WO2005014199A1

WO2005014199A1 - Method and machinery for manufacturing a radiator element, radiator element and radiator

Info

Publication number: WO2005014199A1
Application number: PCT/IT2003/000508
Authority: WO
Inventors: Alberto Sacristani
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-08-12
Filing date: 2003-08-12
Publication date: 2005-02-17
Anticipated expiration: 2006-02-12
Also published as: WO2005014199A8; EP1654081A1; AU2003264867A1

Abstract

The present invention relates to a method for realizing a radiator element (1) comprising: a first plastic deformation of the ends of a pipe, do as to obtain a shoulder on each end; the introduction of the ends of said pipe (2) into special holes obtained into the wall of a manifold, holes exhibiting an abutment complimentary to the shoulder; a second plastic deformation of the pipe end, do as to obtain the mechanical locking of the pipe itself relative to the manifold (3). The invention also relates to the machinery for performing the described method, the resulting radiator element and the radiator.

Description

DESCRIPTION "METHOD AND MACHINERY FOR MANUFACTURING A RADIATOR ELEMENT, RADIATOR ELEMENT AND RADIATOR" [0001] . The present invention relates to a method and machinery for manufacturing a radiant element for a hydraulic system, such as a towel warmer or a radiator of a hot water circulation heating system. The present invention also relates to the radiator obtained by such method. [0002] . To the purpose of simplifying the description of the present finding, in the following description reference shall be made to the radiator of a hot water circulation heating system. [0003] . As known, radiant elements of a hydraulic system often consist of a top tubular manifold, of a similar bottom tubular manifold, and of a plurality of pipes connecting the two manifolds. The two manifolds often consist of modular elements connectable to one another and/or to the central system. It is therefore possible to realise radiant elements of different sizes according to the requirements to obtain, for example, the effect of heating a room by hot water circulation. [0004] . To realise this type of known radiator, side holes are made on each element of the two manifolds to connect them to the adjacent elements, then further holes are made and calibrated on the diameter of the pipes connecting the top manifold with the bottom one. Once the manifold elements are ready and the pipes have been cut to the desired length, the connection is made by welding. This type of connection exhibits the advantage of being watertight and resistant to the stresses arising from the system supply pressure, which may also be very high.

[0005] . The welding connection of the radiator components, however, implies a series of disadvantages during production. In the first place, the calibration of the holes on the manifolds, based on the diameter of the connection pipes, the cut of pieces of such connection pipes, and the setup of the surfaces onto which the welding seam is to be applied, must be very accurate operations to allow a good welding. This should be added to the fact that despite a careful setup, the welding quality is not always satisfactory from a structural, functional and/or aesthetic point of view.

[0006] . The problem at the basis of the present invention is that of devising and implementing a method and a machinery for realising a radiator, which should allow overcoming the disadvantages mentioned above with reference to the prior art . Another problem at the basis of the invention is that of realising a radiator which should exhibit such structural and functional features as to meet the above requirements .

[0007] . Such problems are solved by a method for realising a radiator according to claim 1, by a machinery for realising a radiator according to claim Y, by a radiator element according to claim Z and by a radiator according to claim X.

[0008] . Further features and advantages of the method and device according to the invention will appear more clearly from the following description of some preferred indicative and non-limiting examples of embodiments, with reference to the attached figures, wherein:

[0009] . Figure 1 is a partly cutaway side view of a first embodiment of the radiator element according to the invention;

[0010] . Figure 2 is a partly cutaway exploded side view of a detail of the radiator element of figure 1 ; [0011] . Figure 3 shows a detail of the cutaway view along the plane III-III of figure 1; [0012] . Figure 4 is view similar to that of figure 2 of a second embodiment of the radiator according to the invention; [0013] . Figure 5 shows a block diagram of the method and machinery according to the invention.

[0014] . With reference to the attached figures, in particular to figure 5, the method and the machinery for obtaining the radiator element according to the invention, globally indicated with reference numeral 1, will be described hereinafter. Such radiator element 1 comprises at least one connecting pipe 2 and two manifold elements 3, a top and a bottom one. Of such manifold elements 3, the attached figures only show the top one since the bottom one does not exhibit different structural features.

