GB2322933A

GB2322933A - Water tank for a radiator systen and method for the production thereof

Info

Publication number: GB2322933A
Application number: GB9805689A
Authority: GB
Inventors: Peter Brede; Michael Even
Original assignee: ARUP ALU ROHR U PROFIL GmbH
Current assignee: ARUP ALU ROHR U PROFIL GmbH
Priority date: 1995-09-26
Filing date: 1996-09-25
Publication date: 1998-09-09
Also published as: GB9805689D0; DE19680828D2; WO1997012192A1; AU7214596A

Abstract

The invention relates to a water tank for a radiator system or a collecting pipe for a heat exchanger, and a method and a device for the production thereof. The water tank or the collection pipes according to the invention comprise a pipe section having a cross-section of a D-shaped profile with a flat side, and slots with peripherals linings for holding radiator flat tubes are positioned in the flat side thereby increasing the strength, in particular the fatigue strength, which allows the introduction of radiator flat tubes into the slots. The invention also relates to a method and a device for producing the inventive water tank or collecting pipes from a continuous sheet metal strip.

Description

Tube section for a water box for a radiator arrangement or for a header for a heat exchanger and method and apparatus for producing said radiator arrangement or header.

The invention relates to a tube section for a water box for a radiator arrangement, in particular for automobiles, consisting of an arch-like channel, of a plane slotted headplate closing the longitudinal orifice of the channel and of soldered closing caps slipped on at both ends of the channel, and to a method and an apparatus for producing a tubular water box of a radiator arrangement, for example a radiator arrangement of an automobile.

Water boxes of this type and their advantages, as compared, for example, with water boxes previously known from EP 0,198,581 B1, Figure 5, are described, for example in the journal IMech 1995 C496/043, pages 101 to 104. They are composed essentially exclusively of a single material, for example of aluminum or of an aluminum alloy, and in two parts, an arch-like or Ushaped channel being combined with a plane so-called headplate which covers the orifice of the channel. The headplate has holes which are laterally spaced transversely to its longitudinal extent and in which the head ends of radiator tubes of the radiator arrangement are positively inserted, soldered or welded, the orifices of said radiator tubes opening into the interior of the water box. The connection between the headplate and channel is ensured, for example, by means of a marginal folded seam connection which is likewise soldered or welded. The water boxes are to be produced from preformed parts in one operation (one-shot method) during the assembly of the radiator arrangement as a whole.

A water box of this type, produced essentially from only one material, has, in comparison with previous embodiments, very many advantages which are indicated in the above prior art.

Due to the two-part design of the water box, the crimp contact or folded seam points between the headplate and channel are regions presenting sealing problems on account of the forces present in the water box.

Cramping, with simultaneous soldering or welding, is therefore intended to eliminate the sealing problems, whilst, in addition, the strength of the material is also increased to ensure safety against the enormous pressure.

Both the production of the preformed parts and the production of the water box by means of welding which includes cramping, said production being oriented towards individual manufacture, constitute a high cost outlay.

Furthermore, the invention relates to a tube section for a header for heat exchangers, which has receiving slots which are arranged perpendicularly to the tube axis, are spaced one behind the other and are separated from one another by bridge webs and into which can be inserted in each case an open-ended flat tube which can be soldered to the respective receiving slot at the peripheral connection point, and to a method and an apparatus for producing a header.

A header of this type is described in the publication EP 0,535,664 B1, in which a longitudinal tube segment intended as an end chamber of a header for a heat exchanger is provided with a plurality of receiving slots oriented perpendicularly to the axle direction.

The receiving slots serve for the insertion of flat tubes which, at the same time, constitute spacer tubes between two headers of a heat exchanger in each case and which, in particular, are subjected to high pressure by a medium flowing through.

It is known that the transitional regions from the bridge webs located between the receiving slots to the tube casing constitute critical points in terms of strength and influence the durability of a heat exchanger.

In the known header, stability of the bridge webs in the transitional regions to the tube casing is to be achieved in that, on the one hand, the bridge webs are centrally, at their highest level, either lightly pressed so as to have a plane surface or are provided with a concave upset, both actions countersinking the bridge webs into the tube interior. However, due to the change in direction of the bend toward the tube interior, only the direction of the transitional regions to the tube casing is changed.

On the other hand, additional transverse partitions are introduced inside the longitudinal tube segment transversely into said segment, in each case a transverse partition radially supporting a predetermined bridge web and therefore the longitudinal tube segment. The introduction of the transverse partitions and the additional pressing of the tube in the region of the transverse partitions for the stabilizing retention of the bridge webs constitute an additional outlay.

A further header is known from publication EP 0,198,581 B1, which describes a heat exchanger with headers which are spaced from one another and are directed essentially parallel to one another and each of which possesses, in its longitudinal tube segment, receiving orifices which are spaced from one another perpendicularly to the tube axis and are separated from one another by bridge webs and which may be designed in the form of receiving slots.

The receiving orifices in the longitudinal tube segment of one header are arranged in alignment with those in the opposite longitudinal tube segment of the other header. Open-ended flat tubes between the headers can be inserted into the associated receiving orifices and are soldered at connection points common to the receiving slots. Each of the bridge webs is designed to be arch-like (convex), in particular essentially in the manner of a spherical cap, both in the transverse and in the longitudinal direction relative to the tube axis, that is to say the regions of the longitudinal tube segment which are present between the receiving orifices are arch-like.

In order to compensate for lack of strength of the spherical cap shaped bridge webs in their transitional regions to the tube casing, the edges of the receiving orifices are angled perpendicularly to the tube axis in the direction parallel to the insertable flat tubes, the design of said edges constituting an additional outlay in terms of time and cost.

When a heat exchange medium flows through the heat exchanger, for example pressure fluctuations which occur are transmitted to the arched bridge webs, inter alia, as vibrations and shock-like waves, with the result that weakly soldered connection points between the flat tube and the header are put at risk.

For a contrast, an older patent application proposed that, in the header, bridge webs between the receiving slots each have a material strengthening stamping in one of their bridge web halves and that the bridge webs are flattened, so that the longitudinal tube segment is D-shaped in cross section.

