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Evaporator and process for fabricating sameRelated Patent Categories: Metal Working, Method Of Mechanical Manufacture, Heat Exchanger Or Boiler MakingEvaporator and process for fabricating same description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060236538, Evaporator and process for fabricating same. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is an application filed under 35 U.S.C. .sctn.111(a) claiming the benefit pursuant to 35 U.S.C. .sctn.119(e) (1) of the filing date of Provisional Application No. 60/477,746 filed Jun. 12, 2003 pursuant to 35 U.S.C. .sctn.111(b). TECHNICAL FIELD [0002] The present invention relates to evaporators and a process for fabricating the same, and more particularly to evaporators, for example, for use in motor vehicle air conditioners wherein a chloroflurocarbon refrigerant or CO.sub.2 refrigerant is used, and a process for fabricating the evaporator. BACKGROUND ART [0003] Evaporators of the type mentioned are in wide use which comprise refrigerant passing hollow bodies and corrugated fins brazed to the outer surfaces of adjacent hollow bodies. [0004] Such evaporators are fabricated by making a combination of refrigerant passing hollow bodies and corrugated fins, spraying a flux suspension prepared by suspending a noncorrosive fluoride flux in water onto the combination in its entirety and brazing the fins to adjacent hollow bodies by heating the combination in a nitrogen gas atmosphere. [0005] However, the evaporator fabricated in this way inevitably permits the flux to remain on the portions of the corrugated fins which are not brazed to the hollow bodies. We have found that if the evaporator has an increased amount of flux residue remaining therein, the evaporator gives off a relatively strong odor when incorporated into a motor vehicle air conditioner, and is likely to make the passenger in the vehicle compartment feel discomfort. [0006] The amount of flux residue can be reduced by decreasing the quantity of the flux in the suspension, but this entails the likelihood that faults will occur in the brazed joints. [0007] The evaporators described above include those of the stacked plate type wherein the refrigerant passing hollow bodies each comprise two plates provided by a brazing sheet having a brazing material layer on opposite sides thereof and brazed to each other at their peripheral edge portions, the two plates defining therebetween a bulging refrigerant channel and a bulging header-forming portion communicating with each of opposite ends of the channel, the hollow bodies being stacked so that the outer surfaces of the header-forming portions of each adjacent pair of hollow bodies are in contact with each other, the corrugated fins being arranged between the portions of adjacent hollow bodies corresponding to the respective refrigerant channels thereof and brazed to the hollow bodies. In order to simplify or eliminate the step of washing away the flux residue after brazing, it is known to apply a reduced amount of flux, for example 3 to 7 g/m.sup.2 of flux, to the outer surfaces of the plates making the refrigerant passing hollow bodies in fabricating evaporators of the staked type described (see the publication of JP-A No. 2000-202620). [0008] However, the evaporator fabricated by the method disclosed in the above publication still remains to be improved in fully reducing the emanation of odor due to the flux residue. [0009] An object of the present invention is to overcome the above problem and to provide an evaporator which is adapted to effectively suppress the emanation of odor and a process for fabricating the same. DISCLOSURE OF THE INVENTION [0010] To fulfill the above object, the present invention comprises the following modes. [0011] 1) An evaporator comprising a refrigerant passing hollow body, and a fin brazed to an outer surface of the hollow body by the flux brazing method, the portion of the fin not brazed to the hollow body having a flux remaining on a surface thereof in an amount of 0.03 to 1 g/m.sup.2. [0012] 2) An evaporator set forth in the above para. 1) wherein the flux remains on the surface of the portion of the fin not brazed to the hollow body in an amount of 0.05 to 0.5 g/m.sup.2. [0013] 3) An evaporator set forth in the above para. 1) wherein the flux is a noncorrosive fluoride flux. [0014] 4) An evaporator set forth in the above para. 1)wherein the refrigerant passing hollow body comprises a flat tube bent zigzag, and the fin comprises a corrugated fin made of a brazing sheet having a brazing material layer on opposite sides thereof, the corrugated fin being disposed between and brazed to each adjacent pair of straight tube portions of the zigzag flat tube. 5) An evaporator set forth in the above para. 1) which comprises a plurality of straight flat tubes each constituting the refrigerant passing hollow body and wherein the fin comprises a corrugated fin made of a brazing sheet having a brazing material layer on opposite sides thereof, the plurality of flat tubes being arranged in parallel as spaced from one another, the corrugated fin being disposed between and brazed to each adj acent pair of flat tubes. 