[0015] . As said, at least one connecting pipe 2 must always be provided in each element, but in other preferred embodiments there are two, three or more connecting pipes. The man skilled in the art will choose in each case the number of connecting pipes 2 to be arranged into each element 1 according to the specific requirements, without departing from the scope of the present invention. [0016] . In the first station, raw pipes are loaded and selected according to the project specifications, whereas at the following station, the raw pipes are cut to the desired length to obtain the connecting pipes 2. It should be noted that, here and hereinafter, the single station especially refers to a logical machining step, a step that in the practice can be performed by a single machine or by more machines, if required. On the other hand, it is potentially possible to perform more, logically different steps, with the same machine. [0017] . At the next station, the ends of the connecting pipe 2 are subject to a first plastic deformation, after which a diameter variation 21 occurs in the proximity of the ends 23 of the connecting pipe 2. The diameter variation of figure 1 is a necking down extending to the entire end section, whereas the diameter variation of figure 4 is a localised cross bead. Both variations are obtained by plastic deformation of pipe 2 and are aimed at creating a shoulder 21. [0018] . Preferably, this station can be followed by another optional one, wherein a sealing member 20 is fitted on the end of the connecting pipe 2. In the preferred embodiment of figure 1, the sealing member consists of a common O-ring. The optional sealing member 20 can be made of any suitable material. In the preferred embodiment, it is made of a silicone- based elastomeric material, but it could be made of other elastomeric materials, or of any other suitable material .

[0019] . At a next station, two manifold elements 3 are supplied, preferably picking them from a store of pieces produced beforehand. Of course, the production line of said manifold elements 3 could even merge here, without any passage by the store being needed.

[0020] . The manifold element 3 can be obtained by casting or by any other suitable method. In a preferred embodiment, the manifold element 3 is obtained by high-pressure die casting.

[0021] . The manifold element 3 comprises a box body opened on one side. On two side walls of the box body, adjacent the open side and opposed to one another, there are obtained two side holes 34, whereas a plurality of holes 32 is obtained on the wall opposed the open side. Holes 34 are realised on the element for obtaining, in an in se known way, a structural and functional connection with other adjacent elements, so as to form a radiator. On the other hand, holes 32 are realised for receiving pipes 2, and they exhibit an abutment 30 complementary to shoulder 21. [0022] . At a further station, the connecting pipes 2 are assembled with the manifold element 3. Once inserted into hole 32, the end 23 of the connecting pipe 2 is reached by a punch through the open side of the box body. The punch obtains a second plastic deformation of end 23 of the connecting pipe 2, such second plastic deformation can be a flanging, as seen in figure 2 , or a bead similar to that obtained by the first plastic deformation of figure . In this way it is possible to obtain the mechanical locking of the connecting pipe 2 relative to the manifold element .

[0023] . At this point it is possible to provide for an optional painting station, where the unfinished radiator elements are painted, along with the relevant covers 36. [0024] . At the final station, the elements are completed by closing the box bodies of the manifold elements 3 with their covers 36. Such covers can be attached by bolts 37 or by any other known removable constraint, and if deemed appropriate, they can also comprise a sealing gasket 35. [0025] . The method and the machinery for obtaining a radiator element 1 according to the invention has been described. The structural and functional connection of a plurality of radiator elements 1 produces a radiator according to the invention. [0026] . The man skilled in the art will immediately understand how such method allows obtaining a radiator (or its elements) fully meeting the necessary structural, functional and aesthetic requirements. Such method also allows obtaining considerable advantages compared to the known embodiments, since no welding is used. In this way, there is no stringent need for a coupling tolerance check. In particular, thanks to the locking by plastic deformation of the end of pipe 23, the key coupling, that between the connecting pipe 2 and the manifold element 3, does not require a stringent tolerance check. A 1 mm clearance could also exist between hole 32 and the end of pipe 23, before the second plastic deformation of the latter. In this way the manifold element 2, which as described above is preferably obtained by high-pressure die casting, needs no further machining. A significant reduction of the cost for setting the piece up is therefore obtained, and this positively affects the cost of the entire radiator. By known even though recent high- pressure die casting methods it is possible to obtain hole 34 already provided with the threading required for the attachment to the adjacent element. In this way, the reduction of the machining required for the manifold element 3 is even more considerable. [0027] . While the manifold element 3 and the relevant cover 36 are preferably made of an aluminium alloy, the connecting pipe 2 could advantageously be made of iron or low-carbon percentage steel . The expert designer can choose different materials as needed, without departing from the scope of the invention. [0028] . As the man skilled in the art has certainly understood, seals 20 and 35 help to ensure the seal and therefore the functionality of the radiator element 1. The sealing member 20, in particular, remains permanently seated between shoulder 21 and abutment 30, even during the painting step. This step implies relatively high temperatures (about 200°C) and it is therefore necessary to choose a material for the sealing member 20 which should be capable of standing such temperatures. Should the man skilled in the art deem it appropriate, it is noted that the silicone-based elastomeric materials can stand temperatures as high as 300°C.

[0029] . As it can be noted from what described above, the method and the machinery for realising a radiator element, as well as the radiator element and the radiator itself, according to the invention, allow meeting the above requirements while at the same time obviating the disadvantages mentioned in the introduction to the description.