The longitudinal tube segment is designed to have an essentially plane surface in the longitudinal direction and, together with the unchanged tube casing belonging to the longitudinal tube segment, is D-shaped in cross section. In this case, the receiving slots are not only simple slots, but have slot edges bent downward into the tube interior and, in particular, angled perpendicularly to the tube axis. The two angled slot edges of a receiving slot possess in each case an essentially plane surface oriented perpendicularly to the tube axis, said surfaces resulting, together with the essentially plane side surfaces of an insertable flat tube, in contact increasing connection surfaces.

The receiving slots thus expediently have slot edges, by means of which tilting is avoided when the flat tube is being inserted and which retain the flat tubes by means of their flattened surfaces.

The connection points between the receiving slots and the respective side surfaces of the flat tubes are designed in such a way that a peripheral soldering margin is achieved, said margin lying essentially in one plane. Sealing problems arise when the bridge webs have near-slot detail archings which make it possible to have weak or unevenly soldered or welded connection points.

The tube section is delimited on both sides, in the axial direction, in each case by transitions which descend from the unchanged upper tube casing bend shape.

The header consists of metal, in particular of light metal, preferably of aluminum or of a light metal alloy containing aluminum.

According to the known method of the older patent application, the application of stampings to the bridge webs of longitudinal tube segments of the headers, in order finally to obtain a D-profile shape from scarcely arched bridge webs, necessitates additional devices for supporting the outer wall and for stamping, thus involving cost intensive processing. Moreover, the introduction of the slots into headers of this type is carried out into the already cut-to-length tubes closed by welding, considerable outlay having to be expended in order to avoid undesirable deformations.

In the publication US Patent Specification 5,088,192, Figures 5 to 8, for example in a slot punching device, both the outer wall and the inner wall of the tube to be machined are supported essentially by positively bearing outer and inner shapes and the slot is prenotched beforehand by a stamping die. The stamping die is then replaced by a punching die, only the inner shape is removed and subsequently punching or slotting is carried out in the slot punching device.

Another method of production starts from a wide flat sheet metal band (EP 0 577,239). In this publication, headers of round cross sections are produced transversely relative to the run-through of the flat band. Sheet metal strips are punched transversely, parallel to one another, into the flat sheet metal band, the sheet metal strips in each case remaining connected at the margin, by means of a narrow holding web, to the two-margin guide webs occurring at the same time. The parallel sheet metal strips of predetermined length, which are in series one behind the other are varied by discontinuous transverse machining: After markings and gages have been prepunched, the transverse sheet metal strips are bent in the form of a part tube, in order thereafter to be slotted according to gage.

The concluding tube rolling deformation and welding of the resulting butt seam are then carried out by transverse execution transversely to the run-through direction. The ready-formed and welded header of round cross section is thereafter taken out of the guide web, preferably cut off or sawn off. Production of this kind involves time consuming interruptions between the work steps. Each work step is carried out alternately in steps from sheet metal strip to sheet metal strip.

Operations, for example rolling deformation, are likewise carried out several times in intermediate steps, thus necessitating a cost intensive stock of control equipment and devices during the run through of the flat band. Another problem is that, with the flat band, the length of the headers is limited only to a maximum predeterminable value and the separated guide webs which occur constitute a cost intensive loss of material.

The object on which the invention is based is to improve a tube section for a water box or a header in terms of strength, in particular fatigue strength, and, at the same time, in particular, to reduce the outlay in terms of material in the case of a predetermined strength. Moreover, production is to be simpler, quicker and more cost-effective.

The object is achieved by means of the features of claims 1, 16 and 41.

Advantageous developments of the invention are presented in the subclaims.

The invention is explained in more detail by way of example with reference to several drawings in which: Figure 1 shows a perspective illustration of a cutaway radiator arrangement with a water box having a closing cap together with connection pieces as well as flat radiator tubes with intermediate fins, Figure 2 shows a water box cross section along a slot in a headplate, Figure 3 shows a longitudinal section through the water box according to Figure 1 centrally along the line II and symmetrically through the D-profile and through the butt edge connection, Figure 4 shows an enlarged detail from the section in Figure 2 along the circle curve I, with a detail of an inserted butting flat radiator tube, Figure 5 shows a perspective illustration of a heat exchanger consisting of two headers according to the invention, Figure 6 shows a detail from a slotted endless sheet metal band which is provided for tube rolling deformation to form a D-profile shaped endless sheet metal tube, Figure 7 shows a cross section through a slotted Dprofile shaped soldered endless sheet metal tube deformed by tube rolling, along the line I in Figure 1, within a pressed-in slot, Figure 8 shows a longitudinal section centrally through a header closed on one side by means of a closing cap and sawn off from the endless sheet metal tube, along the line II in Figure 1, Figure 9 shows a diagrammatic illustration of an apparatus for carrying out a continuous slotting process on an endless sheet metal band, taken in sections centrally in a front view, Figure 10 shows a section through the apparatus according to the invention along the line III in Figure 8, through the upper female die roller and lower male die slotting roller which essentially carry out the slotting process, Figure 11 shows an enlarged detail from the section through the two rollers, essentially in the region of the roller nip and of the loopings round the two rollers, Figure 12 shows a front view of a male die knife according to the invention, Figure 13 shows a side view of the male die knife according to Figure 8, Figure 14 shows a top view of the male die knife according to Figures 8 and 9, Figure 15 shows an enlarged detail along the circle curve V in Figure 13 in the region of the cutter of the male die knife, Figure 16 shows an enlarged detail along the circle curve IV according to Figure 7 in the region of the roller nip between the male die slotting roller and the female die roller at the moment of the slotting of the endless sheet metal band, in an engaging bearing contact position P1 and several positions P5, P9, P13, P15, with a rotary angle b=-1 2/3 , Figure 17 shows an enlarged detail according to Figure 12 with an engaging position P2 and several positions P6, P10, P14, P18, with a rotary angle of b=OO, Figure 18 shows an enlarged detail according to Figure 12 with an engaging position P3 and several positions P7, P11, P15, with a rotary angle of b=1 2/30, and Figure 19 shows an enlarged detail according to Figure 12 with a cutting position P4 and several positions P8, P12, P16, with a rotary angle of b=3 1/30.

