Graphite Composite Floor Panel for Gap-Free Tube Heat Transfer
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Solution Overview
Problem
Existing composite components for air conditioning devices in buildings face issues with heat transfer efficiency due to gaps between tubes and grooves, material deformation causing surface irregularities, and insufficient thermal conductivity from low-density expanded graphite.
Innovation Solution
A composite component design featuring a tube partially in a groove of a carrier plate and partially in a thermally conductive plate with expanded graphite, ensuring complete encasement and improved heat transfer through a thermally conductive layer, eliminating gaps and enhancing rigidity without needing additional frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tubes are injected directly into expanded graphite, then the installation process is simplified, but the density of expanded graphite is insufficient, resulting in poor heat transfer
Solution Approach 1:
The patent combines tubes with a composite structure consisting of multiple layers: a carrier plate with grooves, expanded graphite material filled in the grooves, and a thermally conductive plate. This composite structure achieves both easy installation and high heat transfer efficiency by integrating different materials with complementary properties.
Solution Approach 2:
The patent applies different materials and structures to different regions: the carrier plate provides structural support, the grooves concentrate the heat transfer medium, the expanded graphite fills gaps and provides thermal conduction, and the thermally conductive plate ensures efficient heat distribution. Each region is optimized for its specific function.
2Loss of energy
If expanded graphite foils are used to improve heat transfer, then thermal conductivity increases, but the foils crack due to plastic deformation and form surface bumps
Solution Approach 1:
The patent uses expanded graphite material that can deform flexibly to conform to the tube surfaces and groove geometries without cracking. The material's flexible nature allows it to adapt to surface irregularities while maintaining thermal contact, avoiding the cracking problem of rigid foils.
Solution Approach 2:
The heat transfer structure is divided into segments: the carrier plate with grooves, the expanded graphite material in the grooves, and the thermally conductive plate. This segmentation allows each component to perform its specific function optimally without the stress concentration that causes cracking in continuous foils.
3Stability of the object's composition
If tubes are completely accommodated in grooves of a carrier plate, then structural stability is improved, but gaps remain between tubes and grooves reducing heat transfer
Solution Approach 1:
The patent utilizes the porous structure of expanded graphite material to fill the gaps between tubes and grooves. The porous nature allows the material to conform to irregular surfaces and eliminate air gaps, ensuring continuous thermal contact while maintaining the structural stability provided by the groove accommodation.
4Shape
If pressing process is used to flatten heat exchanger surface, then flat surface is achieved, but material shifts cause bumps that prevent decorative panel attachment
Solution Approach 1:
The patent performs preliminary actions during assembly: the carrier plate with grooves is prepared first, then the expanded graphite material is placed in the grooves, and finally the thermally conductive plate is attached. This sequence allows the thermally conductive plate to provide a flat surface for decorative panel attachment without the material shifting problems caused by subsequent pressing operations.
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
This design significantly improves heat transfer efficiency, reduces material weight, and allows for direct attachment to walls or ceilings, providing a self-supporting and cost-effective solution for air conditioning systems.
Implementation Method 1
a thermally conductive layer (6) containing expanded graphite, which contacts at least a part of the tube surface of the tube (2), is interposed between the groove surface of the groove (5) and the tube surface of the tube (2)
Data Source
Figure 1
Figure 2
AI summary
The element (1) has a heat conducting, graphite expandate containing layer (6) contacting a part of a pipe surface of a pipe (2). A contact portion (7) is projected from a groove (5) of a support plate (4). The pipe is held with a cross-section part in the groove of the support plate and another cross-section part in another groove (9) of a graphite expandate containing heat guide plate (10). The heat guide plate is connected with the support plate. The contact portion of the graphite expandate containing, heat conducting layer contacts the heat guide plate.