Radiator Spacer Sealing for Leak-Free Collector Flow
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Solution Overview
Problem
Existing panel radiators experience significant leakage of the heating medium due to large manufacturing tolerances in the metal-forming process, leading to inefficiencies and power losses as the medium takes short-circuit paths past spacers, especially in triangular gusset cross-sections.
Innovation Solution
The introduction of a polymer sealant, which can be elastic, plastic, or a combination of both, is used to create a fluid-tight seal within the collecting channels by being fixed in the spacer or applied directly to the half-shells, ensuring that the spacer and sealant jointly block the duct cross-section, preventing medium flow and maintaining integrity at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spacers are used to direct heating medium flow in panel radiators, then flow direction control is improved, but leakage currents occur through triangular gusset cross-sections reducing efficiency
Solution Approach 1:
A polymer sealing agent is introduced as an intermediary substance between the spacer and the half-shells. This sealing agent fills the triangular gusset cross-sections and prevents leakage currents while allowing the spacer to maintain its flow direction control function. The sealing agent acts as a mediator that eliminates the harmful leakage paths without interfering with the spacer's primary function of directing heating medium flow.
Solution Approach 2:
The sealing agent changes the physical parameters of the triangular gusset cross-sections by filling them with a material that has different flow resistance properties. This parameter change transforms the open triangular sections into sealed passages, preventing leakage currents while maintaining the intended flow paths through the heating channels.
2Ease of manufacture
If large manufacturing tolerances are tolerated in metal-forming process, then production cost and complexity are reduced, but gap areas between spacer and half-shells cause unacceptable leakage flows
Solution Approach 1:
The solution employs a composite sealing system combining the rigid spacer structure with a flexible polymer sealing agent. This composite approach allows the metal half-shells to be manufactured with standard tolerances while the polymer material compensates for dimensional variations, filling gap areas and ensuring reliable sealing without requiring expensive tight-tolerance manufacturing.
Solution Approach 2:
The polymer sealing agent is applied specifically in the gap areas between the spacer and half-shells, particularly in the triangular gusset cross-sections. This localized application provides sealing precisely where needed without affecting the overall structure or requiring changes to the main manufacturing process of the half-shells.
3Ease of operation
If spacers leave free cross-sections in triangular gusset areas, then assembly is simplified, but heating medium takes short-circuit paths causing power losses
Solution Approach 1:
The polymer sealing agent serves as an intermediary that is easily applied during assembly to the triangular gusset areas. It fills the free cross-sections created by the spacer geometry without complicating the assembly process, thereby preventing short-circuit paths and the associated power losses while maintaining assembly simplicity.
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 solution ensures a leak-free flow of the heating medium, enhancing the flow characteristics and reducing power losses by effectively sealing the gaps between the spacer and the half-shells, even with manufacturing tolerances, thus providing uniform heating and extending the service life of the panel radiators.
Implementation Method 1
a polymer sealant, which can be elastic, plastic, or a combination of both, is used to create a fluid-tight seal within the collecting channels by being fixed in the spacer or applied directly to the half-shells
Implementation Method 2
The introduction of a polymer sealant, which can be elastic, plastic, or a combination of both
Implementation Method 3
The introduction of a polymer sealant, which can be elastic, plastic, or a combination of both
Data Source
Figure 1~2
Figure 3a~4b
Figure 4c~5
AI summary
The method involves fixing a distance piece (11) at main collectors (13, 15) in a region of a heating medium connection opening such that supporting surfaces of a supporting region (8) of the piece contact with inner surfaces of half shells (4). A free area of the piece is partially surrounded by the supporting regions and corresponds with the opening. The piece is fixed into the collectors using a polymer-sealant such that the piece and the sealant commonly lock the collectors in fluid-tight manner, so that flow of a heating medium in longitudinal direction of the collectors is controlled. An independent claim is also included for a plate heating body including a heating plate.