality of rolling elements may be arranged along a circumferential direction of the tube expansion body.

According to an embodiment of the disclosure, the bearing may include a plurality of bearings. The plurality of bearings may be arranged along a longitudinal direction of the tube expansion body.

According to an embodiment of the disclosure, the tube expansion body may include a taper portion which narrows in a direction of insertion into the tube base material. The plurality of groove forming protrusions may be arranged on an outer surface of the taper portion.

According to an embodiment of the disclosure, the tube expansion body further includes a cylinder portion extending along the first direction and having a hollow cylindrical shape. The taper portion may extend from a first end of the cylinder portion oriented toward the direction of insertion into the tube base material. At least some of the plurality of groove forming protrusions may be arranged on an outer surface of the cylinder portion.

According to an embodiment of the disclosure, the tube expansion body may include a first end oriented toward a direction of insertion into the tube base material, a second end opposite to the first end, a first hole formed at the first end, and a second hole formed at the second end. The moving rod may extend through the first hole and the second hole.

According to an embodiment of the disclosure, the moving rod may include a head portion that is in contact with an outside of the first end of the tube expansion body. A width of the head portion in a direction perpendicular to the first direction may be wider than a width of the first hole in the direction perpendicular to the first direction.

According to an embodiment of the disclosure, the head portion may include a first portion adjacent to the tube expansion body, and a second portion located on an end of the first portion oriented toward a direction of insertion into the tube base material. The first portion may be formed such that a width in the direction perpendicular the first direction increases in a direction from the tube expansion body toward the second portion.

According to an embodiment of the disclosure, the moving rod may include a pressing portion contacting an outside of the second end of the tube expansion body. The pressing portion may be configured to press the second end in the first direction when the moving rod is moving in the first direction. The pressing portion may have a width in a direction perpendicular to the first direction that is wider than a width of the second hole in the direction perpendicular to the first direction.

According to an embodiment of the disclosure, the plurality of groove forming protrusions may be arranged at equal intervals along an outer circumferential direction of the tube expansion body.

According to an embodiment of the disclosure, the tube expansion body may include a rotating portion configured to be rotatable around the moving rod, and a fixed ball fixed to the moving rod. The fixed ball may be located at an end of the rotating portion oriented toward a direction of insertion into the tube base material. The plurality of groove forming protrusions may be provided on an outer surface of the rotating portion.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other embodiments of the disclosure will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:

FIG. 1 is a view illustrating an example of an air conditioner to which a heat exchanger according to an embodiment of the present disclosure is applied;

FIG. 2 is a perspective view illustrating a heat exchanger according to an embodiment of the present disclosure;

FIG. 3 is a schematic view illustrating an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 4 is a view illustrating a tube expansion mandrel of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 5 is a cross-sectional view of the expansion mandrel shown in FIG. 4 which is taken along a longitudinal direction;

FIG. 6 is an enlarged view of part A shown in FIG. 4;

FIG. 7 is an enlarged cross-sectional view of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure, which shows a plurality of groove forming protrusions taken along a transverse direction;

FIG. 8 is a view for describing the arrangement of a bearing of a tube expansion mandrel of the apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 9 is an enlarged view of part B in FIG. 5;

FIG. 10 is an enlarged view of part C in FIG. 5;

FIG. 11 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 12 is a view illustrating a state of a refrigerant tube after a tube expansion process in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 13 is an enlarged cross-sectional view illustrating a plurality of groove forming protrusions taken along a transverse direction, in an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 14 is an enlarged cross-sectional view illustrating a plurality of groove forming protrusions taken along a transverse direction, in an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 15 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 16 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 17 is a view illustrating a tube expansion mandrel of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 18 is a view illustrating a tube expansion mandrel of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 19 is a view illustrating a tube expansion mandrel of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 20 is a cross-sectional view of the expansion mandrel shown in FIG. 19 which is taken along a longitudinal direction;

FIG. 21 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 22 is a view illustrating an example of a process of arranging a plurality of heat exchange fins to be passed by a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 23 is an enlarged cross-sectional view for describing a state of a tube base material and a plurality of heat exchange fins before expansion, in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 24 is a view illustrating an example of a process of linearly moving a tube expansion mandrel toward a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure;

FIG. 25 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure; and

FIG. 26 is a view illustrating an example of a process of connecting a plurality of refrigerant tubes after expansion, in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Embodiments described in the specification and configurations shown in the accompanying drawings may be merely examples of the present disclosure, and various modifications may replace the embodiments and the drawings of the present disclosure at the time of filing of the present application.

Further, identical symbols or numbers in the drawings of the present disclosure denote components or elements configured to perform substantially identical functions.

Further, terms used herein may be only for the purpose of describing particular embodiments and may be not intended to limit and/or restrict the present disclosure. The singular form may be intended to include the plural form as well, unless the context clearly indicates otherwise. It should be further understood that the terms “include,” “including,” “have,” and/or “having” specify the presence of stated features, integers, steps, operations, elements, components, and/or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Further, it should be understood that, although the terms “first,” “second,” etc., may be used herein to describe various elements, the elements may be not limited by the terms, and the terms may be only used to distinguish one element from another. For example, a first element could be termed a second element, and similarly, a second element could be termed a first element without departing from the scope of the present disclosure. The term “and/or” includes combinations of one or all of a plurality of associated listed items.

Meanwhile, the terms “front”, “rear”, “upper”, “lower”, “front”, “rear”, “top” and “bottom” used in the following description may be defined based on drawings, and the shape and position of each component may be not limited by the terms.

Example embodiments of the disclosure may provide an apparatus and method for manufacturing a heat exchanger that are improved to manufacture a heat exchanger with an enhanced heat exchange efficiency.

Example embodiments of the disclosure may provide an apparatus and method for manufacturing a heat exchanger that are improved to efficiently form a groove on an inner surface of a refrigerant tube.

Example embodiments of the disclosure may provide an apparatus and method for manufacturing a heat exchanger that are improved to enhance the accuracy of forming a groove on an inner surface of a refrigerant tube.

Example embodiments of the disclosure may provide an apparatus and method for manufacturing a heat exchanger that are improved to reduce manufacturing time and manufacturing cost of a heat exchanger.

Hereinafter, embodiments according to the disclosure will be described in detail with reference to the accompanying drawings.

FIG. 1 is a view illustrating an example of an air conditioner to which a heat exchanger according to an embodiment of the present disclosure is applied.

Referring to FIG. 1, heat exchangers 12 and 21 according to an embodiment of the present disclosure may be applied to an air conditioner 1.

The air conditioner 1 may, in order to cool an air conditioning space, which is a target of air conditioning, absorb heat from the inside of the air conditioning space and release heat to the outside of the air conditioning space. In addition, the air conditioner 1 may, in order to heat the air conditioning space, absorb heat from the outside of the air conditioning space and release heat to the inside of the air conditioning space. To this end, the air conditioner 1 may generally include an indoor unit 20 installed inside the air conditioning space and an outdoor unit 10 installed outside the air conditioning space.

The outdoor unit 10 may heat-exchange with outdoor air outside of the air conditioning space. The outdoor unit 10 may perform heat exchange between a refrigerant and outdoor air using a phase change (e.g., evaporation or condensation) of the refrigerant. For example, the outdoor unit 10 may release heat of the refrigerant to the outdoor air using condensation of the refrigerant. In addition, the outdoor unit 10 may absorb heat of the outdoor air into the refrigerant using evaporation of the refrigerant.

Although one outdoor unit 10 is illustrated in FIG. 1, the number of outdoor units 10 is not limited to that shown in FIG. 1. For example, the air conditioner 1 may include a plurality of outdoor units.

The indoor unit 20 may heat-exchange heat with indoor air inside of an air conditioning space. The indoor unit 20 may perform heat exchange between a refrigerant and indoor air using a phase change (e.g., evaporation or condensation) of the refrigerant. For example, the indoor unit 20 may absorb heat from indoor air into the refrigerant using evaporation of the refrigerant, thereby cooling the air conditioning space. In addition, the indoor unit 20 may release heat of the refrigerant to the indoor air using condensation of the refrigerant, thereby heating the air conditioning space.

Although one indoor unit 20 is illustrated in FIG. 1, the number of indoor units 20 is not limited to that shown in FIG. 1. For example, the air conditioner 1 may include a plurality of indoor units. A plurality of different indoor units may be respectively installed in a plurality of different air conditioning spaces.

As described above, the air conditioner 1 may perform heat exchange between the refrigerant and outdoor air outside of the air conditioning space and heat exchange between the refrigerant and indoor air inside of the air conditioning space.

In this case, the air conditioner 1 may, in order to transfer heat between the outside of the air conditioning space and the inside of the air conditioning space, cause the refrigerant to flow between the outside of the air conditioning space and the inside of the air conditioning space. In other words, the air conditioner 1 may include a refrigerant circulation circuit for transferring heat between the outside of the air conditioning space and the inside of the air conditioning space.

For example, the air conditioner 1 may include a refrigerant circulation circuit as shown in FIG. 1.

The refrigerant circulation circuit may include a compressor 11, an outdoor heat exchanger 12, an expansion valve 13, and an indoor heat exchanger 21. The refrigerant may circulate through the compressor 11, the outdoor heat exchanger 12, the expansion valve 13, and the indoor heat exchanger 21 in the order, or may circulate through the compressor 11, the indoor heat exchanger 21, the expansion valve 13, and the outdoor heat exchanger 12 in the order.

In addition, the refrigerant circulation circuit may further include a flow path switching valve 14 and an accumulator 15. The flow path switching valve 14 may be connected to a refrigerant outlet of the compressor 11, and the accumulator 15 may be connected to a refrigerant inlet of the compressor 11.

The compressor 11, the outdoor heat exchanger 12, the expansion valve 13, the flow path switching valve 14, and the accumulator 15 may be disposed in the outdoor unit 10. The indoor heat exchanger 21 may be disposed in the indoor unit 20. When the air conditioner 1 includes a plurality of indoor units, each of the plurality of indoor units may be provided with the indoor heat exchanger 21. The location of the expansion valve 13 is not limited to the outdoor unit 10, and may be located in the indoor unit 20 as needed.

The compressor 11 may compress refrigerant gas and discharge high-temperature, high-pressure refrigerant gas. For example, the compressor 11 may include a motor and a compression mechanism, and the compression mechanism may compress refrigerant gas by the torque of the motor.

The flow path switching valve 14 may be connected to the outlet of the compressor 11.

The flow path switching valve 14 may include, for example, a 4-way valve.

The flow path switching valve 14 may switch the circulation path of the refrigerant depending on the operation mode (e.g., a cooling operation or a heating operation) of the air conditioner 1. For example, during the cooling operation of the air conditioner 1, the flow path switching valve 14 guides the refrigerant gas discharged from the compressor 11 to the outdoor heat exchanger 12, whereby the refrigerant may circulate through the compressor 11, the outdoor heat exchanger 12, the expansion valve 13, and the indoor heat exchanger 21 in the order. In addition, during the heating operation of the air conditioner 1, the flow path switching valve 14 guides the refrigerant gas discharged from the compressor 11 to the indoor heat exchanger 21, whereby the refrigerant may circulate through the compressor 11, the indoor heat exchanger 21, the expansion valve 13, and the outdoor heat exchanger 12 in the order.

In the outdoor heat exchanger 12, heat exchange between the refrigerant and outdoor air may be performed.

For example, the outdoor heat exchanger 12 in a cooling operation may condense high-pressure, high-temperature refrigerant gas, and during condensation of the refrigerant, the refrigerant may release heat to outdoor air. During the cooling operation, the outdoor heat exchanger 12 may discharge refrigerant liquid.