6) An evaporator set forth in the above para. 1) which comprises a plurality of refrigerant passing hollow bodies each comprising two plates made of a brazing sheet having a brazing material layer on opposite sides thereof and brazed to each other at peripheral edge portions thereof, the two plates defining therebetween a bulging refrigerant channel and a bulging header-forming portion communicating with each of opposite ends of the refrigerant channel, the fin comprising a corrugated fin, the plurality of hollow bodies being stacked so that outer surfaces of the header-forming portions of each adjacent pair of hollow bodies are in contact with each other, the corrugated fin being arranged between the portions of each adjacent pair of hollow bodies corresponding to the respective refrigerant channels thereof and brazed to the hollow bodies. 7) An evaporator set forth in the above para. 1) which has been subjected to a treatment for imparting hydrophilic properties thereto. 8) A refrigeration cycle which comprises a compressor, a condenser and an evaporator and wherein a chlorofluorocarbon refrigerant is used, the evaporatorbeing an evaporator according to any one of claims 1 to 7. [0015] 9) A vehicle having installed therein a refrigeration cycle set forth in the above para. 8) as a motor vehicle air conditioner. [0016] 10) A process for fabricating an evaporator comprising preparing a flat tube bent zigzag and having a refrigerant passing channel inside thereof and a fin made of a brazing sheet having a brazing material layer on opposite sides thereof, applying a flux to an outer surface of the zigzag flat tube in an amount of 0.05 to 2.8 g/m.sup.2, disposing the fin between each adjacent pair of straight tube portions of the zigzag flat tube, and brazing the fin to the zigzag flat tube. [0017] 11) A process for fabricating an evaporator set forth in the above para. 10) wherein the flux is applied to the flat tube in an amount of 1 to 2 g/m.sup.2. [0018] 12) A process for fabricating an evaporator comprising preparing a plurality of straight flat tubes each having a refrigerant passing channel inside thereof and a fin made of a brazing sheet having a brazing material layer on opposite sides thereof, applying a flux to an outer surface of each of the flat tubes in an amount of 0.05 to 2.8 g/m.sup.2, arranging the plurality of flat tubes in parallel as spaced from one another, disposing the fin between each adjacent pair of flat tubes, and brazing the fin to the flat tubes. [0019] 13) A process for fabricating an evaporator set forth in the above para. 12) wherein the flux is applied to the flat tube in an amount of 1 to 2 g/m.sup.2. [0020] 14) A process for fabricating an evaporator comprising preparing plates each having a channel-forming bulging portion and a header-forming bulging portion bulging to a greater extent than the channel-forming portion and extending from each of opposite ends of the channel-forming portion and fins from a brazing sheet having a brazing material layer on opposite sides thereof; applying a flux is to opposite surfaces of each of the plates, with the amount of the flux applied to the outer surfaces of both the bulging portions of each plate adjusted to 0.05 to 2.8 g/m.sup.2; arranging the plates in stacked pairs each comprising the combination of two plates with openings of the bulging portions of each type opposed to each other in corresponding relation so that the outer surfaces of bottom walls of the header-forming bulging portions of adjacent pairs of plates are in contact with each other, and arranging the fins between the portions of respective adjacent pairs of plates corresponding to the channel-forming bulging portions thereof; brazing the two plates in each pair to each other along peripheral edge portions thereof to form a refrigerant passing hollow body and brazing the fins to respective adjacent pairs of hollow bodies. 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