WO2013070069A2

WO2013070069A2 - Method of manufacturing radiators, and associated fittings system and radiator

Info

Publication number: WO2013070069A2
Application number: PCT/NL2012/050779
Authority: WO
Inventors: Vincent Dijkema
Original assignee: I.P. Consultancy; Forrest B.V.; Ingenieursbureau Van Der Meer & Verweij Beheer B.V.
Priority date: 2011-11-09
Filing date: 2012-11-07
Publication date: 2013-05-16
Also published as: WO2013070069A3; NL2007760C2; EP2776772A2

Abstract

A method of manufacturing radiators comprises the following steps: (a) providing a profile in at least one of two plates, and providing at least one hole in one of said plates, (b) bringing the two plates into contact with one another such that a profile compartment is formed, (c) welding together said two plates, and (d) providing at least one fitting for supplying liquid to and/or draining liquid from said hole, wherein the method additionally comprises the following step: - enclosing a heat exchanger comprising a supply part and a drain part between the plates in the compartment, wherein at least one of the supply part and the drain part of the heat exchanger extends as far as, or extends through, the at least one hole of the plate. The thickness of the heat exchanger around said hole may be equal to the distance in situ between both plates, and said fitting may be attached by means of resistance welding, and both the supply part and the drain part of the heat exchanger may extend as far as, or extend through, the at least one hole of the plate. One fitting may be provided on said hole, which fitting comprises separate channels for supply and drainage of liquid. The heat exchanger may be provided with at least two separated circuits which each extend between the same two holes in one of the panels.

Description

METHOD OF MANUFACTURING RADIATORS, AND ASSOCIATED FITTINGS

SYSTEM AND RADIATOR

The present invention relates to a method of manufacturing radiators, a fittings system for a radiator and a radiator.

Heating systems in which hot water is circulated for heating rooms in buildings are applied on a large scale.

Such heating systems often comprise flat, rectangular water-filled radiators having a fitting welded to each corner point thereof, to which fitting a supply pipe or drain pipe is connected, generally by means of a screwed joint.

Such a radiator is customarily manufactured according to a method comprising the following steps:

(a) providing a profile in at least one of two plates, and providing at least one hole in one of said plates,

(b) bringing the two plates into contact with each other such that a profile compartment is formed,

(c) welding together said two plates, and

(d) providing at least one fitting for supplying liquid to and/or draining liquid from said hole.

Further, radiators are known in which a medium performs a closed-cycle evaporation-condensation process, whereby, in operation, heat is transferred from a heat source situated at the bottom of the radiator close to a liquid collecting part to a radiation and/or convection part of the radiator. Said closed cycle operates in a manner similar to a so-termed heat pipe. The heat source may be, for example, an electric resistance wire or alternatively a spiral-shaped tube through which hot water is passed.

Japanese Patent Application JP 56068794A shows such a radiator. Radiators which operate according to the heat-pipe principle have considerable advantages over water-filled radiators, such as, inter alia, a more uniform surface temperature enabling per se an improved heat transfer as well as an increased perception of comfort by virtue of a more pleasant radiation behavior.

It is an object of the invention to provide an efficient method of manufacturing a radiator which operates according to the heat-pipe principle. In particular, the invention aims at providing a method which enables use to be made of standard processing machines, such as also used for the manufacture of water-filled radiators.

This object is achieved by the method as claimed in claim 1.

The simple step of enclosing a heat exchanger between the plates, and in such a manner that at least one of the supply part and the drain part of the heat exchanger extends as far as, or extends through, the at least one hole of the plate, is only a minimal extension of the above-described known method of manufacturing a water-filled radiator. Surprisingly, however, this simple step makes it possible to manufacture a radiator which operates according to the heat- pipe principle, that is to say, a totally different physical principle offering the advantages already mentioned hereinabove .

The method according to the invention has the additional advantage that it can be carried out on a production line arranged for the known method, to which only means have been added for fitting said heat exchanger. In certain embodiments, these means may be limited to persons which manually put the heat exchanger on one of the plates. In such a situation, it is even possible to use a production line interchangeably for the known method and the method according to the invention. This in turn enables a flexible production process, and the additional costs of the method according to the invention in relation to the known method are very small.