In addition, the outdoor heat exchanger 12 in a heating operation may evaporate low-pressure, low-temperature refrigerant liquid, and during evaporation the refrigerant, the refrigerant may absorb heat from outdoor air. During the heating operation, the outdoor heat exchanger 12 may discharge refrigerant gas.

An outdoor fan 16 may be provided in the vicinity of the outdoor heat exchanger 12. The outdoor fan 16 may blow outdoor air to the outdoor heat exchanger 12 to promote heat exchange between the refrigerant and the outdoor air.

The expansion valve 13 may expand a high-temperature, high-pressure refrigerant liquid using a throttling effect. In addition, the expansion valve 13 may discharge a low-temperature, low-pressure refrigerant liquid.

The expansion valve 13 may be connected to the indoor unit 20. The number of expansion valves 13 may be provided corresponding in number to the number of indoor units 20.

In the indoor heat exchanger 21, heat exchange between the refrigerant and indoor air may be performed.

For example, the indoor heat exchanger 21 in a cooling operation may evaporate a low-pressure, low-temperature refrigerant liquid, and during evaporation of the refrigerant, the refrigerant may absorb heat from the indoor air. As a result, the air conditioning space may be cooled. During the cooling operation, the indoor heat exchanger 21 may discharge refrigerant gas.

In addition, the indoor heat exchanger 21 in a heating operation condenses high-temperature, high-pressure refrigerant gas, and during condensation of the refrigerant, the refrigerant may release heat to the indoor air. Thereby, the air conditioning space may be heated. During the heating operation, the indoor heat exchanger 21 may discharge a refrigerant liquid.

Depending on embodiments, a separate expansion valve (not shown) or a capillary tube (not shown) may be provided at an inlet side of the indoor heat exchanger 21. The separate expansion valve or capillary tube may expand a refrigerant liquid and provide a low-temperature, low-pressure refrigerant liquid to the indoor heat exchanger 21.

An indoor fan 22 may be provided in the vicinity of the indoor heat exchanger 21. The indoor fan 22 may blow indoor air to the indoor heat exchanger 21 to promote heat exchange between the refrigerant and outdoor air.

At an inlet side of the compressor 11, the accumulator 15 may be provided.

The accumulator 15 may be supplied with a low-temperature, low-pressure refrigerant that has been evaporated in an indoor heat exchanger or an outdoor heat exchanger. For example, the accumulator 15 during a cooling operation may be supplied with a low-temperature, low-pressure refrigerant that has been evaporated in the indoor heat exchanger 21, and during a heating operation, may be supplied with a low-temperature, low-pressure refrigerant evaporated in the indoor heat exchanger 21.

The accumulator 15 may separate a refrigerant liquid from the introduced refrigerant and provide the refrigerant in a gas state to the compressor. Depending on the load, the refrigerant may be incompletely evaporated in the indoor heat exchanger 21 or the outdoor heat exchanger 12, and the accumulator 15 may receive a refrigerant in which liquid refrigerant is mixed refrigerant in a gas state. For example, during a cooling operation, the refrigerant may be incompletely evaporated in the indoor heat exchanger 12 according to the temperature of the air conditioning space.

As described above, the air conditioner 1 according to an embodiment of the present disclosure may include the heat exchangers 12 and 21 configured to exchange heat with outside air.

However, the heat exchanger manufactured by the apparatus and method for manufacturing a heat exchanger according to the concept of the present disclosure is not only applied to the air conditioner as described above, but also applicable to various types of devices using a refrigerating cycle.

Hereinafter, the indoor heat exchanger 21 and the outdoor heat exchanger 12 are collectively referred to as a heat exchanger 100.

FIG. 2 is a perspective view illustrating a heat exchanger according to an embodiment of the present disclosure.

In FIG. 2, for the sake of convenience of description, a configuration of the heat exchanger 100 according to an embodiment of the present disclosure is illustrated except for a connection tube (140 in FIG. 26), which will be described below.

Referring to FIG. 2, the heat exchanger 100 according to an embodiment of the present disclosure may include a refrigerant tube 110. The refrigerant tube 110 may guide the refrigerant for heat exchange. A passage through which the refrigerant flows may be provided inside the refrigerant tube 110.

The refrigerant tube 110 may be provided in a tube shape having a hollow formed inside in which a refrigerant, which is a fluid, may flow.

The refrigerant flowing inside the refrigerant tube 110 may be formed of various types of refrigerants, such as HC single refrigerant, HC mixed refrigerant, R32, R410A, R407C, and carbon dioxide.

The refrigerant tube 110 may be required to be formed as long as possible in order to increase a heat exchange area between the refrigerant flowing along the refrigerant tube 110 and the outside air. However, it may not be easy to form the refrigerant tube 110 long in one direction due to space constraints.

In order to resolve such an issue, the refrigerant tube 110 may include a linear portion 111 extending in one direction and a bending portion 112 bent and extended from an end of the linear portion 111.

The linear portion 111 may be formed to have a linear shape extending in one direction. One end of the linear portion 111 may be connected to the bending portion 112, and the other end of the linear portion 111 opposite to the bending portion 112 may be connected to a connection end (141 or 142 in FIG. 26) of the connection tube 140.

The bending portion 112 may be bent and extended at one end of the linear portion 111. The bending portion 112 may connect the linear portions 111 adjacent to each other. One end of the bending portion 112 may be connected to one end of one part of a pair of linear portions 111 adjacent to each other, and the other end of the bending portion 112 may be connected to one end of the other part of the pair of linear portions 111 adjacent to each other. In this case, the pair of linear portions 111 adjacent to each other may extend in parallel. The bending portion 112 may be formed to have a substantially “U” shape.

That is, the refrigerant tube 110 may include a refrigerant tube having a hairpin shape.

In this way, the refrigerant tube 110 may be formed to have a hairpin shape that is bent and extended, and a heat exchange area of the refrigerant tube 110 may be increased in a limited space.

The refrigerant tube 110 may include a material having high thermal conductivity. For example, the refrigerant tube 110 may include a metal material having high thermal conductivity, such as aluminum or copper.

The heat exchanger 100 may include a heat exchange fin 120 coupled to an outer circumferential surface of the refrigerant tube 110. The heat exchange fin 120 may be passed by the refrigerant tube 110. The refrigerant tube 110 may be disposed to pass through the heat exchange fin 120.

The heat exchange fin 120 may be formed to have a substantially flat plate shape. A direction in which the plate shape of the heat exchange fin 120 extends may be substantially perpendicular to a direction in which the linear portion 111 of the refrigerant tube 110 extends.

The heat exchange fin 120 may be provided in plural. The plurality of heat exchange fins 120 may be arranged in a direction in which the refrigerant tube 110 extends. In other words, the plurality of heat exchange fins 120 may be stacked in a direction in which the linear portion 111 extends.

The heat exchange fin 120 may be coupled to the refrigerant tube 110 to increase a heat exchange area and enhance heat exchange efficiency between the refrigerant flowing along the refrigerant tube 110 and outside air.

That is, the heat exchanger 100 according to an embodiment of the present disclosure may be configured as a fin-tube type heat exchanger including the refrigerant tube 110 and the heat exchange fin 120.

The refrigerant tube 110 may include a material having high thermal conductivity. For example, the refrigerant tube 110 may include a metal material having high thermal conductivity, such as aluminum or copper.

The heat exchanger 100 may include end plates 130 installed on both sides of the heat exchange fins 120 to protect the stacked heat exchange fins 120.

The end plate 130 may be formed to have a substantially flat plate shape. The end plate 130 may be arranged in parallel with the plurality of heat exchange fins 120. The end plate 130 may extend in a direction parallel to the direction in which the plurality of heat exchange fins 120 are formed to extend.

Specifically, a pair of heat exchange fins 120 positioned at both ends of the plurality of heat exchange fins 120 in the stacking direction of the plurality of heat exchange fins 120 among the plurality of heat exchange fins 120 may be covered by a pair of end plates 130. The pair of end plates 130 may cover the heat exchange fins 120 in the stacking direction. The heat exchange fins 120 may be located inside of the pair of end plates 130 in the stacking direction.

The end plates 130 may be passed by the refrigerant tube 110. The refrigerant tube 110 may be disposed to pass through the end plates 130.

In detail, the linear portion 111 may be disposed to pass through the pair of end plates 130 in the stacking direction.

At least a portion of the linear portion 111 may be located inside of the pair of end plates 130 in the stacking direction. Another portion of the linear portion 111 may be located outside of the pair of end plates 130 in the stacking direction. For example, an end portion of the linear portion 111 opposite to the bending portion 112 may be exposed to the outside of the end plate 130.

The bending portion 112 may be exposed to the outside of the end plate 130.

The heat exchange fin 120 may include a fin plate 121, an installation hole 122, and a fin collar 123 (see FIG. 23 and the like).

The fin plate 121 may be formed to have a substantially flat plate shape.

A direction in which the plate shape of the fin plate 121 extends may be substantially perpendicular to a direction in which the linear portion 111 of the refrigerant tube 110 extends.

The fin plate 121 is configured to increase the heat transfer area such that heat exchange efficiency between the refrigerant flowing along the refrigerant tube 110 and the outside air may be improved.

The fin plates 121 of the plurality of heat exchange fins 120 may be arranged in parallel with each other. The fin plates 121 of the heat exchange fins 120 adjacent to each other may be spaced apart from each other.

In detail, the fin plates 121 adjacent to each other may be spaced apart from each other by the fin collar 123. The fin collar 123 may be provided to maintain a spaced distance between the plurality of fin plates 121.

The heat exchange fins 120 are configured to allow air to pass through the space between the fin plates 121 spaced apart from each other and exchange heat with the heat exchange fins 120, so that heat exchange efficiency between the refrigerant flowing along the refrigerant tube 110 and the outside air may be improved.

The installation hole 122 may be formed on the fin plate 121. The installation hole 122 may be provided to allow the refrigerant tube 110 to pass therethrough.

The fin collar 123 may be bent and extended from the edge of the installation hole 122. The fin collar 123 may be formed to contact the outer circumferential surface of the refrigerant tube 110. In detail, the fin collar 123 may be formed to contact the outer circumferential surface of the linear portion 111.

The fin collar 123 may be formed along the circumferential direction of the refrigerant tube 110. The fin collar 123 may extend in a direction parallel to the direction in which the linear portion 111 of the refrigerant tube 110 extends.

The refrigerant tube 110 and the fin plate 121 may heat-exchange through the fin collar 123.

The refrigerant tube 110 of the heat exchanger 100 according to an embodiment of the present disclosure may be formed by processing a tube base material (110a in FIG. 3).

The tube base material 110a may be provided in a tube shape having a hollow therein.

The tube base material 110a may include a base material linear portion 111a extending in one direction and a base material bending portion 112a bent and extended from an end of the base material linear portion 111a (see FIG. 22 and the like).

After the tube base material 110a is processed into the refrigerant tube 110, the base material linear portion 111a may form the linear portion 111 of the refrigerant tube 110. After the tube base material 110a is processed into the refrigerant tube 110, the base material bending portion 112a may form the bending portion 112 of the refrigerant tube 110.

The tube base material 110a may be manufactured by bending a tube extending in one direction. A portion bent during the manufacturing process of the tube base material 110a may form the base material bending portion 112a after the manufacturing is completed.

The hollow formed inside the tube base material 110a may be formed by performing an extrusion, drawing process, etc., on a cylindrical raw material extending in one direction to form a hollow inside thereof, but the method of forming a hollow inside the tube base material 110a is not limited thereto.

