Thermal Radiator Head with Molded Threaded Openings

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Solution Overview

Problem

The production of inner threads for thermal radiator heads is expensive and requires complex machining, and existing solutions for connecting radiator modules either compromise on appearance, are difficult to implement, or unsuitable for on-site sizing.

Innovation Solution

The heads feature axially aligned circular openings with single-thread shaped peripheral edges, allowing for direct screwing of threaded tubular joints with different screwing directions and the use of threaded bushings with sealing gaskets for sealed connections, which can be molded or formed through mechanical deformation, simplifying production and enabling flexible module assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If inner threads are machined after molding the heads, then sealed connection between modules is achieved, but production cost increases and manufacturing complexity increases

Engineering Contradiction:

Improvesealed connectionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The thread profiles are incorporated into the molding cavities during head manufacturing, so the threading is formed as a preliminary action during molding rather than requiring subsequent machining operations. This eliminates post-molding thread cutting while ensuring proper thread formation for sealed connections.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical machining process for creating threads is replaced by a molding process where thread profiles are imprinted into the plastic material during injection molding. This substitution eliminates complex machining equipment and reduces manufacturing steps while maintaining thread integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If inner threads are machined after molding the heads, then sealed connection between modules is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvesealed connectionVSAvoidmachining complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The thread formation operation is merged with the head molding process itself. The molding cavities include thread profiles that directly form the threaded openings during injection molding, combining two separate operations (molding and threading) into one integrated process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Complex mechanical machining systems for cutting threads are replaced by a simpler molding process where thread profiles are imprinted into the plastic material during injection molding. This substitution eliminates the need for thread cutting equipment and operators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If threaded openings are welded to the outside of each head, then threaded connection is achieved, but appearance is compromised due to visible welds

Engineering Contradiction:

Improvethreaded connectionVSAvoidappearance

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The threaded openings are extracted from the external surface and integrated directly into the head body during molding. The thread profiles are formed within the molded plastic material itself, eliminating the need for separate welded threaded components and their associated visible weld seams.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The threaded openings are merged with the head body as an integrated component formed during injection molding. The thread profiles are imprinted into the plastic material, creating a unified structure without separate welded parts, thus maintaining aesthetic appearance.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If threaded openings are welded inside the head, then sealed connection is achieved, but welding becomes difficult to implement

Engineering Contradiction:

Improvesealed connectionVSAvoidwelding difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The welding process is replaced by injection molding where thread profiles are imprinted into the plastic material. This substitution eliminates the difficulties of internal welding (access, heat control, distortion) by using a molding process that naturally forms threads within the material during manufacturing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The thread formation is performed as a preliminary action during the molding process itself, before the heads are assembled or welded. The thread profiles are created within the molded plastic material, eliminating the need for subsequent internal welding operations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP3702717B1Head for thermal radiators and method for making the head

Publication Date: 2021.06.30 W A PROGETTAZIONI SRL

Figure 1
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Figure 3~4

AI summary

Described is a head (3) for thermal radiators, formed by a hollow body (11) which has an end cap (12) and a side wall (13), which extends from the end cap (12) and finishes with at least two tubular extensions (14) facing the end cap (12); wherein the side wall (13) is equipped with two circular openings (15) axially aligned with each other along a direction at right angles to the direction of extension of the tubular extensions (14); and wherein the circular openings (15) are made and lie on respective flat lateral faces (16), parallel to and facing each other, of the hollow body (11), and the peripheral edges (17) of the circular openings (15) are each shaped like a single thread (18) made in the thickness of the respective flat lateral face (16).