Figure 1 shows, cut away, a radiator arrangement for automobiles with a water box 1 according to the invention. The water box 1 consists essentially of an arch-like channel 2 and of a plane slotted headplate 4 closing the longitudinal orifice 3 of the channel, with soldered closing caps 5 slipped on at both ends of the channel (the second closing cap is not shown). The channel 2 and the headplate 4 are in one part, the channel 2 possessing, on two channel bend halves 62, 63, butt edges 6, 7 produced by the tube rolling deformation of the slotted endless sheet metal band 28, said halves being connected to one another preferably by means of a weld seam 8 (in Figures 1 and 2). The headplate 4 possesses slots 9, 10, 11 with slot rims 22, 23, 24 for receiving flat radiator tubes 12, 13, 14, the slots 9, 10, 11 being arranged transversely parallel to one another, at a distance from one another, in relation to the channel 2. Intermediate fins 15, 16 contributing to cooling are located between the flat radiator tubes 12, 13, 14.

The closing caps 5 (in Figures 1 and 3) are, as a rule, provided with connection pieces 17 or threaded pieces for thermostated switches.

The butt edges 6, 7 brought into butting contact with one another are located essentially centrally in the convex channel bend 62, 63 (see Figure 2) and are connected to one another by closing, in particular welding or soldering.

The water box 1 has between the channel 2 and the headplate 4, on both sides of the approximately plane channel wall 18, 19, a bulging longitudinal fold 20, 21 of arcuate cross section, which is directed outward and which merges inward into the headplate 4.

In Figures 2 and 3, in a cross section and a longitudinal section of a tubular water box respectively, slot rims 22, 23, 24, preferably extending peripherally to the margin of the slots 9, 10, 11 in the headplate 4, are angled inward at an angle of 90 , said rims being obtained as a result of the slotting, that is to say the bending displacement of the material, and being offset, in each case in parallel, at the margin of the slots 9, 10, 11 in the outwardly directed angled region relative to the parallel channel walls 18, 19, so as to form a stop edge 25, 26, so that the flat radiator tube 12, 13, 14 insertable in each case butts, with the effect of limiting the insertion, onto the step-like stop edges 25, 26 of the channel 2 which are present on both sides.

In Figure 2, the tube of the water box 1, said tube consisting of a channel 2 and of the headplate 4, preferably has a D-profile.

Figure 4 illustrates the abutment of the inserted flat radiator tube 12 on the stop edge 26, the angled peripheral slot rim 24 retaining the inserted flat radiator tube 12 with stabilizing effect.

In this case, preferably, the flat radiator tubes 12, 13, 14 insertable into the slots 9, 10, 11, on the outside, and that side of the endless sheet metal band 28 which is provided as an outer wall 27 (in Figure 6) are solder-plated.

The closing caps 5 are expediently solder-plated on both sides.

Figure 5 shows a perspective illustration of a heat exchanger 103 consisting of two D-profile shaped headers 101 and 102 according to the invention, produced according to the invention. The two headers 101, 102 are spaced from another and are directed with their flat plates 114 and 115 parallel to one another.

The header 101 possesses, in its longitudinal tube segment 104, receiving slots 106, 110, 111, 112 which are spaced from one another perpendicularly to the corresponding tube axis 105 and which are separated from one another by the bridge webs 107, 108, 109. Like bridge webs and receiving slots are present in the header 102.

The following explanations relate essentially to the header 101, since the observations apply in the same way to the header 102 as a result of the symmetry of the heat exchanger design.

The header 101 according to the invention is cut to length in each case from an endless sheet metal tube which is provided with receiving slots 106, 101, 111, 112 and which is deformed beforehand by tube rolling from an endless sheet metal band 28, containing the receiving slots 106, 110, 111, 112 introduced by slotting, to form a D-profile tube, butt edges 126, 127 present along the endless sheet metal tube in the region of the round casing 123 of the D-profile being connected to one another, and possesses receiving slots 106, 110, 111, 112 which have inwardly angled peripheral slot rims 121, 122, 132.

The receiving slots 106, 110, 111, 112 in the longitudinal tube segment 104 of one header 101 are arranged in alignment with those in the opposite longitudinal tube segment 113 of the other header 102.

The two longitudinal tube segments 104, 113 constitute a D-profile tube in cross section. However, the header 101 or 102 may also be designed continuously and, at the open end regions, in the form of a D-profile. Openended flat tubes 167, 168, 169, 170 can be inserted between the headers 101, 102 into the associated receiving slots 106, 110, 111, 112. The flat tubes 167, 168, 169, 170 are soldered both to the header 101 at the connection points 116, 117, 118, 119, to the receiving slots 106, 110, 111, 112 and to the header 102 of the corresponding connection points.

Figure 6 illustrates a detail from an endless sheet metal band 28 produced according to the invention, which is provided for subsequent continuous tube rolling deformation to form a D-profile shaped endless sheet metal tube. The detail of the endless sheet metal band 28 possesses receiving slots 106, 110, 111, which are arranged centrally one behind the other, are spaced from one another perpendicularly to the tube axis 105 and are separated from one another by bridge webs 107, 108, and rectangularly peripheral slot rims 121, 122, 132 angled into the drawing plane, so that the receiving slots 106, 110, 111 can receive flat tubes 167, 168, 169 of essentially rectangular cross section.

Figure 7 shows a cross section through a slotted Dprofile shaped soldered endless sheet metal tube deformed by tube rolling, along the line I in Figure 1, within the slot 111 having the slot rim 132. The longitudinal tube segment 104 consists essentially of an arch-like, preferably channel-shaped round casing 123 and of a plane slotted flat plate 114 closing the longitudinal orifice 124 of the round casing and having soldered closing caps 125 slipped on at both ends of the tube (the second closing cap is not shown in Figure 4). The round casing 123 and the flat plate 114 are in one part, the round casing 123 possessing, on two bend halves 129, 130, the butt edges 126, 127 produced by the tube rolling deformation of the slotted endless sheet metal band 28, said butt edges being connected to one another by means of a weld seam 131 (in Figures 5 and 7). The flat plate 114 possesses receiving slots 106, 110, 111, 112 having slot rims, for example 121, 122, 132, for receiving the flat radiator tubes 167, 168, 169 and 170, the receiving slots 106, 110, 111, 112 being arranged transversely in parallel, at a distance from one another, in relation to the round casing 123. Intermediate fins contributing to cooling may be located between the flat radiator tubes 167, 168, 169, 170.