The tube base material 110a may include a material having ductility. For example, the tube base material 110a may include a material having ductility, such as aluminum or copper.

The tube base material 110a may include a material having high thermal conductivity. For example, the tube base material 110a may include a metal material having high thermal conductivity, such as aluminum or copper.

Referring to FIG. 22, in order to facilitate a process of stacking the plurality of heat exchange fins 120 such that the tube base material 110a passes therethrough, the diameter of the tube base material 110a may be provided to be smaller than the diameter of the refrigerant tube 110 subjected to the processing. That is, the tube base material 110a before the processing may not be in contact with the fin collar 123 while being fit onto the installation hole 122 of the heat exchange fin 120. In this case, the tube base material 110a and the heat exchange fin 120 may not be coupled to each other, and heat exchange between the tube base material 110a and the heat exchange fin 120 may not occur efficiently.

Therefore, after the plurality of heat exchange fins 120 are disposed to be passed by the tube base material 110a, a process of expanding the diameter of the tube base material 110a may be required. As the diameter of the tube base material 110a expands, the outer circumferential surface of the tube base material 110a may come into contact with the fin collar 123, and the tube base material 110a may be coupled to the heat exchange fin 120.

In other words, as the tube base material 110a is expanded in diameter and processed to form the refrigerant tube 110, the outer circumferential surface of the refrigerant tube 110 may come into contact with the heat exchange fin 120, and the refrigerant tube 110 and the heat exchange fin 120 may be coupled to each other.

Such a process of expanding the diameter of the tube base material 110a is referred to as a tube expansion process, and the tube base material 110a may be coupled to the heat exchange fin 120 by the tube expansion process.

The configuration of the heat exchanger 100 described above with reference to FIG. 2 is only one example of a heat exchanger manufactured by an apparatus and method for manufacturing a heat exchanger according to the concept of the present disclosure. The heat exchanger manufactured by the apparatus and method of manufacturing a heat exchanger according to the concept of the present disclosure is not limited to the embodiment of FIG. 2, and may be configured in various ways. Furthermore, the heat exchanger manufactured by the apparatus and method of manufacturing a heat exchanger according to the concept of the present disclosure is not only applied to an apparatus and manufacturing for manufacturing a finned tube type heat exchanger, but also applicable to an apparatus and method for manufacturing various types of heat exchangers that require a tube expansion process of a refrigerant tube.

Hereinafter, an apparatus and method for manufacturing the heat exchanger 100 shown in FIG. 2 will be described as an example with reference to FIGS. 3 to 26.

FIG. 3 is a schematic view illustrating an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure.

Referring to FIG. 3, an apparatus 3 for manufacturing a heat exchanger may be configured to couple a tube base material 110a to a plurality of heat exchange fins 120.

The apparatus 3 for manufacturing a heat exchanger may include a supporter 31 to support the tube base material 110a and the heat exchange fin 120 passed by the tube base material 110a.

The supporter 31 may include an accommodation space accommodating the tube base material 110a and the heat exchange fin 120 passed by the tube base material 110a. The supporter 31 may support the tube base material 110a and the heat exchange fin 120 accommodated in the accommodation space to maintain a constant position.

For example, the supporter 31 may be provided with a clamp (not shown) for fixing the tube base material 110a and the heat exchange fin 120 supported by the supporter 31.

For example, the supporter 31 may be provided to support at least one surface of the tube base material 110a and the heat exchange fin 120.

The apparatus 3 for manufacturing a heat exchanger may include an actuator 32. The actuator 32 may be configured to transmit power to a tube expansion mandrel 300, which will be described below. The tube expansion mandrel 300 may be provided to be movable by the power transmitted from the actuator 32. The tube expansion mandrel 300 may be provided to be movable relative to the supporter 31 while in connection with the actuator 32.

For example, the actuator 32 may transmit power to the tube expansion mandrel 300 using hydraulic pressure. In this case, the apparatus 3 for manufacturing a heat exchanger may include a hydraulic pump (not shown) generating power by hydraulic pressure. For example, the actuator 32 may be connected to the hydraulic pump to receive hydraulic power. For example, a hydraulic pump may be a part of the actuator 32.

The apparatus 3 for manufacturing the heat exchanger may include a mandrel holder 33 supporting the tube expansion mandrel 300 to be described below. The mandrel holder 33 may movably support the tube expansion mandrel 300. The tube expansion mandrel 300 may be provided to be movable with respect to the mandrel holder 33.

The mandrel holder 33 may have a hollow inside. At least a portion of a moving rod 320 (see FIG. 4) of the tube expansion mandrel 300 may be inserted into the hollow of the mandrel holder 33. The moving rod 320 may be provided to be movable in one direction along the hollow of the mandrel holder 33. The hollow of the mandrel holder 33 may be formed in parallel with a direction in which the tube expansion mandrel 300 or the moving rod 320 moves. Herein, components described as being movable, or linearly movable, in one direction may indicate being movable back and forth along the one direction. For example, the moving rod 320 is movable forward and back along a direction of the longitudinal axis of the moving rod 320.

The mandrel holder 33 may be connected to the actuator 32. The mandrel holder 33 may be provided to transmit power transmitted from the actuator 32 to the tube expansion mandrel 300. The power transmitted from the actuator 32 may be transmitted to the tube expansion mandrel 300 through the hollow inside the mandrel holder 33 described above.

The mandrel holder 33 may be supported by the actuator 32.

The mandrel holder 33 may be provided as a hydraulic cylinder.

The number of the mandrel holders 33 may be provided corresponding in number to the number of the tube expansion mandrels 300, but is not limited thereto. For example, a plurality of tube expansion mandrels 300 may be supported on a single mandrel holder 33.

Different from the description above, the mandrel holder 33 may be a part of the actuator 32.

The tube expansion mandrel 300 may be provided to couple the tube base material 110a to the heat exchange fin 120. The tube expansion mandrel 300 may be provided to expand the tube base material 110a. The tube expansion mandrel 300 may be provided to be inserted into the tube base material 110a.

The tube expansion mandrel 300 may be provided to be movable in one direction with respect to the supporter 31. While moving in one direction, the tube expansion mandrel 300 may be inserted into the tube base material 110a supported by the supporter 31. While moving in one direction, the tube expansion mandrel 300 may be separated from the tube base material 110a. That is, while the tube base material 110a is being expanded, the tube expansion mandrel 300 may be moved in a direction of insertion into the tube base material 110a, and after the expansion of the tube base material 110a is completed, the tube expansion mandrel 300 may be moved in a direction opposite to the direction of insertion into the tube base material 110a.

As shown in FIG. 3, the direction in which the tube expansion mandrel 300 moves may be indicated as a direction Z perpendicular to the X-Y plane.

In this case, the linear portion 111a of the tube base material 110a may extend in the direction Z. In this case, the heat exchange fins 120 passed by the tube base material 110a may be arranged in a direction parallel to the X-Y plane.

In FIG. 3, the direction Z in which the tube expansion mandrel 300 linearly moves is shown as a vertical direction with respect to the ground, but the concept of the present disclosure is not limited thereto. The direction Z in which the tube expansion mandrel 300 linearly moves may be a direction parallel to the ground.

The tube base material 110a may include an insertion end (113a in FIG. 24, etc.) from which the tube expansion mandrel 300 is inserted. The insertion end 113a may be formed at an end of the base material linear portion 111a of the tube base material 110a. The insertion end 113a may be formed at an end portion opposite to the base material bending portion 112a, of the base material linear portion 111a. The tube expansion mandrel 300 may be inserted into the tube base material 110a through the insertion end 113a of the tube base material 110a.

Therefore, for the tube expansion process, the tube base material 110a may be arranged such that the insertion end 113a faces the tube expansion mandrel 300. Before the tube expansion mandrel 300 is inserted into the tube base material 110a, the insertion end 113a may be disposed to face the tube expansion mandrel 300. The supporter 31 may support the tube base material 110a and the heat exchange fin 120 to maintain a position in which the insertion end 113a of the tube base material 110a faces the tube expansion mandrel 300.

Before the tube expansion mandrel 300 is inserted into the tube base material 110a, the insertion end 113a of the tube base material 110a may face the tube expansion mandrel 300 in the Z direction.

The apparatus 3 for manufacturing a heat exchanger may include a connection frame 34 connecting the supporter 31 to the actuator 32.

The connection frame 34 may extend in the direction Z in which the tube expansion mandrel 300 is movable.

In FIG. 3, the supporter 31 and the actuator 32 are illustrated as being connected by the connection frame 34 formed in the shape of a wall, but it is not limited thereto. The connection frame 34 may include a frame structure having a plurality of bar shapes and connect the supporter 31 and the actuator 32.

The configuration of the apparatus 3 for manufacturing a heat exchanger described above with reference to FIG. 3 is only one embodiment of the apparatus for manufacturing a heat exchanger according to the concept of the present disclosure, and the concept of the present disclosure is not limited thereto. An apparatus for manufacturing a heat exchanger according to the concept of the present disclosure may include various configurations including a tube expansion mandrel and provided to transmit power to the tube expansion mandrel to perform a tube expansion process of a tube base material.

FIG. 4 is a view illustrating a tube expansion mandrel of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. 5 is a cross-sectional view of the expansion mandrel shown in FIG. 4 which is taken along a longitudinal direction. FIG. 6 is an enlarged view of part A shown in FIG. 4. FIG. 7 is an enlarged cross-sectional view of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure, which shows a plurality of groove forming protrusions taken along a transverse direction. FIG. 8 is a view for describing the arrangement of a bearing of a tube expansion mandrel of the apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. 9 is an enlarged view of part B in FIG. 5. FIG. 10 is an enlarged view of part C in FIG. 5. FIG. 11 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. 12 is a view illustrating a state of a refrigerant tube after a tube expansion process in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure.

Referring to FIGS. 4 to 12, the tube expansion mandrel 300 may be provided to be linearly movable back and forth along one direction. The tube expansion mandrel 300 may be provided to be linearly movable in the direction Z.

When the tube base material 110a is expanded, the tube expansion mandrel 300 may be moved in a direction L1 to be inserted into the tube base material 110a. The direction L1 may be a direction parallel to the Z direction. After the tube expansion process of the tube base material 110a is completed, the tube expansion mandrel 300 may be moved in a direction opposite to the direction L1 and parallel to the direction Z, to be separated from the tube base material 110a.

The tube expansion mandrel 300 may include a moving rod 320 provided to be linearly movable in one direction. The moving rod 320 may be provided to be linearly movable in the direction Z.

When the tube expansion mandrel 300 expands the tube base material 110a, the moving rod 320 may be moved in the direction L1 such that a tube expansion body 310 to be described below is inserted into the tube base material 110a. After the tube expansion process of the tube base material 110a is completed, the moving rod 320 may be moved in a direction opposite to the direction L1 and parallel to the direction Z such that the tube expansion body 310 to be described below is separated from the tube base material 110a.

For example, the moving rod 320 may receive power while in connection with the actuator 32. For example, the moving rod 320 may be movably supported by the mandrel holder 33.

The moving rod 320 may extend in one direction Z along which the moving rod 320 is movable.

A detailed configuration of the moving rod 320 will be described below.

The tube expansion mandrel 300 may include the tube expansion body 310. The tube expansion body 310 may be provided to be inserted into the tube base material 110a such that the tube base material 110a is expanded.

The tube expansion body 310 may be formed such that the width of at least a portion of the tube expansion body 310 is larger than the diameter of the tube base material 110a. In other words, at least a portion of the tube expansion body 310 may have a larger width in a direction parallel to the X-Y plane than the width of the base material linear portion 111a of the tube base material 110a. When the tube expansion body 310 is inserted into the tube base material 110a, due to the difference between the width of the tube expansion body 310 and the width of the tube base material 110a, the inner surface of the tube base material 110a may be pressed by the tube expansion body 310, causing the diameter of the tube base material 110a to be increased.