Claims

1. Method for realising a radiator element, comprising the steps of : selecting the raw pipes according to the project specifications; cutting said raw pipes to the desired length for obtaining at least one connecting pipe 2 ; first plastic deformation of the ends 23 of said connecting pipe 2 so as to obtain a shoulder 21 on each of said ends; - provision of two manifold elements 3 consisting of a box body opened on one side and comprising: a side hole 34 on each of two side walls of said box body, said side walls being adjacent the open side and opposed to one another; at least one hole 32 on the wall opposed the open side, said at least one hole 32 exhibiting an abutment 30 complementary to said shoulder 21; introducing said ends 23 of said connecting pipe 2 into said holes 32; second plastic deformation of said end 23 so as to obtain the mechanical locking of said connecting pipe 2 relative to said manifold elements 3 ; closing said box bodies of said manifold elements 3 by special covers 36.

2. Method according to claim 1, further comprising a step of introduction of sealing members 20 onto said ends 23 of said connecting pipe 2 before the step of introduction of said ends 23 into said holes 32.

3. Method according to claim 1, further comprising a step of painting said connecting pipe 2, said manifold elements 3 and said covers 36 before the step of closing said box bodies of said manifold elements 3 by said covers 36.

4. Machinery for realising a radiator element, comprising the stations for: selecting the raw pipes according to the project specifications; cutting said raw pipes to the desired length for obtaining at least one connecting pipe 2 ; first plastic deformation of the ends 23 of said connecting pipe 2 so as to obtain a shoulder 21 on each of said ends; - provision of two manifold elements 3 consisting of a box body opened on one side and comprising: a side hole 34 on each of two side walls of said box body, said side walls being adjacent the open side and opposed to one another; at least one hole 32 on the wall opposed the open side, said at least one hole 32 exhibiting an abutment 30 complementary to said shoulder 21; introducing said ends 23 of said connecting pipe 2 into said holes 32; second plastic deformation of said end 23 so as to obtain the mechanical locking of said connecting pipe 2 relative to said manifold elements 3 ; - closing said box bodies of said manifold elements 3 by special covers 36.

5. Machinery according to claim 4, further comprising a station of introduction of sealing members 20 onto said ends 23 of said connecting pipe 2 before the station of introduction of said ends 23 into said holes 32.

6. Method according to claim 4, further comprising a station for painting said connecting pipe 2, said manifold elements 3 and said covers 36 before the station for closing said box bodies of said manifold elements 3 by said covers 36.

7. Radiator element comprising: two manifold elements 3, each consisting of a box body comprising a side hole 34 on each of two side walls of said box body, said side walls being opposed to one another, and at least one hole 32 on a wall adjacent said side walls; and at least one connecting pipe 2 ; characterised in that each end 23 of said connecting pipe 2 comprises a shoulder 21 obtained by a first plastic deformation; said box bodies exhibit a side consisting of a cover 36, said side being adjacent said side walls and opposed said hole 32; said hole 32 exhibits an abutment 30 complementary to said shoulder 21; each end 23 of said connecting pipe 2 is inserted into one of said holes 32 and is mechanically locked into said manifold element 3 by a second plastic deformation.

8. Radiator element according to claim 7, characterised in that it further comprises sealing members 20 arranged between each shoulder 21 and each abutment 30.

9. Radiator element according to claim 7, characterised in that it is painted.

10. Radiator comprising at least one radiator element according to claim 7, 8 or 9.

11. Invention according to claim 1, 4, 7 or 10, characterised in that said first plastic deformation causes a section variation adapted for creating a shoulder 21.

12. Invention according to claim 11, characterised in that said diameter variation is a necking down extending to the entire end of pipe 2.

13. Invention according to claim 11, characterised in that said diameter variation is a localized cross bead.

14. Invention according to claim 2, 5, 8 or 10, characterised in that said sealing member 20 is made of an elastomeric material .

15. Invention according to claim 14, characterised in that said sealing member 20 is made of a silicone-based elastomeric material .

16. Invention according to claim 1, 4, 7 or 10, characterised in that said manifold element 3 is obtained by high-pressure die casting.

17. Invention according to claim 1, 4, 7 or 10, characterised in that said manifold element 3 and said cove 36 are made of an aluminium alloy.

18. Invention according to claim 1, 4, 7 or 10, characterised in that said connecting pipe 2 is made of iron.

19. Invention according to claim 1, 4, 7 or 10, characterised in that said connecting pipe 2 is made of low carbon percentage steel .

20. Invention according to claim 1, 4, 7 or 10, characterised in that said second plastic deformation is a flanging.

21. Invention according to claim 1, 4, 7 or 10, characterised in that said second plastic deformation is a bead.

22. Invention according to claim 1, 4, 7 or 10, characterised in that said cover 36 is attached by removable constraints .

23. Invention according to claim 22, characterised in that said removable constraints comprise bolts.

24. Invention according to claim 1, 4, 7 or 10, characterised in that said cover 36 comprises a sealing gasket .