The closing cap 125 (in Figure 8) is, as a rule, provided with a connection piece 128.

The butt edges 126, 127 brought into butting contact after tube rolling deformation are located essentially centraling in the convex round casing 123 (Figure 7) and are connected to one another by closing, in particular welding or soldering.

Figure 8, in conjunction with Figure 6, illustrates a header 101 in longitudinal section, since slot rims 121, 122, 132, preferably extending peripherally at the margin of the receiving slots 106, 110, 111 are angled inward at an angle of 900 in the flat plate 114, said rims being obtained as a result of the slotting, that is to say the bending displacement and pressing in of the material.

In this case, preferably, the flat radiator tubes 167, 168, 169, 170 insertable into the receiving slots 106, 110, 111, 112, on the outside, and that side of the endless sheet metal band 28 which is provided as an outer wall 133 are solder-plated.

The closing caps 125 are expediently solder-plated on both sides.

Figure 9 illustrates an apparatus according to the invention for continuously carrying out the slotting of the endless sheet metal band 28. Located in the housing 29 are essentially two interconnected chambers 58, 59, in which are located two rollers arranged one above the other, namely an upper female die roller 30 and a lower male die slotting roller 31 which both form a roller nip 55, in which an endless sheet metal band 28 is transported continuously. The endless sheet metal band 28, slotted at equal intervals, leaves the roller nip 55.

The female die roller 30 is mounted rotatably in the needle bearings 32, 33 and is driven via the drive shaft 34 by means of an external separate drive.

Located on the drive shaft 34 is a gearwheel 35 which can be braced together with the female die roller 30 by means of a clamping part 36. The female die roller 30 possesses parallel to the axis of rotation 75, along its circumference, slot-like indentations (female dies) 37, the depth of which is greater than the length of the slotting cutters 65 of the male die knives (male dies) 49 which, during the continuously running slotting process of the invention, are pushed into these slot-like indentations 37.

In the female die roller 30, the slot-like indentations 37 are formed (Figures 10, 11) in a channel-like manner, parallel to the axis of rotation 75 of the female die roller 30, on the roller circumference, equally spaced teeth 80 being located between the indentations 37, said teeth being preferably rounded slightly at the margin.

The channel-like indentations 37 have, directed toward the axis of rotation 75, an end region of preferably Vshaped cross section (Figure 10).

The delimiting inside walls 76, 77 of an indentation 37 are, at the same time, the outside walls of a tooth 80 and form a radial angle g of preferably 3 1/3 in relation to the axis of rotation 75 of the female die roller 30, so that, in this example, the female die roller 30 possesses fifty-four teeth 80 and fifty-four indentations 37.

In the cross section of an indentation 37, the width between the opposite inside walls 76, 77 of the indentation 37 is at least equal to the thickness of the cutter 65 of the male die knife 49 and double the thickness of the endless sheet metal band 28.

The male die slotting roller 31 has a fixed supporting shaft 38. Two ball bearings 40, 41 are symmetrically located axially relative to the supporting shaft axis 39 at a distance from one another, an approximately can-shaped male die slotting housing 42 being mounted rotatably on said ball bearings. Within the male die slotting housing 42, the supporting shaft 38 is provided with an eccentric 43 which is cylindrical eccentrically to the supporting shaft 39 and on the outer surface 44 of which is located a ball bearing 45 carrying a male die carrier ring 46 which is mounted rotatably on the ball bearing 45. The male die carrier ring 46 circumferentially possesses, centrally, a narrow annular groove 47 which merges, within the male die carrier ring 46, into a widened wide annular groove 48. The male die knives 49, which are located in the narrow annular groove 47 and which have a base widening 54 at their base, are thereby rotatably held in the axial direction in the widened wide annular groove 48.

The male die knives 49 bear with their respective base on the wide annular groove inner surface 60, on which they can slide movably.

The male die slotting housing 42 possesses, in the radial direction, slot-like through orifices 52, in which the male die knives 49 are inserted and radially retained. Between two through orifices 52, the male die slotting housing 42 possesses in each case a radially inwardly directed projection 53 which engages preferably into the narrow annular groove 47 of the male die carrier ring 46. The male die knives 49 are thus both retained and moved in the slot-like through orifices 52 between the projections 53 of the male die slotting housing 42 and, with their base widening 54, in the widened wide annular groove 48. When the male die slotting housing 42 is rotated, the eccentric arrangement on the fixed supporting shaft 38 causes the male die knives 49, functioning as male dies, to be pushed slightly out of the male die slotting housing 42 and pushed into the opposite slot-like indentations 37 functioning as female dies. As a result of this action, the sheet metal band material is not punched, but shifted or displaced.

Consequently, according to the invention, stable slot rims 22, 23, 24 or 121, 122, 132 reinforcing slots 9, 10, 11 or 106, 110, 111, 112 are achieved, said rims being capable of retaining the insertable flat radiator tubes 12, 13, 14 or 167, 168, 169, 170 more effectively.

The male die slotting housing 42 also possesses a gearwheel 50 which is fastened to it and which meshes 51 with the gearwheel 35 of the female die roller 30.

By means of the gearwheel 35 which drives the female die roller 30, the gearwheel 50 of the male die slotting housing 42 and therefore the male die slotting roller 31 are synchronously rotated in opposition.

The meshing 51 of the gearwheels 35, 50 of the female die roller 30 and of the male die slotting roller 31 is designed and adjusted in such a way that the cutting edge 66 of a male die knife 49 touches the nonslotted endless sheet metal band 28, with a fixing effect, in the region prior to the roller nip 55, at an engaging bearing line 73 which preferably intersects, in cross section, with the indentation center line 74 (Figures 11 and 16 to 19).