The tube expansion body 310 may include a material that is harder than the material constituting the tube base material 110a. For example, the tube expansion body 310 may be composed of metal materials that are harder than materials constituting the tube base material 110a (e.g., aluminum and copper), and other various materials.

The tube expansion body 310 may be formed to have a shape corresponding to the shape of the tube base material 110a. For example, the tube expansion body 310 may be formed to have a shape with a substantially uniform distance from the central axis to the outer surface thereof so as to correspond to the shape of the hollow inside the tube base material 110a. Accordingly, the tube expansion body 310 may transmit a uniform external force to the tube base material 110a, and the tube base material 110a may be uniformly expanded. However, it is not limited thereto, and the tube expansion body 310 may be formed to have various shapes depending on the shape of the tube base material 110a or a desired shape of the refrigerant tube 110.

The tube expansion body 310 may be connected to the moving rod 320. The tube expansion body 310 may be provided to be linearly movable in one direction Z together with the moving rod 320.

When the tube base material 110a is expanded, the tube expansion body 310 may be moved in the direction L1 to be inserted into the tube base material 110a. After the expansion process of the tube base material 110a is completed, the moving rod 320 may be moved in a direction opposite to the direction L1 and parallel to the direction Z such that the tube expansion body 310 to be described below is separated from the tube base material 110a.

That is, while moving in the direction L1 together with the moving rod 320, the tube expansion body 310 may be inserted into the tube base material 110a, and during insertion into the tube base material 110a, expand the tube base material 110a.

Depending on the length of the tube expansion body 310 or the length of the tube base material 110a, at least a portion of the moving rod 320 may also be inserted into the tube base material 110a when the tube expansion body 310 is inserted into the tube base material 110a.

The tube expansion body 310 may include a plurality of groove forming protrusions 313 provided to form a plurality of grooves 113 on the inner surface of the tube base material 110a during insertion of the tube expansion body 310 into the tube base material 110a.

The plurality of groove forming protrusions 313 may be formed on the outer surface of the tube expansion body 310. When the tube expansion body 310 is inserted into the tube base material 110a and moved in the direction L1, the plurality of groove forming protrusions 313 may come into contact with the inner surface of the tube base material 110a and form the plurality of grooves 113.

Each of the plurality of groove forming protrusions 313 may be formed to protrude in an outward direction of the tube expansion body 310. Each of the plurality of groove forming protrusions 313 may be formed to protrude in a direction toward the inner surface of the tube base material 110a in a state in which the tube expansion body 310 is inserted into the tube base material 110a. Each of the plurality of groove forming protrusions 313 may protrude in a direction substantially parallel to the X-Y plane.

Each of the plurality of grooves 113 may be formed by being concavely recessed in the inner surface of the tube base material 110a. The plurality of grooves 113 may be formed to correspond to the shape of the plurality of groove forming protrusions 313.

For example, the plurality of groove forming protrusions 313 may form a plurality of grooves 113 on the inner surface of the tube base material 110a through press working. For example, the plurality of groove forming protrusions 313 may form a plurality of grooves 113 on the inner surface of the tube base material 110a through machining.

Each of the plurality of grooves 113 may be formed to extend in a sloping direction with respect to the one direction Z on the inner surface of the tube base material 110a. In other words, each of the plurality of grooves 113 may be formed to extend substantially in a spiral direction on the inner surface of the tube base material 110a. Each of the plurality of grooves 113 may be arranged in parallel with each other. Accordingly, after the tube base material 110a has been processed, the refrigerant tube 110 may be provided on the inner surface thereof with the plurality of grooves 113 extending substantially in a spiral direction along the longitudinal direction of the refrigerant tube 110as shown in FIG. 12.

The tube expansion body 310 may include the plurality of groove forming protrusions 313, and may be provided to form the plurality of grooves 113 inclined with respect to the one direction Z on the inner surface of the tube base material 110a when inserted into the tube base material 110a.

The plurality of groove forming protrusions 313 may extend along a sloping direction with respect to the one direction Z on the outer surface of the tube expansion body 310. In other words, each of the plurality of groove forming protrusions 313 may extend in a spiral direction along the one direction Z. The plurality of grooves 113 may be formed to extend in a direction parallel to the direction in which the plurality of groove forming protrusions 313 extend, on the inner surface of the tube base material 110a.

The tube expansion body 310 may be rotatably provided with respect to the moving rod 320. In detail, the tube expansion body 310 may be provided to be rotatable around the moving rod 320. The tube expansion body 310 may be provided to be rotatable around a rotational axis in the direction Z in which the moving rod 320 extends. The tube expansion body 310 may be provided to be rotatable around a rotation axis in one direction Z in which the tube expansion body 310 and the moving rod 320 are linearly movable.

For example, the tube expansion body 310 may be provided to be rotatable along the outer circumferential direction of the tube expansion body 310 with respect to the moving rod 320. The outer circumferential direction of the tube expansion body 310 may be a direction parallel to the X-Y plane.

When the tube expansion body 310 is inserted into the tube base material 110a and moved in the direction L1, the inner surface of the tube base material 110a may be pressed by the plurality of groove forming protrusions 313. Correspondingly, when the tube expansion body 310 is inserted into the tube base material 110a and moved in the direction L1, the plurality of groove forming protrusions 313 may be provided to be pressed by the inner surface of the tube base material 110a.

The tube expansion body 310 may be provided to rotate around the moving rod 320 as the plurality of groove forming protrusions 313 are pressed by the inner surface of the tube base material 110a.

In detail, when the tube expansion body 310 is moved in the direction L1 of insertion into the tube base material 110a, each of the plurality of groove forming protrusions 313 may come in contact with the inner surface of the tube base material 110a along a direction inclined with respect to the direction L1. Therefore, each of the plurality of groove forming protrusions 313 may be pressed along the direction inclined to the one direction Z by the inner surface of the tube base material 110a, and the tube expansion body 310 may be pressed along the direction inclined to the one direction Z by the inner surface of the tube base material 110a.

Here, since the tube expansion body 310 is provided to be rotatable with respect to the moving rod 320, the tube expansion body 310 may be caused to rotate as being pressed by the inner surface of the tube base material 110a when inserted into the tube base material 110a.

Referring to FIGS. 4 to 12, the tube expansion body 310 may be provided to rotate in a first rotational direction R1 when inserted into the tube base material 110a.

As the tube expansion body 310 linearly moves in the direction L1 while rotating in the first rotational direction R1, the plurality of groove forming protrusions 313 on the outer surface of the tube expansion body 310 may form the plurality of grooves 113 extending in a substantially spiral direction on the inner surface of the tube base material 110a. As described above, the plurality of grooves 113 may extend to slope with respect to the one direction Z on the inner surface of the tube base material 110a.

Each of the plurality of groove forming protrusions 313 may include one end oriented toward the direction L1 of insertion into the tube base material 110a and the other end opposite to the one end. In this case, each of the plurality of groove forming protrusions 313 may extend to slope with respect to one direction Z from the other end to one end thereof along the first rotational direction R1.

With such a configuration, the tube expansion body 310 may be rotated in the first rotational direction R1 when inserted into the tube base material 110a.

When the plurality of groove forming protrusions 313 extend to slope in a direction opposite to the inclined direction shown in FIG. 4 with respect to the one direction Z, the tube expansion body 310 may be rotated in a direction opposite to the rotational direction R1 when inserted into the tube base material 110a shown in FIG. 4.

The plurality of grooves 113 may be extended to slope with respect to the direction L1 along the first rotational direction R1 on the inner surface of the tube base material 110a. The direction in which the plurality of grooves 113 extend may vary depending on the direction in which the plurality of groove forming protrusions 313 extends or the rotational direction of the tube expansion body 310.

The angle at which the extension direction of each of the plurality of groove forming protrusions 313 is inclined with respect to the one direction Z may correspond to the ratio of the distance moved by the tube expansion body 310 in the direction L1 to the distance moved by the outer surface of the tube expansion body 310 in the first rotational direction R1 when the tube expansion body 310 is inserted into the tube base material 110a.

When the tube expansion body 310 moves in a direction opposite to the direction L1 to be separated from the tube base material 110a, the tube expansion body 310 may rotate in a direction opposite to the first rotational direction R1, but it is not limited thereto.

The plurality of groove forming protrusions 313 may be arranged in parallel with each other along the outer circumferential direction of the tube expansion body 310. However, it is not limited thereto, and at least some of the plurality of groove forming protrusions 313 may not be arranged in parallel with each other.

The plurality of groove forming protrusions 313 may be arranged at regular intervals along the outer circumferential direction of the tube expansion body 310. However, it is not limited thereto, and the plurality of groove forming protrusions 313 may be arranged at non-uniform intervals.

The tube expansion body 310 may include a taper portion 311. The taper portion 311 may have a tapered shape in which the width is narrowed in the direction L1 of insertion into the tube base material 110a.

By the taper portion 311, the tube expansion body 310 may be guided when inserted into the tube base material 110a. As the taper portion 311 is inserted into the tube base material 110a starting from the narrow part, the tube expansion body 310 may be stably inserted into the tube base material 110a.

In addition, as the tube expansion body 310 is inserted, the inner surface of the tube base material 110a may be pressed by an area of the taper portion that becomes wider.

Accordingly, the external force transmitted from the taper portion 311 to the tube base material 110a may gradually increase, and the tube base material 110a may be prevented from being damaged during the tube expansion process.

At least some of the plurality of groove forming protrusions 313 may be disposed on the outer surface of the taper portion 311.

The tube expansion body 310 may include a cylinder portion 312 having a cylindrical shape. The cylinder portion 312 may extend in one direction Z.

The taper portion 311 may extend from the cylinder portion 312 in one direction Z. The taper portion 311 may extend from one end of the cylinder portion 312 that is oriented toward the direction L1 of insertion into the tube base material 110a. In other words, the cylinder portion 312 may extend from one end of the taper portion 311 facing away from the direction L1 of insertion into the tube base material 110a.

The width of the cylinder portion 312 may have a size corresponding to the width of the one end of the taper portion 311 facing away from the direction L1 of insertion into the tube base material 110a. In detail, the width of the cylinder portion 312 may be the same as or similar to the maximum width of the taper portion 311.

At least some of the plurality of groove forming protrusions 313 may be disposed on an outer surface of the cylinder portion 312.

Some of the plurality of groove forming protrusions 313 disposed on the outer surface of the taper portion 311 and other some of the plurality of groove forming protrusions 313 disposed on the outer surface of the cylinder portion 312 may be connected to each other.

The moving rod 320 may extend along one direction Z, and at least a portion of the moving rod 320 may be disposed inside the tube expansion body 310. The moving rod 320 may be disposed on the central axis of the tube expansion body 310. The moving rod 320 may be disposed on the rotation axis of the tube expansion body 310. The tube expansion body 310 may be provided to be rotatable around the moving rod 320.

The tube expansion body 310 may include a hollow formed such that at least a portion of the moving rod 320 is disposed inside thereof. The taper portion 311 may have a hollow formed inside thereof. The hollow of the taper portion 311 may extend in one direction Z. For example, the hollow of the taper portion 311 may be formed to have a width that varies along one direction Z. For example, the hollow of the taper portion 311 may be formed to have a constant width along one direction Z.