In an advantageous embodiment, the thickness of the heat exchanger around said hole is equal to the distance in situ between both plates and said fitting is attached by means of resistance welding. By virtue thereof, the heat exchanger can also be used as a spacer between both plates during resistance welding the fitting, thereby having a dual function. Such a spacer helps to absorb the pressure exerted on the fitting and the radiator during the welding process. Without such a spacer, the radiator will deform to an unacceptable extent, unless other special countermeasures have been taken, such as local stiffening members. In known radiators, use is also made of a spacer, however, this is in the form of a ring that is only used as a spacer, not in the form of a heat exchanger.

In a favorable embodiment, both the supply part and the drain part of the heat exchanger extend as far as, or extend through, the at least one hole of the plate. In this manner, both supply and drainage of water can take place through one hole, and both said supply and said drain can be positioned at the same corner of the radiator, which increases the installation possibilities in rooms in buildings and which is preferable from an esthetic point of view in many cases. In addition, this enables one fitting to be provided on said hole, which fitting comprises separate channels for supply and drainage of liquid. Thus, only one fitting is required, which is cost saving and esthetically favorable.

In an embodiment, the heat exchanger is provided with at least two separated circuits which each extend between the same two holes in one of the panels. In this manner, it is possible to choose, also after the manufacturing process, between (1) a configuration with parallel flow between both circuits and separated supplies and drains or (2) a configuration with counter flow in the circuits and a single, combined supply and drain on one of the holes and a baffler for the flow on the other hole. This choice influences the thermodynamic behavior of the radiator, such as inter alia the temperature distribution of the heat-radiating part of the radiator (where condensation takes place) and the connection possibilities. Furthermore, both holes may be provided with a fittings system which is connected to the supply part and the drain part of the heat exchanger, and which, in a first configuration, interconnects the supply and the drain so as to be in fluid communication which each other, and which, in a second configuration, enables the supply and the drain to be each in fluid communication with another one of two connection points of the fittings system. In these ways, the various flow and connection configurations are readily realized.

In an embodiment, the heat exchanger, prior to confining it in said compartment, is provided with heat transfer fins which are dimensioned so as to subsequently fit between both plates when these plates are brought into contact with one another. In this comparatively simple way, an improved heat transfer can be obtained between the water flowing inside the heat exchanger and the medium in liquid form which is present outside the heat exchanger and which is to be evaporated, and also a space can be provided for this medium in liquid form, and the heat exchanger can be fixed in position within the compartment to be formed between the two panels.

In another embodiment, both the supply part and the drain part of the heat exchanger are connected to an individual hole of a panel and are each situated close to an end portion in the longitudinal direction of the heat exchanger, and said heat exchanger is provided with an expansion part in the longitudinal direction thereof. In this manner, differences in expansion or shrinkage between the heat exchanger and the compartment formed by the plates which accommodates the heat exchanger can be compensated for, whereby the service life and/or sturdiness of the radiator are substantially improved. In this embodiment said expansion part may be a tube provided with corrugations extending transversely to the longitudinal direction thereof.

The invention further relates to a fittings system for a radiator, comprising:

(a) a fitting, comprising:

- a closed envelope,

- provided with a first aperture, and

- a second aperture,

wherein a first passage and a second passage are formed between the first and the second aperture, which two passages are mutually separated; and

(b) a fittings accessory, comprising:

- two tubes, the first, outermost, tube being attached to the first aperture and leading to the first passage, and the second tube being concentrically arranged inside the first tube and forming part of the second passage, and

- connections to the first and the second tube for, respectively, supply and drain pipes at a distance from the fitting,

wherein the fittings accessory is detachable from the fitting .

