Tube Radiator Tapered Interference Coupling Assembly
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Solution Overview
Problem
Existing tube radiators of the 'ladder' type face challenges in simplicity, speed, reliability, and service life of tube-to-rail fastening, as well as defect rates in joint areas, while requiring additional processing steps for differentiated hydraulic circuits and heat-exchange optimization.
Innovation Solution
A tube radiator design featuring extruded aluminium rails with tapered and interference zones for mechanical coupling, combined with adhesive sealing, allowing for rapid and effective assembly, reduced coupling size, and flexible production to optimize geometry and heat-exchange characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastening methods are used to ensure effective mechanical coupling and watertight seal, then reliability is improved, but assembly simplicity and speed deteriorate
Solution Approach 1:
The patent merges the mechanical coupling function and watertight sealing function into a single integrated coupling structure. The coupling comprises a receiving portion formed directly in the rail and a coupling portion on the tube that both mechanical engagement and sealing in one component, eliminating the need for separate fastening elements and sealing components.
Solution Approach 2:
The coupling structure serves multiple functions simultaneously: it provides mechanical support through the receiving portion and coupling portion, ensures watertight sealing through the sealing element, and enables thermal transfer. This multi-functional design simplifies assembly while maintaining reliability.
2Strength
If traditional fastening methods ensure effective mechanical coupling, then strength is improved, but assembly time increases
Solution Approach 1:
The receiving portion is pre-formed directly in the rail during the extrusion or forming process, and the coupling portion is pre-shaped on the tube. This preliminary preparation of the coupling interfaces eliminates the need for on-site machining or assembly of separate fastening components, significantly reducing assembly time while maintaining mechanical strength.
Solution Approach 2:
By combining the fastening mechanism and sealing element into a single integrated coupling structure, the patent reduces the number of assembly steps. The coupling portion is inserted into the receiving portion in a single action, achieving both mechanical coupling and sealing simultaneously.
3Strength
If larger couplings are used to ensure reliable connection, then mechanical resistance is improved, but coupling size increases
Solution Approach 1:
The coupling design concentrates the mechanical engagement and sealing functions in a localized region. The receiving portion and coupling portion are designed with optimized local geometry to achieve maximum mechanical resistance in the minimum space, with the sealing element concentrated at the interface where it is most effective.
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 solution enables simple, rapid, and reliable tube-to-rail fastening with improved mechanical resistance, reduced defect rates, and flexible production for differentiated hydraulic circuits, enhancing both mechanical and watertight sealing while optimizing heat exchange.
Implementation Method 1
combined with adhesive sealing
Implementation Method 2
tapered and interference zones for mechanical coupling
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A tube radiator (1) for heating comprises a pair of rails (2), provided with respective pluralities of holes (13) axially spaced apart from one another along the rails (2); and a plurality of tubes (3) positioned between the rails (2) and joined to the rails (2) at respective axial ends (21) of the tubes (3), inserted in respective holes (13); the ends (21) of the tubes (3) being fastened to the rails (2) via respective mechanical interference couplings (30); each coupling (30) is formed by a coupling portion (24) of a tube (3), at least partially tapered, and by a seat (14), formed in a hole (13) and in which the coupling portion (24) is inserted with radial interference; each coupling (30) is also sealed in a fluid- tight manner, for example by gluing.