The cylinder portion 312 may have a hollow formed inside thereof. The cylinder portion 312 may be formed to have a hollow cylindrical shape. For example, the hollow of the cylinder portion 312 may have a constant width and extend in one direction Z, but it is not limited thereto.

The tube expansion body 310 may include a first end 314 oriented toward the direction L1 of insertion into the tube base material 110a and a second end 315 opposite to the first end 314. The first end 314 and the second end 315 may be arranged side by side in the one direction Z.

For example, the first end 314 may be provided on one side of the taper portion 311 in the direction L1. For example, the second end 315 may be provided on one side of the cylinder portion 312 oriented toward a direction opposite to the direction L1.

For example, the first end 314 may be formed to have a substantially flat shape. The first end 314 may be formed in parallel with the X-Y plane. For example, the second end 315 may be formed to have a substantially flat shape. The second end 315 may be formed in parallel with the X-Y plane.

However, it is not limited thereto, and the first end 314 and the second end 315 may be formed to have various shapes.

The tube expansion body 310 may include a first hole 314a formed at the first end 314 and a second hole 315a formed at the second end 315. The first hole 314a and the second hole 315a may be arranged side by side in one direction Z.

For example, the first hole 314a may be formed in the taper portion 311. For example, the second hole 315a may be formed in the cylinder portion 312.

For example, the first hole 314a may be formed at a substantially central portion of the taper portion 311. For example, the second hole 315a may be formed at a substantially central portion of the cylinder portion 312.

The hollow of the tube expansion body 310 may be formed between the first hole 314a and the second hole 315a.

The moving rod 320 may pass through the first hole 314a and the second hole 315a. At least a portion of the moving rod 320 may be positioned between the first hole 314a and the second hole 315a.

Specifically, the moving rod 320 may include an extension portion 321 extending in one direction Z. For example, the extension portion 321 may be connected to the actuator 32 to receive power for linear movement.

The extension portion 321 may be disposed to pass through the first hole 314a and the second hole 315a. At least a portion of the extension portion 321 may be positioned between the first hole 314a and the second hole 315a. At least a portion of the extension 321 portion may be located inside the tube expansion body 310.

The moving rod 320 may include a head portion 322. The head portion 322 may be in contact with the first end 314 at the outside of the tube expansion body 310. The head portion 322 may be in contact with the first end 314 in one direction Z.

The head portion 322 may be provided at one side of the moving rod 320. The head portion 322 may be located at one side of the extension portion 321 in the direction L1.

The head portion 322 may cover the first hole 314a. The head portion 322 may be formed such that a width w2 in a direction (i.e., a width in a direction parallel to the X-Y plane) perpendicular to the one direction Z is wider than a width w1 of the first hole 314a in the direction perpendicular to the one direction Z. This is taken to mean that the width w2 of at least a portion of the head portion 322 may be wider than the width w1 of the first hole 314a, rather than the widths of all portions of the head portion 322 are wider than the width w1 of the first hole 314a.

With such a configuration, when the moving rod 320 is linearly moved in the opposite direction to the direction L1, the head portion 322 may not escape from the position in contact with the tube expansion body 310. When the moving rod 320 is linearly moved in the direction opposite to the direction L1, the head portion 322 may press the first end 314 of the tube expansion body 310, and the tube expansion body 310 may be separated from the tube base material 110a while moving in the direction opposite to the direction L1.

The head portion 322 may include a first portion 322a adjacent to the tube expansion body 310 and a second portion 322b positioned on a side of the first portion 322a oriented toward the direction L1 of insertion into the tube base material 110a.

The first portion 322a of the head portion 322 may be formed such that a width in a direction perpendicular to the one direction Z (i.e., the width in a direction parallel to the X-Y plane) increases in a direction from the tube expansion body 310 toward the second portion 322b. In other words, the first portion 322a may be formed to have the narrowest width at a side oriented toward a direction opposite to the direction L1. Accordingly, a contact area between the first portion 322a and the first end 314 may decrease, and friction between the first portion 322a and the first end 314 may be reduced. Therefore, the tube expansion body 310 may rotate more efficiently with respect to the moving rod 320.

The head portion 322 may be integrally formed with the extension portion 321, but it is not limited thereto.

The moving rod 320 may include a pressing portion 323. The pressing portion 323 may be in contact with the second end 315 at the outside of the tube expansion body 310. The pressing portion 323 may be in contact with the second end 315 in one direction Z.

The pressing portion 323 may be provided to press the second end 315a in the one direction Z during linear motion in one direction Z. In detail, the pressing portion 323 may include a pressing surface 323s that comes in contact with the second end 315 in one direction Z. The pressing portion 323 may press the second end 315 that comes in contact with the pressing surface 323s in the direction L1 when the moving rod 320 is moved in the direction L1.

The pressing portion 323 may cover the second hole 315a. The pressing portion 323 may be formed such that a width w4 in a direction perpendicular to one direction Z (that is, a width in a direction parallel to the X-Y plane) is wider than a width w3 of the second hole 315a in a direction perpendicular to one direction Z. This is taken to mean that the width w4 of at least a portion of the pressing portion 323 may be wider than the width w3 of the second hole 315a, rather than the widths of all portions of the pressing portion 323 are greater than the width w3 of the second hole 315a.

With such a configuration, when the moving rod 320 linearly moves in the direction L1, the pressing portion 323 may press the tube expansion body 310 in the direction L1.

The pressing portion 323 may be formed in a substantially flat plate shape. The pressing surface 323s may be formed substantially flat. For example, the pressing surface 323s may extend in a direction parallel to the X-Y plane. However, it is not limited thereto, and the pressing portion 323 may be formed to have various shapes.

The pressing portion 323 may be fixed to the extension portion 321 of the moving rod 320.

The pressing portion 323 and the extension portion 321 may be provided separately from each other and then coupled to each other, but are not limited thereto.

Hereinafter, an example of a configuration in which the tube expansion body 310 is provided to be rotatable with respect to the moving rod 320 will be described in detail.

The tube expansion mandrel 300 may include a bearing 330 provided between the tube expansion body 310 and the moving rod 320. The bearing 330 may be configured to reduce frictional force between the tube expansion body 310 and the moving rod 320, and thus the tube expansion body 310 may be rotatably provided with respect to the moving rod 320.

The bearing 330 may be provided inside the tube expansion body 310. The bearing 330 may be provided between the first end 314 and the second end 315. The bearing 330 may be disposed in the hollow of the tube expansion body 310. The bearing 330 may be disposed between the inner circumferential surface of the tube expansion body 310 and the outer circumferential surface of the moving rod 320. For example, the bearing 330 may be in contact with the inner circumferential surface of the tube expansion body 310 and the outer circumferential surface of the moving rod 320.

The bearing 330 may include a plurality of bearings 330. The plurality of bearings 330 may be arranged along the longitudinal direction of the tube expansion body 310. The plurality of bearings 330 may be arranged along the longitudinal direction of the moving rod 320. The plurality of bearings 330 may be arranged along one direction Z.

The bearing 330 may include a plurality of rolling elements 331 disposed between the inner circumferential surface of the tube expansion body 310 and the outer circumferential surface of the moving rod.

The plurality of rolling elements 331 may be arranged along the circumferential direction of the tube expansion body 310. The plurality of rolling elements 331 may be arranged along the inner circumferential surface of the tube expansion body 310. The plurality of rolling elements 331 may be arranged along the outer circumferential surface of a portion of the moving rod 320 located inside the tube expansion body 310. For example, the plurality of rolling elements 331 may be arranged in parallel with the X-Y plane.

As described above, when a plurality of bearings 330 are provided, each of the plurality of bearings 330 may include a plurality of rolling elements 331, and the plurality of rolling elements 331 of each of the plurality of bearings 330 may be arranged along the circumferential direction of the tube expansion body 310.

With such configuration, the tube expansion body 310 may be rotatably provided with respect to the moving rod 320.

The structure of the bearing 330 described above is only one example of a configuration in which the tube expansion body is rotatable with respect to the moving rod in the apparatus for manufacturing a heat exchanger according to the concept of the present disclosure, and the concept of the present disclosure is limited thereto.

In FIG. 5 and the like, the plurality of rolling elements 331 are illustrated as being arranged to be in contact with each other, but it is not limited thereto. In addition, in FIG. 5 and the like, each of the plurality of rolling elements 331 is illustrated as being in contact with the inner circumferential surface of the tube expansion body 310 and the outer circumferential surface of the moving rod 320, but it is not limited thereto.

For example, the bearings provided between the tube expansion body 310 and the moving rod 320 may include an outer ring (not shown), an inner ring (not shown), a plurality of rolling elements provided between the outer ring and the inner ring, a retainer (not shown) that maintains a gap between the plurality of rolling elements, and other configurations.

For example, the plurality of rolling elements may be disposed to be spaced apart from each other along the circumferential direction of the tube expansion body 310.

For example, the plurality of rolling elements may be disposed to be spaced apart from each other along the longitudinal direction of the tube expansion body 310.

In addition, the bearings may be arranged in a direction different from that shown in FIG. 5 and the like.

For example, the plurality of rolling elements may be obliquely arranged at a predetermined angle with respect to one direction Z. For example, the plurality of rolling elements may be arranged in a direction parallel to the extending direction of the plurality of groove forming protrusions 313.

In addition, the bearing may not only be located inside the tube expansion body 310, but may also be located in various positions in which friction may occur between the tube expansion body 310 and the moving rod 320, for example, between the pressing surface 323s of the pressing portion 323 and the second end 315 or between the first portion 322a of the head portion 322 and the first end 314.

In addition, in FIG. 5 and the like, the bearing is illustrated as being composed of a ball bearing including a plurality of rolling elements formed in a substantially spherical shape, but the concept of the present disclosure is not limited thereto.

For example, the bearing may be composed of a roller bearing including a plurality of rolling elements formed in a cylindrical shape.

Alternatively, as an example, the bearing may be configured as a sleeve bearing.

Alternatively, the tube expansion mandrel 300 may be provided such that the frictional force between the tube expansion body 310 and the moving rod 320 is reduced by a fluid.

For example, tube expansion oil may be injected into the tube base material 110a to reduce frictional force between the tube base material 110a and the tube expansion mandrel 300 during the tube expansion process. The tube expansion mandrel 300 may be inserted into the tube base material 110a, in which tube expansion oil has been injected, and expand the tube base material 110a.

In this case, as the tube expansion mandrel 300 moves in the direction L1, some of the tube expansion oil may flow while passing through at least one component of the tube expansion mandrel 300. The tube expansion mandrel 300 may be provided with an oil flow hole (not shown) through which the expansion oil flows.

For example, the oil flow hole may be formed in the first end 314 or the second end 315 of the tube expansion body 310 to communicate with the hollow inside the tube expansion body 310. Alternatively, for example, the oil flow hole may be formed in the head portion 322 of the moving rod 320.

For example, the tube expansion oil flowing through the oil flow hole may flow along a space between the tube expansion body 310 and the moving rod 320. Specifically, the tube expansion oil may be introduced from the first end 314 to flow along the space between the inner surface of the tube expansion body 310 and the outer surface of a portion of the moving rod 320 located inside the tube expansion body 310, and then flow out through the second end 315.

Alternatively, for example, the tube expansion oil flowing through the oil flow hole may flow along a passage (not shown) formed inside each of the tube expansion body 310 or the moving rod 320, and some of the tube expansion oil flowing along the passage may flow into a space or a contact surface between the tube expansion body 310 and the moving rod 320.

For example, the tube expansion oil may flow along various regions such as between the first hole 314a and the moving rod 320, between the second hole 315a and the moving rod 320, between the first end 314 and the head portion 322 (particularly, the first portion 322a), between the second end 315 and the pressing portion 323 (particularly, the pressing surface 323s), and the like.