Such a fittings system addresses similar issues to the above-described method according to the invention, i.e. it contributes to the manufacture of radiator panels which operate according to the heat-pipe principle elucidated hereinabove, requiring as little adaptation as possible of the existing production line of known water-filled radiators because it fits on a standard hole in a radiator and can be attached thereto in a standard manner by means of resistance welding . Another advantage of the fittings system according to the invention is that it enables use to be made in a simple manner of the same connection point for either only the supply flow or the drain flow or for a combined supply and drain flow.

Other advantageous embodiments will be described in the subsidiary claims.

Finally, the invention relates to a radiator comprising a fittings system in accordance with the invention. Such a radiator offers advantages similar to those of the fittings system in accordance with the invention.

The invention will now be explained in greater detail with reference to the drawings shown below, in which corresponding parts bear the same reference numerals. In said drawings :

Figures la, lb and lc diagrammatically show a radiator according to the state of the art,

Figures 2a and 2b are a front view and a sectional view, respectively, of an embodiment of a radiator manufactured according to the method of the invention,

Figures 3a through 3c are sectional views of a fitting of a first embodiment of a fittings system according to the invention, and Figure 3d is a sectional view of said first fittings system, and

Figures 4a and 4b are sectional views of two fittings of respectively a second and a third embodiment of a fittings system according to the invention. in Figure la, a corner point is shown of a rectangular radiator 1 of a well-known type which is manufactured according to a well-known method. The radiator is comprised of two metal plates 2 and 3 which are fitted together, only one of which is shown in figure la. Both plates 2 and 3 are provided with profiling, obtained by means of pressing in a mould. In the visible plate 2, a hole 4 is formed on which a fitting can be mounted for supply or drainage of water. The fitting is not shown in Figure la for the sake of clarity. In the hatched edge areas, the two plates are attached to one another in a liquid-tight manner by means of roll lap welding. In the central area of the radiator, the plates 2 and 3 are also attached to one another, here by means of spot welding, as is diagrammatically shown by means of circles. The lines around said circles denote the profiling of the plate. Although not shown in figure la, a hole 4 with a fitting is present at each one of the four corner points. The non-visible side, i.e. plate 3, does not have holes.

Figure lb is a sectional view taken on the line A-A in Figure la, showing the disassembled state of the parts. The two plates 2 and 3 are visible, and also hole 4 and a ring 5 provided with apertures 6 are visible.

Figure lc shows the same sectional view taken on the line A-A in Figure la, but in this figure the radiator is in the assembled state with a fitting 7 attached to it. The oblique edge 8 serves to keep the ring 5 in place.

The radiator shown in Figures la-lc is manufactured in a method comprising the following steps, which are not necessarily exactly in this order:

- providing profile by means of deep drawing,

- punching holes,

- deforming the edges of the holes,

- arranging the plates one on top of the other, with the rings 5 between them,

- roll lap welding the edges,

- spot welding the central area, and

- hot press welding the fittings.

Figures 2a and 2b show a front view and a sectional view, respectively, of an embodiment of a radiator 1' manufactured according to the method of the invention. A difference with respect to the known radiator 1 shown in Figures la-lc is that the radiator 1' shown in figures 2a and 2b comprises a metal heat exchanger 9, which is situated between the two plates 2 and 3. Said heat exchanger is indicated by means of dashed lines, since it is situated behind plate 2 and hence is actually invisible. In the embodiment shown, this heat exchanger 9 comprises a tube 10, provided with a corrugated portion 10a for absorbing contraction or elongation differences between the tube 10 and the plates 2 and 3, and two rings 11 and 12 connecting the tube 10, for the purpose of fluid communication, with the holes 4 and forming a supply part and a drain part, respectively. The holes 4 at the location of the rings 5' are provided with fittings, prior to operation of the radiator, and the other two holes 4 are sealed with plugs, after the radiator has been filled via these holes 4 with a medium for the heat pipe, i.e. a medium that evaporates as soon as hot water flows through the heat exchanger 9 and that condenses at the inner walls of the plates 2 and 3 while releasing heat to the outsides of these plates.

