Modular Thermal Panel Design for Easy Repair and Expansion Control
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Solution Overview
Problem
Conventional thermal transfer systems are not compatible with pre-formed paver or slab units, require continuous monolithic mass, are difficult to repair, and suffer from inefficiencies due to linear fluid flow and expansion issues, leading to premature deterioration and leakage problems.
Innovation Solution
Modular thermal transfer panels with thermally conductive materials and channels that can be easily connected and disconnected, allowing for efficient heat transfer between a fluid and architectural tiles, and accommodating expansion and contraction, while being compatible with pavers on pedestals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If conventional continuous tubing is used for thermal transfer, then thermal energy transfer can occur, but the system cannot be easily disassembled or repaired and requires continuous monolithic mass
Solution Approach 1:
The patent divides the continuous tubing system into modular segments that can be independently installed, removed, and reconfigured. Each module contains a portion of the thermal transfer tubing embedded in or attached to a discrete mass unit (such as a paver or slab), allowing the system to be assembled from separate components rather than requiring a continuous monolithic structure.
2Productivity
If conventional smooth round tubing is used, then fluid can flow through, but thermal energy transfer efficiency is reduced due to boundary layer formation
Solution Approach 1:
The patent modifies the interior surface of the tubing to have non-uniform characteristics - specifically, the tubing includes protrusions or roughened surfaces at specific locations rather than being uniformly smooth. This creates localized turbulence in the fluid flow at key points, disrupting the boundary layer and enhancing heat transfer efficiency without requiring complete redesign of the entire tubing interior.
3Area of stationary object
If long continuous runs of tubing are used, then thermal transfer can occur over extended areas, but expansion and contraction causes ticking noises and accelerates concrete deterioration
Solution Approach 1:
The patent divides the thermal transfer system into multiple discrete modules, each covering a portion of the total area. Each module has its own separate tubing runs that are shorter in length, reducing thermal expansion and contraction issues. The modular design allows each segment to move independently without transmitting stress or noise to adjacent segments, while still achieving comprehensive area coverage when modules are installed together.
4Ease of operation
If conventional compression-type connectors are used for tube connections, then tubes can be connected, but the connectors leave marks or deformations that cause leakage upon reconnection
Solution Approach 1:
The patent employs connectors that automatically maintain their sealing function through self-adjusting mechanisms. The connector design includes features such as elastic sealing elements or self-centering mechanisms that compensate for minor misalignments or deformations, allowing the connection to self-correct and maintain reliability without requiring perfect initial alignment or causing permanent damage to the tubing.
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 modular design enables efficient thermal energy transfer, allows for easy disassembly and repair, and prevents premature deterioration of concrete slabs, while being aesthetically integrated into architectural surfaces.
Implementation Method 1
The first panel (26) is configured to abut an architectural tile (24). The plurality of channels (30) allows a heat exchange fluid to pass between the first and second panels and transfer heat to or from the architectural tile (24)
Implementation Method 2
The inlet tube (42) and the outlet tube (44) are curved in a shape so the second ends of the inlet and outlet tubes are oriented at an angle to the inlet and outlet of the plurality of channels
Data Source
AI summary
A modular thermal panel can include a heat exchanger having connected top and bottom plates with channels formed there between for receiving a heat exchange fluid. An architectural tile (e.g., a paver, stone, acoustic tile, or any other architectural element) can rest on the top of the modular thermal panel, while an insulator panel is positioned below the modular thermal panel. The heat exchanger can transfer heat between the architectural tile and the heat exchange fluid to either cool or heat the architectural panel. Additional implementations include heat transfer systems including such modular thermal panels, and methods of collecting and utilizing thermal energy using such modular thermal panels.