The type of material applied to reduce the frictional force between the tube expansion body 310 and the moving rod 320 is not limited to the tube expansion oil and may be provided in various types.

With the above configuration, as shown in FIG. 11, when the tube expansion mandrel 300 is inserted into the tube base material 110a, the tube base material 110a may be expanded. As shown in FIG. 12, when the tube expansion mandrel 300 is inserted into the tube base material 110a, the plurality of grooves 113 may be formed on the inner surface of the tube base material 110a. That is, the refrigerant tube 110 subjected to the processing may be provided with the plurality of grooves 113 on the inner surface thereof.

As the plurality of grooves 113 are provided on the inner surface of the refrigerant tube 110, the area in which the refrigerant flowing along the inside of the refrigerant tube 110 contacts the inner surface of the refrigerant tube 110 may be widened, and thus the heat transfer area may be increased.

In particular, as the plurality of grooves 113 extend substantially in a spiral direction, the length of the plurality of grooves 113 may become longer compared to a case in which the plurality of grooves 113 extend in only one direction, and the heat transfer area of the refrigerant may be further increased.

In addition, as the plurality of grooves 113 extend substantially in a spiral direction, the refrigerant flowing along the refrigerant tube 110 may flow in a direction corresponding to the spiral direction, and the heat transfer coefficient of the refrigerant may increase.

Accordingly, heat exchange efficiency between the refrigerant and the outside air may be improved.

In addition, since the tube base material 110a is expanded by the tube expansion mandrel 300 at the same time as forming the plurality of grooves 113 inside the tube base material 110a, manufacturing time and manufacturing cost may be reduced.

In addition, compared to a case in which the tube expansion process of the tube base material 110a is performed after forming the plurality of grooves 113 on the inner surface of the tube base material 110a, the simultaneous processes of expanding the tube base material 110a and forming the plurality of grooves 113 may prevent the plurality of grooves 113 from being damaged due to wear or the like.

In addition, since the tube expansion body 310 is provided to rotate as the plurality of groove forming protrusions 313 are pressed by the inner surface of the tube base material 110a, the tube expansion body 310 may rotate while linearly moving in one direction. Therefore, the ratio of the linear movement distance and the rotational distance of the plurality of groove forming protrusions 313 on the inner surface of the tube base material 110a may be maintained constant within a certain range, and the accuracy of forming the plurality of grooves 113 may be improved.

In addition, a driving source for supplying power to rotate the tube expansion body 310 with respect to the moving rod 320 is not separately required, so manufacturing time and cost may be reduced.

FIG. 13 is an enlarged cross-sectional view illustrating a plurality of groove forming protrusions taken along a transverse direction in an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. 14 is an enlarged cross-sectional view illustrating a plurality of groove forming protrusions taken along a transverse direction in an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure.

In describing the embodiments of FIGS. 13 and 14, the same reference numerals are assigned to components identical to those shown in FIGS. 1 to 12, and descriptions thereof may be omitted.

Referring to FIGS. 7, 13 and 14, the thickness of each of the plurality of groove forming protrusions 313; 1313-1, 1313-2 of the tube expansion body 310 may be provided in various sizes. The thickness of each of the plurality of groove forming protrusions 313; 1313-1, 1313-2 represents a thickness on a cross section, that is, a thickness in the X-Y plane. In detail, the thickness of each of the plurality of groove forming protrusions 313; 1313-1, 1313-2 may be defined as the thickness of the outer end, that is, the tip of the groove forming protrusion.

In the embodiment shown in FIG. 7, each of the plurality of groove forming protrusions 313 may have a thickness of t0.

In the embodiment shown in FIG. 13, each of the plurality of groove forming protrusions 1313-1 may have a thickness of t1. The thickness t1 may be greater than the thickness to.

In the embodiment shown in FIG. 14, each of the plurality of groove forming protrusions 1313-2 may have a thickness close to 0.0. Here, the unit of thickness may be, for example, millimeters (mm).

As the thickness of the groove forming protrusions 313; 1313-1, 1313-2 of the tube expansion body 310 increases within a predetermined range, the expansion efficiency of the tube base material 110a may be improved.

For example, when the tube expansion body 310 includes the groove forming protrusions 1313-1 having a thickness t1, the tube expansion efficiency of the tube base material 110a may be improved compared to a case of including the groove forming protrusions 313 having a thickness t0 or including the groove forming protrusions 1313-2 having a thickness close to 0.0. That is, when the tube expansion body 310 includes the groove forming protrusions 1313-1 having a thickness t1, the diameter of the refrigerant tube 110 after processing may be improved compared to a case of including the groove forming protrusions 313 having a thickness t0 or including the groove forming protrusions 1313-2 having a thickness close to 0.0.

The depth (i.e., the depth depressed from the inner surface of the refrigerant tube 110) of each of the plurality of grooves 113 formed by the plurality of groove forming protrusions 313; 1313-1, 1313-2 may not be sufficiently secured when the thickness of each of the protrusions 313; 1313-1, 1313-2 is excessively large or excessively small.

For example, the plurality of grooves 113 formed by the plurality of groove forming protrusions 313 having a thickness t0 may be formed to be deeper than the plurality of grooves 113 formed by the plurality of groove forming protrusions 1313-1 having a thickness t1 and the plurality of groove forming protrusions 1313-2 having a thickness close to 0.0.

In the apparatus for manufacturing a heat exchanger according to the concept of the present disclosure, the plurality of groove forming protrusions may have various thicknesses depending on the purpose of design.

FIG. 15 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. 16 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure.

In describing the embodiments of FIGS. 15 and 16, the same reference numerals are given to components identical to those shown in FIGS. 1 to 14 and descriptions thereof may be omitted.

For example, in the embodiment of FIG. 15, a tube expansion mandrel 2300-1 may include a moving rod 320 and a tube expansion body 2310-1. The tube expansion body 2310-1 may include a taper portion 2311-1 and a cylinder portion 2312-1. The configuration of the taper portion 2311-1, the cylinder portion 2312-1, and the tube expansion mandrel 2300-1 including the taper portion 2311-1 and the cylinder portion 2312-1 may have characteristics corresponding to those of the tube expansion mandrel 300 shown in FIG. 11.

For example, in the embodiment of FIG. 16, a tube expansion mandrel 2300-2 may include a moving rod 320 and a tube expansion body 2310-2. The tube expansion body 2310-2 may include a taper portion 2311-2 and a cylinder portion 2312-2. The configuration of the taper portion 2311-2, the cylinder portion 2312-2, and the expansion mandrel 2300-2 including the taper portion 2311-2 and the cylinder portion 2312-2 may have characteristics corresponding to those of the tube expansion mandrel 300 shown in FIG. 11.

Referring to FIGS. 11, 15, and 16, the expansion bodies 310, 2310-1, and 2310-2 may include taper portions 311, 2311-1, and 2311-2 of various shapes.

For example, the taper portions 311, 2311-1, and 2311-2 of the expansion bodies 310, 2310-1, and 2310-2 may have a variety of angles between the inclined outer surface and the X-Y plane. Hereinafter, an angle formed between the inclined outer surface of the taper portions 311, 2311-1, and 2311-2 and the X-Y plane is referred to as an angle of the taper portions 311, 2311-1, and 2311-2 for the sake of convenience of description.

In the embodiment of FIG. 11, the taper portion 311 of the tube expansion body 310 may have an angle of a0. In FIG. 11, the angle a0 is shown to be approximately 72 degrees, but it is not limited thereto.

In the embodiment of FIG. 15, the taper portion 2311-1 of the tube expansion body 2310-1 may have an angle of a1. The angle a1 may be smaller than the angle a0. In FIG. 15, the angle a1 is shown to be approximately 52 degrees, but it is not limited thereto.

In the embodiment of FIG. 16, the taper portion 2311-2 of the tube expansion body 2310-2 may have an angle of a2. The angle a2 may be greater than the angle a0. In FIG. 16, the angle a2 is shown to be approximately 82 degrees, but it is not limited thereto.

As the angle of the taper portions 311, 2311-1, and 2311-2 increases within a predetermined range, the tube expansion efficiency of the tube base material 110a may be improved.

For example, the tube expansion body 2310-2 including the taper portion 2311-2 with the angle a2 may provide an improved tube expansion efficiency of the tube base material 110a compared to the tube expansion body 310 including the taper portion 311 with the angle a0 or the tube expansion body 2310-1 including the taper portion 2311-1 with the angle a1. That is, the tube expansion body 2310-2 including the taper portion 2311-2 with the angle a2 may allow the refrigerant tube 110 to be processed with an improved diameter compared to the tube expansion body 310 including the taper portion 311 of the angle a0 or the tube expansion body 2310-1 including the taper portion 2311-1 of the angle a1.

As the angle of the taper portions 311, 2311-1, and 2311-2 decreases within a predetermined range, the depth (that is, the depth of a depression on the inner surface of the refrigerant tube 110) of each of the plurality of grooves 113 formed by the plurality of groove forming protrusions 313 may increase.

For example, the plurality of grooves 113 formed by the plurality of groove forming protrusions 313 of the tube expansion body 2310-1 including the taper portion 2311-1 of the angle a1 may be formed to be deeper than the plurality of grooves 113 formed by the plurality of groove forming protrusions 313 of the tube expansion body 310 including the taper portion 311 of the angle a0 and the plurality of grooves 113 formed by the plurality of groove forming protrusions 313 of the tube expansion body 2310-2 including the taper portion 2311-2 having an angle a2.

In the apparatus for manufacturing a heat exchanger according to the concept of the present disclosure, the angle of the taper portion may have a variety of thicknesses depending on the purpose of design.

FIG. 17 is a view illustrating a tube expansion mandrel of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure.

In describing the embodiment of FIG. 17, the same reference numerals may be assigned to components identical to those shown in FIGS. 1 to 16 and description thereof may be omitted.

Referring to FIG. 17, a tube expansion mandrel 3300 includes a moving rod 3320 linearly movable in one direction Z, and a tube expansion body 3310 connected to the moving rod 3320 and linearly movable in one direction Z. The tube expansion body 3310 may be rotatably provided with respect to the moving rod 3320.

The configuration of the moving rod 3320 may have characteristics corresponding to those of the moving rod 320 shown in FIGS. 1 to 16.

The tube expansion body 3310 may include a plurality of groove forming protrusions 3313 formed on the outer surface of the tube expansion body 3310 and forming a plurality of grooves 113 on the inner surface of the tube base material 110a when inserted into the tube base material 110a. The configuration of the plurality of groove forming protrusions 3313 may have characteristics corresponding to those of the plurality of groove forming protrusions 313, 1313-1, and 1313-2 shown in FIGS. 1 to 16.

The tube expansion body 3310 may include a taper portion 3311 and a cylinder portion 3312. The configurations of the taper portion 3311 and the cylinder portion 3312 may have characteristics corresponding to the configuration of the taper portions 311, 2311-1, and 2311-2 and the cylinder portions 312, 2312-1, and 2312-2 shown in FIGS. 1 to 16.

The taper portion 3311 may include a plane region 3311a in which the groove forming protrusion 3313 is not formed and a groove region 3311b in which the groove forming protrusion 3313 is formed.

On the outer surface of the tube expansion body 3310, the plurality of groove forming protrusions 3313 may be provided on the cylinder portion 3312 and the groove region 3311b of the taper portion 3311.

The plane region 3311a may be formed on a side of the groove region 3311b oriented toward the direction L1 of insertion into the tube base material 110a.