The example description refers hereafter to Figures 12 to 19 taken as a whole. In this case, the male die knives 49; 491, 492, 493, 494, 495 are designed to be essentially plate-shaped and in each case consist of the base widening 54, of a knife middle part 64 and of the cutter 65 with a cutting edge 66, the base widening 54 being enlarged on the wide side in the manner of a pedestal and the cutter 65 being stepped in a tapered manner from the knife middle part 64 at the circumferential margin.

Figure 13 and Figure 15, in enlarged form, illustrate the cutter 65 which consists of an essentially plane right flank surface 69 and of an essentially convexly curved left flank surface 70. The left flank surface 70 has an upper head flank surface 71 and a lower foot flank surface 79 merging into the knife middle part 64.

On the cutter 65 of the male die knife 49, the right flank surface 69 directed to the roller nip 55 is

The ground bevel of the head flank surface 71 may also have an angle of inclination a greater than 300.

In this case, the cutting edge 66 of the male die knives 49; 491, 492, 493, 494, 495 may be designed outside the knife center plane 72, preferably almost at the margin on the right flank.

The cutters 65 of the male die knives 49 are designed in such a way that the circumference of an associated cutter foot 78 has a preferably elongate shape which is convexly rounded at the end and which corresponds to the peripheral outer wall of an insertable flat tube provided (Figure 14).

Figures 16 to 19 show in each case a detail from the region of the roller nip 55 of the two rollers 30, 31 at the moment of different rotary angles b. In this case, the rotary angle b is defined by an angle of b=OO, when the axes of rotation 75 and 39 of the female die roller 30 and the male die slotting roller 31 are located in one plane, and by a counterclockwise direction of rotation. The inside walls 76, 77 of the channel-like indentations 37 and the outer flank surfaces 69, 70 of the cutter 65 are shaped in such a way that the slotted endless sheet metal band 28 acquires the slots 9, 10, 11 or 106, 110, 111 together with the slot rims 22, 23, 24 or 121, 122, 132, the respective upstanding circumferential margin of said slot rims being directed, on the inside wall, essentially perpendicularly and smoothly in relation to the unformed endless sheet metal band 28.

The paraxial indentations 371, 372, 373, 374, 375 are formed in the female die roller 30 at equal intervals circumferentially. The intermediate teeth 801, 802, 803, 804 are rounded at the margin. The inside walls 76, 77 of the indentations 371, 372, 373, 374, 375 form a radial angle g of 3 1/3 to the axis of rotation 75 of the female die roller 30. The female die roller 30 therefore has fifty-four teeth 80 and fifty-four indentations 37.

The method according to the invention for producing tubular water boxes or headers is described hereafter, Figures 9, 10 and 11 as well as 16 to 19 being jointly taken into account.

In this case, for a simplified illustration of the invention, Figures 10 and 11 show, in a cross section and in a detail from this, the two rollers 30, 31 during the continuous method of slotting the endless sheet metal band.

The result of the slotting method according to the invention, as a part method of the entire method of production of water boxes 1 or D-profile shaped headers 101, 102, is that a slotted endless sheet metal band 28 is made. As a result of subsequent tube rolling deformation, the endless sheet metal band 28 is deformed by rolling to form an endless sheet metal tube and subsequently, in particular welded, is cut off, in particular sawn off, to length, from the one-piece tube as a basis for the water box 1 according to the invention or as headers 101, 102 for the heat exchanger 103.

The endless sheet metal band 28, when being introduced to the roller nip 55, will preferably bear on the female die roller 30 and, after leaving the roller nip 55, loop in follow-up around the male die slotting roller 31 (Figures 10 and 11). In this case, the endless sheet metal band 28 is moved through the nip 55 at an appropriately set speed. The endless sheet metal band 28 bears on the male die slotting housing 42 and thus loops round the male die slotting roller 31 on a looping part 56. In the roller nip 55 of the two rollers 30, 31, the endless sheet metal band 28 is slotted by the male die slotting roller 31, in that the material of the endless sheet metal band 28 is displaced or slotted, preferably at equal intervals, by the male die knife 49 which gradually emerges from the male die slotting roller 31 in an angle dependent manner.

In the roller nip 55, the male die knives 49 are pushed into the endless sheet metal band 28, the looping of the slotted endless sheet metal band 28 around the male die slotting housing 42 subsequently persisting as a result of a suitable position of a following deflecting roller 61 in relation to the male die slotting roller 31.

The endless sheet metal band 28 remains looped around the looping part 56 (Figure 11) of the male die slotting roller 31 until the essentially plate-shaped male die knives 49 or 491, 492, 493, 494, 495, provided with the end knife cutter 65, are retracted under the outer surface of the male die slotting housing 42 of the male die slotting roller 31. In this case, the male die knives 49 can be displaced radially by means of a cylindrical eccentric 43 (Figure 9) mounted eccentrically to the supporting shaft axis 39 of the male die slotting roller 31, in each case the greatest radial eccentric displacement of the male die knife 49 into the opposite female die 37 of the female die roller 30 taking place in the roller nip 55 between the two rollers 30, 31.

The male die knives 49 move, above the supporting shaft axis 39, toward the outside of the male die slotting housing 42 of the male die slotting roller 31 with the effect of pushing forward the cutter (Figure 16 to 19) and, below the supporting shaft axis 39, toward the inside of the male die slotting housing 42 with the effect of retracting the cutter (Figure 10). In this case, the male die knives 49 are guided radially.

Consequently, starting in the upper semicircle, during rotation the male die knives 49 are led radially out of the slot-like through orifices 52 of the male die slotting roller 31, said male die knives 49 being retained displaceably along the slot-like through orifices 52 by an inner cylindrical surface 44, mounted eccentrically to the supporting shaft axis 39, of the eccentric 43 which has an eccentric axis 57 spaced from the supporting shaft axis 39 (Figure 11).

The two rollers 30, 31 rotate synchronously in opposition, in such a way that, when the endless sheet metal band 28 runs through the roller nip 55, a male die knife 49 is always pushed into a slot-like indentation 37. The two axes 39 and 57 of the male die slotting housing 42 and the eccentric 43 are at a spacing which corresponds approximately to the depth of the indentations 37 in the female die roller 30.

