KIT FOR A MODULAR RADIATOR FOR FLUID CIRCULATION AND MANUFACTURING METHOD THEREOF

Abstract

 The present disclosure describes modular systems (together or a said kit) for the construction of elements which allow to radiate thermal energy through an internal water circuit or other equivalent fluid. In particular, a modular kit for fluid circulation and manufacturing method thereof is described. More particularly, the present disclosure describes a kit for a modular radiator for the circulation of fluids in additive manufacturing comprising: a plurality of Y-shaped forked parts with three ends connected by a fluid-tight channel, produced by additive manufacturing, wherein said parts are couplable to one another by said ends; and a plurality of terminals for enclosing open ends of the modular radiator parts.

Description

Technical Field

[0001] This disclosure relates to the manufacturing of modular systems, namely for the construction of planar elements (partition or structural walls) enabling thermal energy to be radiated through an internal water circuit or other fluid capable of doing so.

Background Art

[0002] Additive manufacturing technology consists of a set of technologies for the manufacturing of three-dimensional objects by layer-by-layer material overlap, as opposed to subtractive models. Objects can have any geometry and are produced from a digital model. 3D printing technology emerged in the 1980s as a rapid prototyping process. This process, as the name implies, consists in the rapid creation of a physical prototype of the final product from a digital model.

[0003] Printing makes it possible to accelerate new product development processes, reducing costs associated with errors in design and mold investments. However, as such sector evolves, 3D printing technology now enables obtaining parts that are very close to the final product, rather than mere prototypes.

[0004] In the face of this advance, the association of 3D printing with just a rapid prototyping process has become obsolete. This has meant that within the scientific community the so-called rapid prototyping is formally referred to as additive manufacturing (FA). Ceramics is a relatively new material when applied to additive manufacturing processes mediated by digital tools.

[0005] The properties of ceramic materials allow for a wide variety of applications in architecture. Its physical characteristics such as hardness, density, durability, ability to have various appearances and finishes have facilitated the application of ceramics in buildings around the world for centuries, yet all of this notorious history of building applications takes place resorting to quite simple processes for component design, usually by extrusion of material.

[0006] The integration of digital design and manufacturing processes enables the expansion of the formal, performative and functional boundaries of ceramic architectural systems. Unlike bulk manufacturing processes, ceramic additive manufacturing allows for greater freedom and formal variation without the need to change equipment configurations, build new molds or increase production times, making room for mass customization.

[0007] Additive manufacturing is based on the successive addition of material until the formation of the object. In computer-controlled additive manufacturing processes, commonly referred to as three-dimensional printing, the object takes shape from the deposition and subsequent solidification of the material in layers, where required. Such a process allows the production of geometries that are far more complex than those achieved by subtractive processes or traditional additive processes where a mold is normally required.

[0008] In the vast majority of prior art disclosures, the use of ceramic material takes place, not as the main material of the system construction, but rather as an auxiliary material for the retention and dissipation of thermal energy, given its high thermal inertia, which is exactly the opposite of what happens with the present invention.

[0009] The systems of the disclosures analyzed use the traditional construction methodology, distinguishing only by introducing a material capable of holding energy and subsequently providing a slow release.

[0010] Another prior art system describes a modular heating system capable of extracting "hot energy" from water, however in this case the protection falls on the heating system and not on the heated system (radiator).

[0011] In this sense, and due to the absence of constructive systems capable of being simultaneously a structural system (with a bearing capacity) and a performative system (capable of actively climatizing spaces), we propose the creation of a modular system that allows the connection of these two components (structure and infrastructure). The novelty of this invention lies precisely in the definition and possibility of constructing both simple and small scale elements, as well as complex and large scale elements with structural capacity, from simple components interconnected with each other.

[0012] In addition to the latter, the proposed invention stands out from existing ones by the possibility of constructing complex shapes according to the intents of the user. Being a modular system made up of small scale elements, it provides the user with a wide range of possible connections between elements without compromising the efficiency of the system, unlike other systems with the same modular construction which are limited with respect to connections and configuration that the radiation system can assume, thus compromising the efficiency of the system in particular cases.

[0013] US 20150341987 A1 describes an electric radiator with multiple heating zones.

[0014] US 20040200830 A1 describes an electric heating device that can operate at different power, modular and extensible stages.