In a process of the expansion mandrel 3300 being inserted into the tube base material 110a while moving in the direction L1, grooves 113 may not be formed when the plane region 3311a is in contact with the inner surface of the tube base material 110a, and may be formed from a point in time when the groove region 3311b comes in contact with the inner surface of the tube base material 110a.

The ratio of the area occupied by the plane region 3311a and the area occupied by the groove region 3311b is not limited as shown in FIG. 17.

FIG. 18 is a view illustrating a tube expansion mandrel of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure.

In describing the embodiment of FIG. 18, the same reference numerals are given to components identical to those shown in FIGS. 1 to 17 and descriptions thereof may be omitted.

Referring to FIG. 18, a tube expansion mandrel 4300 may include a moving rod 4320 linearly movable in one direction Z, and a tube expansion body 4310 connected to the moving rod 4320 and linearly movable in one direction Z. The tube expansion body 4310 may be rotatably provided with respect to the moving rod 4320.

The tube expansion body 4310 may include plurality of groove forming protrusions 4313 formed on the outer surface of the tube expansion body 4310 and forming a plurality of grooves 113 on the inner surface of the tube base material 110a when inserted into the tube base material 110a. The configuration of the plurality of groove forming protrusions 4313 may have characteristics corresponding to those of the plurality of groove forming protrusions 313, 1313-1, 1313-2, and 3313 shown in FIGS. 1 to 17.

The tube expansion body 4310 may include a first end 4314 on the side oriented toward the direction of insertion into the tube base material 110a and a second end 4315 opposite to the first end 4314.

The tube expansion body 4310 may be formed to have a shape in which the width is narrowed along the direction L1 of insertion into the tube base material 110a from the second end 4315 to the first end 4314. That is, the tube expansion body 4310 may have a tapered shape as a whole.

The configuration of the moving rod 4320 may have characteristics corresponding to those of the moving rods 320 and 3320 shown in FIGS. 1 to 17.

The moving rod 4320 may include an extension portion 4321, a head portion 4322, and a pressing portion 4323. The extension portion 4321, the head portion 4322, and the pressing portion 4323 may have characteristics correspond to the configurations of the extension portion 321, the head portion 322, and the pressing portion 323 shown in FIGS. 1 to 16, respectively.

The extension portion 4321 may be disposed to pass through the first end 4314 and the second end 4315.

The head portion 4322 may be in contact with the first end 4314 at the outside of the tube expansion body 4310 in one direction Z.

The pressing portion 4323 may be in contact with the second end 4315 at the outside of the tube expansion body 4310 in one direction Z.

FIG. 19 is a view illustrating a tube expansion mandrel of an apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. is a cross-sectional view of the expansion mandrel shown in FIG. 19 which is taken along a longitudinal direction. FIG. 21 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure.

In describing the embodiments of FIGS. 19 to 21, the same reference numerals are assigned to the same components as those shown in FIGS. 1 to 18, and descriptions thereof may be omitted.

Referring to FIGS. 19 and 21, a tube expansion mandrel 5300 may include a moving rod 5321 provided to be linearly movable in one direction Z and a tube expansion body 5310 provided to be inserted into the tube base material 110a such that the tube base material 110a may be expanded.

The tube expansion body 5310 may include a rotating portion 5311 rotatably provided with respect to the moving rod 5320 and a fixed ball 5312 fixed to the moving rod 5320. The fixed ball 5312 may be positioned on a side of the rotating portion 5311 oriented toward the direction L1 of insertion into the tube base material 110a.

The rotating portion 5311 and the fixed ball 5312 may be formed as components distinguished from each other. The rotating portion 5311 may be provided to be rotatable with respect to the fixed ball 5312.

The rotating portion 5311 may be formed in a cylindrical shape extending substantially in one direction Z. However, it is not limited thereto, and the rotating portion 5311 may be formed to have a variety of shapes.

The rotating portion 5311 may include a first end 5311a on a side oriented toward the direction L1 of insertion into the tube base material 110a and a second end 5311b opposite to the first end 5311a.

The first end 5311a may be in contact with the fixed ball 5312. The second end 5311b may be located on a side opposite to the fixed ball 5312.

The rotating portion 5311 may include a first hole 5311aa formed in the first end 5311a and a second hole 5311bb formed in the second end 5311b.

The rotating portion 5311 may be provided with a hollow formed inside thereof such that at least a portion of the moving rod 5320 is positioned therein. The hollow of the rotating portion 5311 may be formed between the first hole 5311aa and the second hole 5311bb.

The fixed ball 5312 may include a first portion 5312a adjacent to the rotating portion 5311 and a second portion 5312b located on a side of the first portion 5312a oriented toward the direction of insertion into the tube base material 110a.

The first end 5311a of the rotating portion 5311 may be in contact with the first portion 5312a of the fixed ball 5312. In detail, the first end 5311a of the rotating portion 5311 may be in contact with the first portion 5312a of the fixed ball 5312 in one direction Z.

The first portion 5312a of the fixed ball 5312 may cover the first hole 5311aa. The width of the first portion 5312a of the fixed ball 5312 may be greater than that of the first hole 5311aa.

The fixed ball 5312 may include a first partial hole 5312aa formed in the first portion 5312a and a second partial hole 5312bb formed in the second portion 5312b.

The first partial hole 5312aa may be formed at one end of the first portion 5312a oriented away from the direction L1. The second partial hole 5312bb may be formed at one end of the second portion 5312b oriented toward the direction L1.

The fixed ball 5312 may have a hollow inside such that at least a portion of the moving rod 5320 is positioned therein. The hollow of the fixed ball 5312 may be formed between the first partial hole 5312aa and the second partial hole 5312bb.

The first portion 5312a of the fixed ball 5312 may be formed such that a width in a direction perpendicular to one direction Z increases in a direction from the rotating portion 5311 toward the second portion 5312b. In other words, the first portion 5312a may be formed to have the narrowest width at a side facing away from the direction L1. Accordingly, a contact area between the first portion 5312a and the first end 5311a may decreases, and friction between the first portion 5312a and the first end 5311a may be reduced. Accordingly, the rotating portion 5311 may rotate more efficiently around the moving rod 5320.

The moving rod 5320 may include an extension portion 5321 extending in one direction Z, a head portion 5322, and a pressing portion 5323.

The extension portion 5321 may pass through the first hole 5311aa and the second hole 5311bb. At least a portion of the extension portion 5321 may be located in the hollow inside the rotating portion 5311.

The extension portion 5321 may pass through the first partial hole 5312aa and the second partial hole 5312bb. At least another portion of the extension portion 5321 may be located in the hollow inside the fixed ball 5312.

The head portion 5322 may be in contact with an end of the second portion 5312b of the fixed ball 5312 at the outside of the fixed ball 5312. In detail, the head portion 5322 may be in contact with the end of the second portion 5312b of the fixed ball 5312 in one direction Z.

The head portion 5322 may cover the second partial hole 5312bb. The width of the head portion 5322 may be greater than that of the second partial hole 5312bb.

The pressing portion 5323 may be in contact with the second end 5311b of the rotating portion 5311 at the outside of the rotating portion 5311. In detail, the pressing portion 5323 may be in contact with the second end 5311b of the rotating portion 5311 in one direction Z.

The pressing portion 5323 may cover the second hole 5311bb. The width of the pressing portion 5323 may be wider than that of the second hole 5311bb.

The expansion mandrel 5300 may include a plurality of groove forming protrusions 5313 provided to form a plurality of grooves 113 on an inner surface of the tube base material 110a when inserted into the tube base material 110a. The plurality of groove forming protrusions 5313 may be formed on an outer surface of the rotating portion 5311.

The plurality of groove forming protrusions 5313 may extend to slope with respect to one direction Z. The plurality of groove forming protrusions 5313 may extend substantially in a spiral direction along one direction Z on the outer surface of the rotating portion 5311.

The configuration of the plurality of groove forming protrusions 5313 may have characteristics corresponding to those of the plurality of groove forming protrusions 313, 1313-1, 1313-2, 3313, and 4313 shown in FIGS. 1 to 18.

The tube expansion mandrel 5300 may include a bearing 5330 provided between the rotating portion 5311 and the moving rod 5320. The bearing 5330 may be configured to reduce frictional force between the rotating portion 5311 and the moving rod 5320.

The configuration of the bearing 5330 may have characteristics corresponding to those of the bearing 330 shown in FIGS. 1 to 12. For example, the bearing 5330 may include a plurality of rolling elements 5331.

The bearing 5330 may include various configurations provided such that the rotating portion 5311 may efficiently rotate around the moving rod 5320.

In addition, as described above, the frictional force between the rotating portion 5311 and the moving rod 5320 may be reduced by various materials, such as a fluid, for example, tube expansion oil. Frictional force between the rotating portion 5311 and the fixed ball 5312 may also be reduced by various materials, such as fluid, for example, tube expansion oil.

Unlike the above description, in the apparatus for manufacturing a heat exchanger according to an embodiment of the present disclosure, the tube expansion body may not rotate around the moving rod. For example, the moving rod may be rotatably provided with respect to the mandrel holder 33 shown in FIG. 3 or a separate support structure (not shown) connected to the mandrel holder 33. Here, the tube expansion body may include a plurality of groove forming protrusions extending to slope with respect to one direction Z, and when the tube expansion body is inserted into the tube base material, the plurality of groove forming protrusions may be pressed by the inner surface of the tube base material, and the tube expansion body and the moving rod may be rotated around a rotation axis extending in one direction Z. Even in this case, the tube expansion body may be rotated while linearly moving, and the plurality of groove forming protrusions may form a plurality of grooves extending to slope with respect to one direction Z on the inner surface of the tube base material.

FIG. 22 is a view illustrating an example of a process of arranging a plurality of heat exchange fins to be passed by a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. 23 is an enlarged cross-sectional view for escribing a state of a tube base material and a plurality of heat exchange fins before expansion, in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. 24 is a view illustrating an example of a process of linearly moving a tube expansion mandrel toward a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. 25 is a view illustrating an example of a process of expanding a tube base material in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure. FIG. 26 is a view illustrating an example of a process of connecting a plurality of refrigerant tubes after expansion in a method of manufacturing a heat exchanger according to an embodiment of the present disclosure.

A method of manufacturing a heat exchanger according to an embodiment of the present disclosure will be described with reference to FIGS. 22 to 26.

In FIGS. 22 to 26, a method of manufacturing a heat exchanger according to an embodiment of the present disclosure is described based on the tube expansion mandrel 300 according to the embodiment of FIGS. 1 to 12, but the concept of the present disclosure is not limited thereto. The method of manufacturing a heat exchanger described in FIGS. 22 to 26 may be equally applied to a process of manufacturing a heat exchanger using the expansion mandrel 300, 2300-1, 2300-2, 3300, 4300, or 5300 according to various embodiments described with reference to FIGS. 1 to 21.

In an operation shown in FIG. 22, a plurality of heat exchange fins 120 may be arranged to be passed by a tube base material 110a. The plurality of heat exchange fins 120 may be stacked along a base material linear portion 111a of the tube base material 110a.

Installation holes 122 and fin collars 123 of the plurality of heat exchange fins 120 may be formed in various ways. For example, the installation hole 122 and the fin collar 123 may be formed by a burring process. In order to prevent the end of the fin collar 123 from being inserted between the installation holes 122 of adjacent heat exchange fins 120 when the heat exchange fins 120 are stacked, the end of the fin collar 123 may be press-bent after the burring process.

As shown in FIG. 23, the tube base material 110a before the tube expansion process may not be coupled to the heat exchange fin 120. Even while the tube base material 110a before the tube expansion process is disposed to pass through the installation holes 122, the tube base material 110a may not be in contact with all or part of the fin collar 123.