The radiator is manufactured by means of a method as described hereinabove with reference to Figures la-lc, with this difference that when the two plates 2 and 3 are joined together, the heat exchanger 9 is enclosed. The supply part 11 and the drain part 12 of the heat exchanger extend as far as the two associated holes 4 of the plate 2. In addition, the supply part 11 and the drain part 12 each have a thickness equal to the distance in situ between the two plates 2 and 3, and the fittings, not shown, are attached by means of resistance welding. The fittings of the radiator 1' shown in Figures 2a en 2b are completely identical for that matter to those of radiator 1 shown in Figures la-lc, viz. standard fittings.

Figures 3a through 3c show sectional views of a fitting of a first embodiment of a fittings system in accordance with the invention, while Figure 3d shows a sectional view of this first fittings system. Figure 3a is a longitudinal sectional view, taken on the line B-B in Figure 3b, and Figure 3c shows a similar longitudinal sectional view, yet with a cap provided on the fitting.

The fitting 12 is provided with separate channels 13, 14 for, respectively, supplying liquid to and draining liquid from the radiator to which it is mounted (for example the radiator 1' of Figures la-lc) . These channels are separated by a partition 15 provided with a passage 16.

The fitting 12 further has a closed envelope 17 provided with a first opening 18 and a second opening 19 having a flange 20, and the channels 13 and 14 open into the second opening 19 as well as into the first opening 18. The passage 16 serves to accommodate a tube 21, see Figure 3d.

In Figure 3c, a cap 22 is provided on the fitting 12, as a result of which the channels 13 and 14 form, via the passage 16, a return loop such that fluid flowing in through the opening 13 flows out again through opening 14, which is diagrammatically shown by means of the line with arrows L.

In Figure 3d, the fittings system as a whole is shown, without the associated radiator. The flow of radiator fluid, generally water, is represented by the lines M en N. The system comprises, as shown, in addition to the fitting 12, an accessory 12a comprising two concentric tubes 21 and 23 for the supply of hot water to the radiator and drainage thereof from the radiator, respectively.

The tube 21 extends at one end thereof into the passage 16 and at the other end thereof into a narrowed portion 26 in the tube 23. In order to preclude a thermal short circuit during operation, and associated loss of efficiency, between the hot incoming fluid flow and the cooler outgoing fluid flow, the innermost tube 21 is made of a thermally insulating material, in this example a polyethylene-coated ceramic. Also the partition 15 is heat insulating. Both the tube 21 and the partition 16 are subjected only to the differential pressure between incoming and outgoing flow, not to the absolute pressure of these flows. Therefore, a very rigid construction of these parts is not necessary, as a result of which the number of suitable thermally insulating materials increases, resulting in greater freedom of design and lower costs.

The fittings accessory 12a further comprises an inlet 27 and an outlet 28; the pipes 29 en 30 connected thereto do not form part of the accessory.

The fittings accessory 12a is screwed down on the fitting 12 and can be detached in a simple manner by unscrewing it. If necessary, the fitting 12 can subsequently be closed by means of a cap 22 (see Figure 3c) , as a result of which a reverse flow originates in the fitting during operation.

In this example, a thermostat 24, known per se, with a temperature adjustment knob 25 also forms part of the fittings system, which thermostat controls, in known manner, the water passage through the supply pipe 21 in dependence on the room temperature detected by the thermostat . Instead of the thermostat 24, the system may comprise a shut off valve which is only manually adjustable, or no shut off valve at all .

Figures 4a and 4b are sectional views of two fittings of, respectively, a second and a third embodiment of a fittings system according to the invention. In Figure 4a, the fitting 12' does not have a partition 16, such as in Figure 3c, but instead the radiator 1' has an insert 27 with a passage 28 in the side wall of said insert 27, through which tube 21 extends. The insert 27 rests in a ring 11 or 12 of the radiator 1', thereby forming a supply channel together with tube 21. Next to this channel there is a drain channel that leads to the space between tube 21 and tube 23. The insert 27 is made of a ceramic material and is heat insulating. This embodiment of the fitting 12' can be manufactured in a simpler and more economical manner as compared to the fitting 12 of Figure 3.