The slotting operation in the region of the roller nip 55 is explained in more detail below with reference to Figures 16 to 19. In Figure 16, the cutting edge 66 of the male die knife 491 touches the endless sheet metal band 28 with a fixing effect at the engaging bearing line 73, the engaging bearing line 73 preferably running centrally along the channel-like indentation 371 and intersecting with the cross-sectional indentation center line 74. The male die knife 491 is thus located in an engaging bearing position P1 prior to the indentation 371. The positions P1 to P18, defined by reference symbols, in Figures 16 to 19 show in each case instantaneous positions of the male die knives 491 to 495 in the associated indentations 371, 372, 373, 374, 375 and the intermediate teeth 801, 802, 803, 804, engaging positions P1 to P3 and the cutting position P4 relating to successive engagement and piercing by means of the male die knife 491 in the region of the indentation 371, the passage positions P5 to P8 relating to successively displacing slotting by the male die knife 491 in the region of the indentation 372, the passage positions P9 and P10 relating to further displacement and shifting by the male die knife 493 in the region of the indentation 373, and the holding positions P11 to P18 relating to the male die knives 494, 495 looping round the slot rims 23, 24 with bearing contact in the regions of the indentations 374 and 375.

In this case, the respective positions P1 to P4, P5 to P8, P9 to P13 and P14 to P18 are in each case rotated further in jumps about a rotary angle of 1 2/30, the positions P1 to P4 representing displacement and first cutting in at the engaging bearing line 73, the positions P5 to P8 representing piercing, slotting and shifting, the positions P9 and P10 representing complete slotting and the positions P11 to P18 representing the retention of the endless sheet metal band 28 on the outer surface of the male die slotting roller 31 in the region of the looping part 56.

In the passage position P10 of the male die knife 493, the position of the knife center line 72 coincides with the position of the indentation center line 74. The male die knife 493 is located centrally in the channellike indentation 373, with the slot rims 22 and 106 deformed on both sides. In the indentation 373, in position P10 the width between the opposite inside walls 76, 77 of an indentation 37 is, in cross section, in each case at least equal to the thickness of the cutter 65 of the male die knife 49 and double the thickness of the endless sheet metal band 28.

After the slotted endless sheet metal band 28 has been lifted off from the male die slotting roller 31, preferably after passing the deflecting roller 61, the slotted endless sheet metal band 28 is deformed by tube rolling, thereby causing the formation of two bend halves or channel bend halves 62, 63 touching one another at butt edges 6, 7 which, in a following welding plant, are closed, in particular welded, soldered or the like. The tubes for the water boxes 1 or the headers 101, 102 of the heat exchanger 103 are then cut to a set length, preferably sawn off in a sawing device.

Of course, by means of the method according to the invention for the production of water boxes or headers, in particular by means of the slotting method and the slotting apparatus, it is also possible to produce other profile tubes for other uses, in which, according to the invention, slots having angled peripheral slot rims are introduced in each case in the D-bar plane of the D-profile tube, whilst flat tubes associated with the intended use can be inserted in each case into said slots.

As a rule, the D-profile tubes produced according to the invention have the advantages of simple insertability and stabilization of flat tubes and simple solderability or weldability. Sealing problems in the case of a connecting combination with other tubes are also essentially eliminated as a result of the one-part and profile-oriented design.

These headers according to the invention also afford the possibility, after a heat exchanger has been assembled together with the headers, of finishing the heat exchanger in one welding or soldering operation.

Claims

1. A tube section, in particular for a water box or for a heat exchanger, with a D-profile shaped longitudinal tube segment having receiving slots which are spaced perpendicularly to the tube axis in the longitudinal direction and are separated from one another by bridge webs and into which can be inserted in each case an open-ended flat tube which can be soldered to the respective receiving slot at the peripheral connection point, defined in that it is cut to length from an endless sheet metal tube, which is provided with receiving slots (106, 110, 111, 112) and which is deformed by tube rolling from an endless sheet metal band (28) containing the receiving slots (106, 110, 111, 112) introduced by slotting, to form a D-profile tube, butt edges (6, 7) present along the endless sheet metal tube in the region of the round casing of the D-profile being connected to one another, and possesses receiving slots (106, 110, 111, 112) which have peripheral slot rims (121, 122, 132) angled inward.

2. The tube section as claimed in claim 1, defined in that it is designed continuously and, at the open end regions, in the form of a D-profile.

3. The tube section as claimed in claim 2 or 3, wherein the butt edges (6, 7) brought into butting contact perpendicularly to the D-profile are located essentially centrally in the convex round casing (123) and are connected to one another by closing, in particular by welding or soldering.

4. The tube section as claimed in one of claims 1 to 3, wherein the flat tubes (167, 168, 169, 170) insertable into the receiving slots (106, 110, 111, 112) are solder-plated at least on the outside.

5. The tube section as claimed in one of claims 1 to 4, wherein at least that side of the endless sheet metal band (28) which is provided as an outer wall (133) is solder-plated.

6. The tube section as claimed in one of claims 1 to 5, wherein the closing caps (125) of the header (101, 102) are solder-plated preferably on both sides.

7. A tube section for a water box for a radiator arrangement as claimed in claim 1, in particular for automobiles, consisting of an arch-like channel and of a plane slotted headplate closing the longitudinal orifice of the channel as well as of soldered closing caps slipped on at both ends of the channel, the channel (2) and the head plate (4) consisting of a one-part sheet metal part, the tube section, butt edges (6, 7) present in the region of the channel (2) being connected to one another, and the headplate (4) having slots (9, 10, 11) with peripheral slot rims (22, 23, 24), for the reception of flat radiator tubes (12, 13, 14), in a row, preferably transversely parallel to one another, at a distance from one another, in relation to the channel (2).

8. The tube section as claimed in claim 7, wherein the butt edges (6, 7) brought into butting contact in the channel (2) are located essentially centrally in the convex channel bend (62, 63) and are connected to one another by closing, in particular by welding or soldering.

9. The tube section as claimed in claim 7 or 8, defined in that it has between the channel (2) and the head plate (4), on both sides of the channel wall (18, 19), a bulging longitudinal fold (20, 21) of arcuate cross section, which is directed outward and which merges inward into the head plate (4).