In an operation shown in FIG. 24, the tube base material 110a and the plurality of heat exchange fins 120 disposed to be passed by the tube base material 110a may be located at a position for a tube expansion process (e.g., on the supporter 31 shown in FIG. 3). The tube base material 110a and the plurality of heat exchange fins 120 disposed to be passed by the tube base material 110a may be arranged in line with a tube expansion mandrel 300. Specifically, an insertion end 113a of the tube base material 110a may be aligned to face the tube expansion mandrel 300.

Thereafter, the tube expansion mandrel 300 may be linearly moved toward the tube base material 110a. In detail, the tube expansion mandrel 300 may be moved in a direction L1 of insertion into the tube base material 110a.

The tube expansion mandrel 300 may be inserted into the tube base material 110a through the insertion end 113a.

In an operation shown in FIG. 25, the tube expansion mandrel 300 may be moved in a direction L1 of insertion into the tube base material 110a, so that the tube base material 110a may be expanded.

The tube expansion mandrel 300 may be moved in the direction L1 along the base material linear portion 111a up to one end of the base material linear portion 111a adjacent to the base material bending portion 112a, expanding the tube base material 110a.

As the tube base material 110a is expanded, the outer circumferential surface of the tube base material 110a may be press-welded to the fin collar 123. That is, the tube base material 110a may be coupled to the plurality of heat exchange fins 120.

The tube expansion body 310 of the tube expansion mandrel 300 may be rotated with respect to the moving rod 320 while moving linearly inside the tube base material 110a. While the linearly moving tube expansion mandrel 300 is inserted into the tube base material 110a and expands the tube base material 110a, the plurality of groove forming protrusions 313 formed on the outer surface of the tube expansion mandrel 300 may be rotated. Accordingly, a plurality of grooves 113 may be formed on the inner surface of the tube base material 110a.

As shown in FIG. 26, once the tube expansion process of the tube base material 110a is complete, the refrigerant tube 110 and the plurality of heat exchange fins 120 may be coupled to each other.

In this case, some of the plurality of linear portions 111 may be connected to each other by the bending portions 112, but some other of the plurality of linear portions 111 may not be connected to each other.

In an operation shown in FIG. 26, a pair of linear portions 111 adjacent to each other, among some other of the plurality of linear portions 111 that are not connected to each other, may be connected by a connection tube 140.

The connection tube 140 may have a bent shape. The connection tube 140 may include a first connection end 141 and a second connection end 142, and may extend from the first connection end 141 toward the second connection end 142 in a bent shape.

The first connection end 141 may be connected to one end of one part of the pair of linear portions 111 on a side opposite to the bending portion 112. The second connection end 142 may be connected to one end of the other part of the pair of linear portions 111 on a side opposite to the bending portion 112.

The connection tube 140 and the linear portion 111 may be fixed to each other in various ways, such as fixation through welding, fixation through a fixing member (not shown), e.g., a fixing clip or iron wire.

As described above, the connection tube 140 may connect the refrigerant tubes 110 adjacent to each other to form a refrigerant passage extending as one part.

Through each operation described in FIGS. 22 to 26, the heat exchanger 100 according to an embodiment of the present disclosure may be manufactured.

The method of manufacturing a heat exchanger described above with reference to FIGS. 22 to 26 is only one example of a method of manufacturing a heat exchanger using the apparatus for manufacturing a heat exchanger according to the concept of the present disclosure, and the concept of the present disclosure is limited thereto.

According to the concept of the present disclosure, an apparatus for manufacturing a heat exchanger may include a plurality of groove forming protrusions provided to form a plurality of grooves on an inner surface of a tube base material, thereby manufacturing a heat exchanger having improved heat exchange efficiency.

According to the concept of the present disclosure, grooves may be formed on a tube base material of a heat exchanger while the tube base material is expanded, so that the grooves may be efficiently formed on the inner surface of a refrigerant tube.

According to the concept of the present disclosure, a tube expansion body may be rotated when inserted into a tube base material, to thereby expand the tube base material while forming grooves, so that the accuracy of forming grooves on an inner surface of a refrigerant tube may be improved.

According to the concept of the present disclosure, a tube base material of a heat exchanger may have grooves formed when the tube base material is expanded, so that the manufacturing time and manufacturing cost of the heat exchanger may be reduced.

A specific shape and a specific direction of a refrigerator have been described above with reference to the accompanying drawings, but the present disclosure may be variously modified and changed by those skilled in the art, and the modifications and changes should be interpreted as being included in the scope of the present disclosure.

According to an aspect of the disclosure, there may be provided an apparatus for manufacturing a heat exchanger including a refrigerant tube, the apparatus including: a moving rod configured to be linearly movable in one direction; and a tube expansion body configured to be linearly movable in the one direction by being connected to the moving rod, the tube expansion body configured to be inserted into a tube base material of the refrigerant tub such that the tube base material is expanded. The tube expansion body may include a plurality of groove forming protrusions formed on an outer surface of the tube expansion body to extend along a direction inclined with respect to the one direction, the plurality of groove forming protrusions and configured to form a plurality of grooves on an inner surface of the tube base material when inserted into the tube base material. The plurality of groove forming protrusions may be provided to be pressed by the inner surface of the tube base material when inserted into the tube base material. The tube expansion body may be provided to rotate around the moving rod as the plurality of groove forming protrusions are pressed against the inner surface of the tube base material.

The plurality of groove forming protrusions may be arranged side by side in an outer circumferential direction of the expansion tube body. Each of the plurality of groove forming protrusions may extend in a spiral direction along the one direction.

The apparatus may further include a bearing disposed between the inner circumferential surface of the tube expansion body and the outer circumferential surface of the moving rod.

The tube expansion body may include a cylinder portion extending in the one direction and formed to have a cylindrical shape, and a taper portion extending in the one direction from the cylinder portion and having a shape of which the width is narrowed toward a direction of insertion into the tube base material. At least some of the plurality of groove forming protrusions may be disposed on an outer surface of the taper portion. At least other some of the plurality of groove forming protrusions may be disposed on an outer surface of the cylinder portion.

According to an aspect of the disclosure, there may be provided a method of manufacturing a heat exchanger, which is a method of coupling a tube base material to a plurality of heat exchange fins, the method including: disposing the plurality of heat exchange fins to be passed by the tube base material; linearly moving a tube expansion mandrel toward the tube base material; and with the linearly moving tube expansion mandrel being inserted into the tube base material and expanding the tube base material, allowing the plurality of groove forming protrusions formed on the outer surface of the tube expansion mandrel to be rotated while forming a plurality of grooves on an inner surface of the tube base material.

According to an aspect of the disclosure, there may be provided an apparatus for manufacturing a heat exchanger, which is an apparatus for coupling a tube case material to a heat exchange fin, the apparatus including: a supporter configured to support the tube base material and the heat exchange fin passed by the tube base material, an actuator; and a tube expansion mandrel movably provided with respect to the supporter by being connected to the actuator and configured to expand the tube base material. The tube expansion mandrel may include a moving rod provided to be linearly movable in one direction and a tube expansion body configured to be inserted into the tube base material according to the linear movement of the moving rod, and provided to be rotatable around the moving rod. The tube expansion body may include a plurality of groove forming protrusions formed on an outer surface of the tube expansion body to extend in a sloping direction with respect to the one direction, the plurality of groove forming protrusions configured to form a plurality of grooves on an inner surface of the tube base material when inserted into the tube base material.

Claims

1. An apparatus for manufacturing a heat exchanger including a refrigerant tube, the apparatus comprising:

a moving rod configured to be linearly movable along a first direction; and

a tube expansion body connected to the moving rod so as to be linearly movable along the first direction, the tube expansion body configured to be insertable into a tube base material of the refrigerant tub such that the tube base material is expanded outward by the tube expansion body when the tube expansion body is moved by the moving rod to be inserted into the tube base material of the refrigerant tube,

wherein the tube expansion body includes: a plurality of groove forming protrusions formed on an outer surface of the tube expansion body so as to extend along a direction inclined with respect to the first direction, the plurality of groove forming protrusions form a plurality of grooves on an inner surface of the tube base material, when the tube expansion body is moved by the moving rod to be inserted into the tube base material of the refrigerant tube.

2. The apparatus of claim 1, wherein

the tube expansion body is configured to be rotatable about the longitudinal axis of the moving rod.

3. The apparatus of claim 1, wherein

the tube expansion body is configured to rotate in a first rotational direction when inserted into the tube base material,

each groove forming protrusion of the plurality of groove forming protrusions includes a first end oriented toward a direction of insertion into the tube base material and a second end opposite to the first end, and

each groove forming protrusion of the plurality of groove forming protrusions is extended to slope with respect to the first direction from the first end to the second end along the first rotational direction.

4. The apparatus of claim 1, wherein

the moving rod is elongated along the first direction, and has at least a portion disposed inside the tube expansion body, and

the tube expansion body is configured to be rotatable around the moving rod.

5. The apparatus of claim 4, further comprising:

a bearing configured between the tube expansion body and the moving rod.

6. The apparatus of claim 5, wherein

the bearing includes a plurality of rolling elements disposed between an inner circumferential surface of the tube expansion body and an outer circumferential surface of the moving rod, and

the plurality of rolling elements are arranged along a circumferential direction of the tube expansion body.

7. The apparatus of claim 5, wherein

the bearing includes a plurality of bearings, and

the plurality of bearings are arranged along a longitudinal direction of the tube expansion body.

8. The apparatus of claim 1, wherein

the tube expansion body includes a taper portion which narrows in a direction of insertion into the tube base material, and

the plurality of groove forming protrusions are arranged on an outer surface of the taper portion.

9. The apparatus of claim 8, wherein

the tube expansion body further includes a cylinder portion extending along the first direction and having a hollow cylindrical shape,

the taper portion extends from a first end of the cylinder portion oriented toward the direction of insertion into the tube base material, and

at least some of the plurality of groove forming protrusions are arranged on an outer surface of the cylinder portion.

10. The apparatus of claim 1, wherein

the tube expansion body includes: a first end oriented toward a direction of insertion into the tube base material, a second end opposite to the first end, a first hole formed at the first end, and a second hole formed at the second end, and

the moving rod extends through the first hole and the second hole.

11. The apparatus of claim 10, wherein

the moving rod includes a head portion that is in contact with an outside of the first end of the tube expansion body, and

a width of the head portion in a direction perpendicular to the first direction is wider than a width of the first hole in the direction perpendicular to the first direction.

12. The apparatus of claim 11, wherein

the head portion includes: a first portion adjacent to the tube expansion body, and a second portion located on an end of the first portion oriented toward a direction of insertion into the tube base material, and

the first portion is formed such that a width in the direction perpendicular the first direction increases in a direction from the tube expansion body toward the second portion.

13. The apparatus of claim 10, wherein

the moving rod includes a pressing portion contacting an outside of the second end of the tube expansion body,

the pressing portion is configured to press the second end in the first direction when the moving rod is moving in the first direction, and

the pressing portion has a width in a direction perpendicular to the first direction that is wider than a width of the second hole in the direction perpendicular to the first direction.

14. The apparatus of claim 1, wherein

the plurality of groove forming protrusions are arranged at equal intervals along an outer circumferential direction of the tube expansion body.

15. The apparatus of claim 1, wherein

the tube expansion body includes: a rotating portion configured to be rotatable around the moving rod, and a fixed ball fixed to the moving rod,

the fixed ball is located at an end of the rotating portion oriented toward a direction of insertion into the tube base material, and

the plurality of groove forming protrusions are provided on an outer surface of the rotating portion.