A panel radiator and manufacturing method thereof

Abstract

The present invention relates to a panel radiator (1) comprising a panel fin sheet (2) and a convector (3), which are preferably made of different materials, and a manufacturing method of the panel radiator (1) having such properties.

Description

[0001] A PANEL RADIATOR AND MANUFACTURING METHOD THEREOF Field of the Invention

[0002] The present invention relates to a panel radiator for heating the surrounding area and the manufacturing method of the panel radiator.

[0003] Background of the Invention

[0004] Panel radiators are preferred for heating various areas such as schools, homes, and hospitals. In panel radiators, heat is distributed through conduction, convection, and radiation heat transfer methods. Panel radiators transfer the heat from the incoming hot water to the panel fins through conduction. The panel fins transfer heat to the convectors in the flap structure inside the radiator through conduction. In convectors, heat is transferred through convection. In panel radiators, heat is distributed through radiation heat transfer via the outer surface area.

[0005] In the known state of the art, panel radiators are manufactured from steel sheets. The panel fin and convector of panel radiators are formed by means of cold forming method using presses. In the state of the art, resistance welding methods are used in the manufacturing of radiators. In the state of the art, the radiator fin sheet and the steel convector sheet of the steel panel are joined together by means of resistance spot welding method. Resistance spot welding machines used in the mass production of panel radiators have an alternating current (AC) transformer and are sufficient for joining two steel sheets together. On the other hand, the selection of panel radiator material also affects the thermal capacity of the radiator.

[0006] In the field, there are different joining methods based on increasing energy density for welding different metals, such as laser welding, metal inert gas (MIG) welding, and metal active gas (MAG) welding by means of using soldering technologies. However, when considered in terms of suitability for panel radiator mass production lines, the aforementioned welding technologies cannot be used due to their unsuitability for panel radiator mass production.

[0007] Summary of the Invention

[0008] The objective of the present invention is to provide a panel radiator with increased thermal capacity which heats the surrounding area.

[0009] The objective of the present invention is to provide a method for manufacturing a panel radiator which has increased thermal capacity at a lower cost.

[0010] The objective of the present invention is to manufacture a panel radiator, wherein sheets with different raw materials are manufactured using resistance welding, laser welding, MIG-MAG welding, diffusion welding, and friction stir welding methods.

[0011] Detailed Description of the Invention

[0012] The panel radiator developed for achieving the objective of the present invention is illustrated in the accompanying figure, in which:

[0013] Figure 1. is an exemplary perspective view of the panel radiator of the present invention.

[0014] The parts in the figures are individually numbered, and their equivalents are given below.

[0015] 1. Panel radiator

[0016] 2. Panel fin sheet

[0017] 3. Convector The manufacturing method for manufacturing the panel radiator of the invention comprises the steps of

[0018] forming the convector (3) and the panel fin sheet (2) by pressing,

[0019] - joining the panel fin sheet (2) and the convector (3) by welding using laser welding, resistance welding, MIG-MAG welding, diffusion welding, or friction stir welding methods.

[0020] In the method of the invention, preferably a material such as aluminum or copper, which has a higher thermal capacity than steel, is used as the raw material for the convector (3). In a first step, the convector (3) is formed into the desired shape by means of pressing the convector (3). Then, the convector (3) and the panel fin sheet (2) are joined together using laser welding, MIG-MAG welding, diffusion welding, resistance welding, or friction stir welding. Steel, magnesium, aluminum, or copper materials can be used as raw materials for panel fin sheet (2). Magnesium, aluminum, or copper materials can be used as raw materials for the convector (3).

[0021] In a preferred embodiment of the invention, the panel fin sheet (2) and the converter (3) are welded together using a precision frequency-adjusted resistance welding equipped with a medium-frequency direct current transformer (MFDC transformer). The welding connection made with resistance welding equipped with an MFDC transformer is achieved thanks to welding controllers operating in the 1-10 kHz frequency range with the advantages of welding time reduced by 15% (+ / -5%), 30% (+ / - 5%) energy savings, precise adjustment (current regulation applied at 1 ms intervals), three-phase balanced loading on the grid and smart sheet thickness detection option, longer electrode grinding and replacement period.

[0022] In an embodiment of the invention, the energy density at the welding points of the convector (3) and the panel fin sheet (2) is increased. Because the diameter of the spot electrodes is relatively larger than the diameter of the laser beam used in the laser welding process, the energy density per unit area is lower in spot electrodes. By increasing the energy density per unit area using laser welding method, a more cost-effective welding connection is achieved using a 1.5 kW laser welding machine compared to 40 kW convector multi-spot welding transformers.

[0023] In the panel radiator of the invention (1), the panel fin sheet (2) and the convector (3) are preferably made of different raw materials. For example, the panel fin sheet (2) is made of steel, while the convector (3) is made of aluminum, magnesium, or copper.

[0024] Instead of AC transformers operating at 50 Hz frequency in the resistance spot welding process used in the radiator manufacturing method known state of the art, in the method of the invention, convector radiators with alternative raw materials are manufactured instead of steel-steel type radiators by welding different materials with precise adjustment with welding controllers operating in the 1-10 kHz frequency range in order to reduce costs. When joining different materials, the energy density at the joining points must be increased since their melting points and heat conduction coefficients will differ. Energy density is the amount of energy per unit volume. For this purpose, welding methods such as laser welding and precision frequency-adjusted resistance welding equipped with an MFDC transformer have been used, which increase the energy density at the welding point. Energy density at the welding points of alternative raw materials such as aluminum, magnesium, copper, etc., which have a higher heat conduction coefficient than steel, has been increased by using lower energy for the laser welding method and by passing the welding point through a smaller volume. In precision-adjusted MFDC resistance welding machines, energy density has been increased through lower energy consumption and current regulation at 1 ms intervals. This enables the manufacturing of panel radiators made from different materials, which are environmentally friendly, recyclable, and has high thermal performance compared to steel convectors, while also having the property of being lighter than steel panel radiators of the same size in the known structure.

Claims

CLAIMS1. A manufacturing method of a panel radiator (1) characterized by the steps of forming the convector (3) and the panel fin sheet (2) by means of pressing; joining the panel fin sheet (2) and the convector (3) by welding using laser welding, resistance welding, MIG-MAG welding, diffusion welding, or friction stir welding methods.

2. A method according to Claim 1, characterized in that steel, aluminum, magnesium, or copper material are used as the raw material for the panel fin sheet (2) and aluminum, magnesium, or copper material are used as the raw material for the convector (3).

3. A method according to Claim 1 or 2, characterized in that the connection made with the resistance welding is performed with welding controllers operating in the 1-10 kHz frequency range.

4. A method according to any one of the preceding claims, characterized in that the panel fin sheet (2) and the converter (3) are welded together using a precision frequency-adjusted resistance welding equipped with a mediumfrequency direct current transformer (MFDC transformer).

5. A method according to Claim 1 , characterized in that laser welding, MIG-MAG welding, diffusion welding, or friction stir welding is applied to the welding points in order to increase the energy density at the welding points of the convector (3) and panel fin sheet (2).

6. A method according to any one of Claims 1-5, characterized in that the MFDC resistance welding machines apply current regulation at 1 ms intervals.

7. A panel radiator (1) which is manufactured using a method according to any one of the preceding claims.

8. A panel radiator (1) comprising a panel fin sheet (2) made of steel, magnesium, aluminum, or copper raw material, and characterized by a convector (3) made of aluminum, magnesium, and copper raw material.

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