10. The tube section as claimed in claim 7, wherein preferably peripheral slot rims (22, 23, 24) are angled inward in the head plate (4) at the margin of the pressed-in slots (9, 10, 11), said slot rims being offset, in each case in parallel, to the parallel channel walls (18, 19) at the margin of the slots (9, 10, 11), to form a stop edge (25, 26), so that the flat tube (12; 13; 14) insertable in each case butts onto the step-like stop edge (25, 26) of the channel (2) with the effect of limiting insertion.

11. The tube section as claimed in one of claims 1 to 10, wherein the flat radiator tubes (12, 13, 14) insertable into the slots (9, 10, 11) are solder plated on the outside.

12. The tube section as claimed in one of claims 1 to 11, wherein at least that side of the endless sheet metal band (28) which is provided as an outer wall (27) is solder-plated.

13. The tube section as claimed in one of claims 7 to 12, wherein the closing caps (5) are solder-plated on both sides.

14. The tube section as claimed in one of claims 7 to 13, wherein the closing caps (5) are provided with connection pieces (17) or threaded pieces for thermostatic switches.

15. The tube section as claimed in one of claims 7 to 13, wherein the tube section of the water box (1) has a D-profile.

16. An apparatus for carrying out a slotting method on an endless sheet metal band (28) for producing a D-profile shaped water box or header as claimed in the preceding claims, wherein there are located in a housing (29) essentially two interconnected chambers (58, 59), in which are located two rollers arranged one above the other, preferably an upper female die roller (30) and a lower male die slotting roller (31) which form a roller nip (55), in which an endless sheet metal band (28) is transported continuously and, slotted preferably at equal intervals, leaves the roller nip (55).

17. The apparatus as claimed in claim 16, wherein the male die slotting roller (31) possesses radially displaceable male die knives (49) which can be introduced into the roller nip (55) axially rotatably about an eccentric axis (57) and which make slots (9, 10, 11 or 106, 110, 111, 112), preferably having slot rims (22, 23, 24 or 121, 122, 132), in the endless sheet metal band (28).

18. The apparatus as claimed in claims 16 or 17, wherein the female die roller (30) is mounted rotatably in the needle bearings (32, 33) and can be driven via the drive shaft (54) by means of an external separate drive.

19. The apparatus as claimed in one or more of claims 16 to 18, wherein a gearwheel (35), which can be braced together with the female die roller (30) by means of a clamping part (36), is located on the drive shaft (34).

20. The apparatus as claimed in one or more of claims 16 to 19, wherein the female die roller (30) possesses, along its circumference, slot-like indentations (37), the depth of which is greater than the length of the slotting cutters (65) of the male die knives (49) of the male die slotting roller (31).

21. Apparatus according to one or more of claims 16 to 20, wherein, in the female die roller (30), the slot-like indentations (37; 371 to 375) are formed in a channel-like manner, parallel to the axis of rotation (75) of the female die roller (30), on the roller circumference and form intermediate equally spaced teeth (80; 801, 802, 803, 804) which are preferably slightly rounded at the margin.

22. The apparatus as claimed in one or more of claims 16 to 21, wherein the channel-like indentations (37; 371, 372, 373, 374, 375) have, directed toward the axis of rotation (75), an end region of preferably V-shaped cross section.

23. The apparatus as claimed in one or more of claims 16 to 22, wherein the delimiting side walls (76, 77) of a tooth (80; 801 to 804) form a radial angle (g) of preferably 3 1/3 in relation to the axis of rotation (75) of the female die roller (30).

24. The apparatus as claimed in one or more of claims 16 to 23, wherein, in the cross section of an indentation (37), the width between the opposite inner side walls (76, 77) of an indentation (37) in each case is at least equal to the thickness of a cutter (65) of the male die knife (49) and double the thickness of the endless sheet metal band (28).

25. The apparatus as claimed in one or more of claims 16 to 24, wherein the male die slotting roller (31) has a fixed supporting shaft (38), on which two ballbearings (40, 41) are symmetrically located axially relative to the supporting shaft axis (39) at a distance from one another, an approximately can-shaped male die slotting housing (42) being mounted rotatably on said ball bearings.

26. The apparatus as claimed in one or more of claims 16 to 25, wherein there is mounted on the supporting shaft (38), within the male die slotting housing (42), a cylindrical eccentric (43) which is arranged eccentrically to the supporting shaft (39) and on the outer surface (44) of which is located a ball bearing (45) carrying a male die carrier ring (46) which is mounted rotatably on the ball bearing (45).

27. Apparatus according to one or more of claims 16 to 26, wherein the male die carrier ring (46) centrally possesses, circumferentially, a narrow annular groove (47) which merges, within the male die carrier ring (46), into a widened wide annular groove (48).

28. The apparatus as claimed in one or more of claims 16 to 27, wherein the male die knives (49) are located in the narrow annular groove (47), said knives having a base widening (54) at their base, being held rotatably in the axial direction in the widened wide annular groove (48) and bearing with their respective base on the wide annular groove inner surface (60), on which they can move slidably.

29. The apparatus as claimed in one or more of claims 16 to 28, wherein the male die slotting housing (42) possesses, in the radial direction, slot-like through orifices (52), in which the male die knives (49) are inserted and radially retained, an inwardly directed projection (53) being present in each case radially between two through orifices (52), said projection preferably engaging into the narrow annular groove (57) of the male die carrier ring (46).

30. The apparatus as claimed in one or more of claims 16 to 29, wherein the male die knives (49) are both retained and movable in the slot-like through orifices (52) between the radially inwardly directed projections (53) of the male die slotting housing (42) and, with their base widening (54), in the widened wide annular groove (48).

31. The apparatus as claimed in one or more of claims 16 to 30, wherein the male die slotting housing (42) possesses a gearwheel (50) which is fastened to it and which meshes (51) with the gearwheel (35) of the female die roller (30), the female die roller (30), by means of the driving gearwheel (35) and the meshing gearwheel (50) of the male die slotting housing (42), and the male die slotting roller (31) being rotatable synchronously in opposition.

