Roll-Formed Convector Sheet with Continuous Forming Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Convector plates with suboptimal cross-sectional geometries result in insufficient convection channels, limiting energy transfer efficiency and requiring costly, time-consuming cyclical pressing processes, which also generate noise.
Innovation Solution
A convector plate design featuring two kinks in the long wall, allowing for a continuous forming process that optimizes the angle between long and short walls, reducing convection duct width and increasing channel density, enabling a higher area ratio and efficient energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cyclical pressing process is used to achieve optimal convection duct geometry, then the area ratio is optimized, but production time increases and noise is generated
Solution Approach 1:
The patent implements continuous forming instead of cyclical pressing, where the convector plate is formed in one continuous operation through a forming device with multiple forming elements. This eliminates the periodic stop-and-start nature of cyclical pressing, maintaining continuous material flow and reducing production time while achieving the same geometric optimization through the continuous arrangement of forming elements along the forming path.
2Manufacturing precision
If cyclical pressing process is used to achieve optimal convection duct geometry, then the area ratio is optimized, but noise is generated
Solution Approach 1:
By transitioning from cyclical pressing to continuous forming, the patent eliminates the periodic acceleration and deceleration cycles that generate noise. The continuous forming process maintains steady-state operation throughout, with the forming elements distributed along the continuous path creating uniform deformation without the shock loads and vibrations characteristic of cyclical pressing operations.
3Productivity
If continuous forming is used with traditional roller geometry, then production efficiency is maintained, but convection channel density is insufficient
Solution Approach 1:
The patent extends the forming concept from two-dimensional roller surfaces to three-dimensional forming elements arranged along the length of the convector plate. Multiple forming elements are positioned at different locations along the forming path, creating complex cross-sectional geometries with increased convection channel density that cannot be achieved with traditional single-plane roller forming, while maintaining continuous operation.
Solution Approach 2:
The forming device is divided into multiple discrete forming elements distributed along the forming path, each creating specific geometric features. This segmentation allows the continuous forming process to achieve complex geometries with high convection channel density by accumulating the effects of multiple forming elements acting on the material as it progresses through the forming zone.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The continuous forming process enhances energy transfer efficiency by increasing the number of convection channels while reducing production time and noise, achieving a material-saving, high-performance convector plate with improved heat absorption.
Implementation Method 1
a strip made of aluminum or an aluminum alloy can be continuously brought into a meandering cross-sectional shape by means of two interlocking rollers
Implementation Method 2
convection channels are formed between the convector sheet and the heating plate, in which heated air can rise supported by the chimney effect and thus increase the heat output of the heater
Implementation Method 3
heated air can rise supported by the chimney effect
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The convector plate made of aluminum or aluminum alloy, has a cross-sectional portion (1) having a short wall (2) and an extending wall (3). A symmetric point (10) is provided in middle of wall. Two terminals (6) are provided at ends of the wall. The extending wall is divided into two short wall sections (4) and a long wall section (5). The bending sections (7) are arranged symmetrically with respect to symmetry point.