In Figure 4b, the tube 10 of the heat exchanger 9 (see Figure 2b) is bent to reach into the fitting 12" . The end portion of the tube 10 opens into the tube 21' which is bent at the end thereof. In this manner, two channels are formed, i.e. one channel inside the tube 10 and the tube 21' and one channel outside said tubes. An attachment stud 28 keeps the tube 21' in place. The embodiment in accordance with Figure 4b can be manufactured in a very simple and economical way.

Variations are possible to the exemplary embodiment described above. For example, the second tube may be S-shaped and both ends thereof may be situated outside the envelope 17 of the fitting.

Claims

1. Method of manufacturing radiators, comprising the following steps:

(a) providing a profile in at least one of two plates(2,3), and providing at least one hole (4) in one of said plates,

(b) bringing the two plates into contact with one another such that a profile compartment (la) is formed,

(c) welding together said two plates, and

(d) providing at least one fitting (12a) for supplying liquid to and/or draining liquid from said hole, wherein the method additionally comprises the following step: - enclosing a heat exchanger (9) comprising a supply part (11) and a drain part (12) between the plates in the compartment ,

wherein at least one of the supply part and the drain part of the heat exchanger extends as far as, or extends through, the at least one hole (4) of the plate.

2. Method of manufacturing radiators according to claim 1, characterized in that the thickness of the heat exchanger around said hole (4) is equal to the distance in situ between both plates (2,3) and said fitting (12a) is attached by means of resistance welding.

3. Method of manufacturing radiators according to any one of the preceding claims, characterized in that both the supply part and the drain part of the heat exchanger extend as far as, or extend through, the at least one hole of the plate.

4. Method of manufacturing radiators according to claim 3, characterized in that one fitting is provided on said hole, which fitting comprises separate channels for supply and drainage of liquid.

5. Method of manufacturing radiators according to any one of the preceding claims, characterized in that the heat exchanger is provided with at least two separated circuits which each extend between the same two holes in one of the panels .

6. Method of manufacturing radiators according to claim 5, characterized in that one of these holes is provided with a fittings system which is connected to the supply part and the drain part of the heat exchanger, and which, in a first configuration interconnects the supply and the drain so as to be in fluid communication which each other, and which, in a second configuration, enables the supply and the drain to be each in fluid communication with one of two connection points of the fittings system.

7. Method of manufacturing radiators according to any one of the preceding claims, characterized in that the heat exchanger, prior to confining it in said compartment, is provided with heat transfer fins which are dimensioned so as to subsequently fit between both plates when these plates are brought into contact with one another.

8. Method of manufacturing radiators according to any one of the preceding claims, characterized in that both the supply part and the drain part of the heat exchanger are connected to an individual hole of a panel and are each situated close to an end portion in the longitudinal direction of the heat exchanger, and in that said heat exchanger is provided with an expansion part in the longitudinal direction thereof.

9. Method of manufacturing radiators according to claim 8, characterized in that said expansion part is a tube provided with corrugations extending transversely to the longitudinal direction thereof.

10. Fittings system for a radiator, comprising

(a) a fitting, comprising:

- a closed envelope,

- provided with a first aperture, and

- a second aperture,

(b) a fittings accessory, comprising:

wherein the fittings accessory is detachable from the fitting.

11. Fittings system according to claim 10, characterized in that an end portion of the second tube is situated inside the envelope and opens into a space within the envelope which is in fluid communication with the second aperture.

12. Fittings system according to claim 10, characterized in that an end portion of the second tube is situated inside the envelope and has a connection for an end portion of a third tube which is to be inserted into the envelope via the second aperture and which forms such a closed space .

13. Fittings system according to any one of claims 10 through 12, characterized in that heat insulating means are provided between the two passages .

14. Fittings system according to claim 13, characterized in that the heat insulating means comprise ceramic or synthetic resin wall parts of at least one of the passages.

15. Radiator provided with a fittings system according to any one of claims 10 through 14.