32. The apparatus as claimed in one or more of claims 16 to 31, wherein the meshing (51) of the gearwheels (35, 50) of the male die slotting roller (31) and of the female die roller (30) being designed and adjusted in such a way that the cutting edge (66) of a male die knife (49) touches the nonslotted endless sheet metal band (28), with a fixing effect, in the region prior to the roller nip (55) at an engaging bearing line (73) which preferably intersects, in cross section, with the indentation center line (74).

33. The apparatus as claimed in one or more of claims 16 to 32, wherein the male die knives (49; 491, 492, 493, 494, 495) are of essentially plate-shaped design and consist in each case of the base widening (54), of a knife middle part (64) and of the cutter (65) with a cutting edge (66), the base widening (54) being stepped, so as to be enlarged on the wide side in the manner of a pedestal, and the cutter (65) being stepped so as to be tapered at the circumferential margin from the knife middle part (64).

34. The apparatus as claimed in one or more of claims 16 to 33, wherein the cutter (65) consists of an essentially plane right flank surface (69) and of an essentially convexly curved left flank surface (70) which has an upper head flank surface (71) and a lower foot flank surface (79).

35. The apparatus as claimed in one or more of claims 16 to 34, wherein, on the cutter (65) of the male die knife (49), the right flank surface (69) directed to the roller nip (55) is designed, starting from the cutting edge (66), to be directed essentially parallel to the right wide side surface (67) of the knife middle part (64).

36. The apparatus as claimed in one or more of claims 16 to 35, wherein the left flank surface (70) located opposite the right flank surface (69) on the other side is essentially convexly curved, the head flank surface (71) being provided, starting from the cutting edge (66) located preferably on the right flank in relation to the knife center plane (72), with a ground bevel extending beyond the knife center plane (72) on the left flank, at an angle of inclination (a) of preferably 300, and, after the ground bevel, merging into the preferably bent, slightly curved foot flank surface (79) inclined at more than 30 and angled relative to the knife center plane (72).

37. The apparatus as claimed in one or more of claims 16 to 36, wherein the ground bevel of the head flank surface (71) has an angle of inclination (a) greater than 300.

38. The apparatus as claimed in one or more of claims 16 to 37, wherein the cutting edge (66) of the male die knife (49; 491, 492, 493, 494, 495) is designed to be preferably almost marginal on the right flank outside the knife center plane (72).

39. The apparatus as claimed in one or more of claims 16 to 38, wherein the cutters (65) of the male die knives (49) are designed in such a way that the circumference of a cutter foot (78) has a preferably elongate shape which is convexly rounded at the end and which corresponds to the peripheral outer wall of an insertable flat tube provided.

40. The apparatus as claimed in one or more of claims 16 to 39, wherein the inside walls (76, 77) of the channel-like indentations (37) and the outer flank surfaces (69, 70) of the cutter (65) are shaped in such a way that the slotted endless sheet metal band (28) acquires the slots (9, 10, 11, or 106, 110, 111) together with the slot rims (22, 23, 24 or 121, 122, 132), the respective upstanding circumferential margin of said slot rims being directed, on the inside wall, essentially perpendicularly and smoothly relative to the unformed endless sheet metal band (28).

41. A method for producing water boxes or headers according to the invention, using the apparatus according to the invention for carrying out a slotting method on an endless sheet metal band (28) as claimed in the preceding claims, wherein one-piece tubes are produced from the endless sheet metal band (28) by moving the endless sheet metal band (28) between two rollers, a female die roller (30) and a male die slotting roller (31), as a result of which, at an appropriately set rotational speed of the rollers (30, 31), the endless sheet metal band (28) is slotted in the nip of the two rollers by the male die slotting roller (31) at equal intervals by means of male die knives (49) and is subsequently deformed by tube rolling in such a way that the endless sheet metal band is deformed to form an endless sheet metal tube essentially with a head plate or flat pate (4, 114) with the central slots (9, 10, 11 or 106, 110, 111, 112) and the two bend halves (62, 63 or 129, 130), so that the endless sheet metal band margins become butt edges (6, 7) which touch one another and which are closed, preferably welded, soldered or the like, and the endless sheet metal tube is then cut to a set tube length, preferably sawn off, to form headers (101, 102) or tubes for the water boxes (1).

42. The method as claimed in claim 41, wherein the endless sheet metal band (28), bearing on the female die roller (30), is introduced into the roller nip (55) and after slotting, bearing on the male die slotting roller (31), is led further along a looping part (56) on the male die slotting housing (42), until the male die knives (49) are retracted.

43. The method as claimed in claim 42, wherein the looping part (56) of the male die slotting roller (31) remains looped around until the male die knives (49) leave the slots (9, 10, 11 or 106, 110, 111, 112) without destroying the slot rims.

44. The method as claimed in the preceding claims, wherein, when the endless sheet metal band (28) is being introduced into the roller nip, the male die knives (49), displaced radially beyond the male die slotting housing (42), are guided axially in rotation into the roller nip (55), so that slots (9, 10, 11 or 106, 110, 111, 112) preferably spaced in parallel, in particular with slot rims (22, 23, 24 or 121, 122, 132), are made in the endless sheet metal band (28), and, when the male die slotting roller (31) is rotated further, the male die knives (49) are retracted in an ordered manner below the outer surface of the male die slotting housing (42).

45. A method for producing a radiator arrangement, for example a radiator arrangement of an automobile, using the tubular water boxes according to the invention, as claimed in claims 1 to 9, wherein the radiator arrangement is connected to the water box, the flat tubes, with intermediate fins, closing caps, in particular including the connection pieces, in one welding or soldering operation.

46. A water box for a radiator arrangement by the method according to the invention and using the apparatus according to the invention as claimed in one of claims 16 to 40, defined in that it is produced from an endless sheet metal band (28) which is slotted, deformed by tube rolling, closed, in particular welded or soldered, and cut to length in a continuous cycle.

47. A header for heat exchangers by the method according to the invention, using the apparatus according to the invention as claimed in one of claims 16 to 40, defined in that it is produced from an endless sheet metal band (20) which is slotted, deformed by tube rolling, closed and cut to length in a continuous cycle.