[0015] CN 202281295U describes a combined domestic vertical heater comprising a housing and a heating tube arranged in the housing.

[0016] CN109104839 relates to a ceramic radiator and a method of manufacturing thereof, wherein the ceramic radiator comprises a sintered ceramic body molded with a powder composite material, wherein the powdered material is mixed with nitride ceramic powder and titanium metal powder.

[0017] CN109058990 discloses an external heat ceramic heat-preservation radiator.

[0018] These facts are disclosed in order to illustrate the technical problem addressed in the present disclosure.

General Description

[0019] The present disclosure describes modular systems (assemblies or a said kit) for radiating thermal energy through an internal water circuit or other equivalent fluid. In particular, a modular kit for fluid circulation, manufacturing method and uses thereof are described. In particular, the present disclosure describes a kit for a modular radiator for the circulation of fluids in additive manufacturing comprising: a plurality of Y-shaped forked parts with three ends connected by a fluid-tight channel, produced by additive manufacturing, wherein said parts are couplable to one another by said ends; and a plurality of terminals for enclosing open ends of the modular radiator parts.

[0020] One of the objectives of the present disclosure is the development of small or large scale modular systems from simple tubular elements produced by additive manufacturing capable of thermal energy radiation from the circulation of liquids within them.

[0021] The described modular system intends to bring digital design and manufacturing closer to the effective construction of architectural elements, focusing on the performance of buildings, contributing to the construction system, namely to the walls, ability to change and/or condition the surrounding environment.

[0022] To this end, the following techniques are used: a) parametric design, for the definition of the geometry of each part according to their role in the assembly, namely for the definition of the fluid circuit and the compatibility of the various dimensions of the tubular elements (taking into account the pressures exerted by the fluids on the part walls); b) additive manufacturing for the production of the elements that make up the system primarily, but not solely, in ceramic material, by the ratio of the thermal transmission coefficient to the high mechanical resistance to compressive stresses.

[0023] In one embodiment, the system comprises three diffuser elements with three distinct morphologies and a connecting part, which varies depending on the section geometry of the previous parts. Linear elements, which can vary the size in Z (up to twice the size of the division module on the Z axis), have the function of lengthening the circuit linearly, allowing the user to form varied configurations suitable for the intended purpose of the system.

[0024] In one embodiment, the channel dividers allow the division of a terminal into several outlets, for example a path and two outlets, and also the displacement of the construction in the three Cartesian dimensions, preferably having the number of outlets to a maximum of 5, considering the characteristics of the material to be used in the production (plasticity), which will influence the maximum wall angle of the parts during production. Circuit terminals have the functions of connecting to the fluid supply network and channel closure in specific situations, where it is not possible or desirable to extend the circuit. This last part provides the connection to standard elements normally used in these systems, making the connection between the established system and the system patented in this proposal, using threaded mechanical connections.

[0025] In one embodiment, the three previously designated parts have maximum and minimum dimensions. The minimum dimensions are 100 mm (Z axis) and 30 mm as minimum diameter of the section of the tubular elements perpendicular to the pipe axis. The maximum dimensions of the modules shall not exceed 400 mm on the Z axis, except for the linear element which shall not exceed twice the dimension of the channel division element on Z axis, i.e. 800 mm maximum. With respect to the X and Y axes of the channel division part, the maximum dimensions shall be based on the angle formed by the hypotenuse (center of the tubes) of the triangle drawn by the centers of the inlet, outlet and projection sections of the inlet on the XY plane, preferably in the case of ceramics not exceeding 35° with respect to the XY plane.

[0026] In one embodiment, the section of the tubular members may vary in size in response to the necessary matching of pressures exerted by the fluid throughout the modular system. In this sense, the geometry of the elements may change depending on the characteristics of the aggregation assembly, that is, so that there are no circuit constraints at certain times, such as channel divisions, the inlet section must invariably be of equal area to the sum of the base section areas (channels into which it is divided).

[0027] One aspect of the present embodiment relates to a kit or system for a modular radiator for the circulation of fluids in additive manufacturing comprising:

a plurality of Y-shaped forked parts with three ends connected by a fluid-tight channel, produced by additive manufacturing,

wherein said parts are couplable to one another by said ends; and

a plurality of terminals for enclosing open ends of the modular radiator parts.

[0028] In one embodiment, the Y-shaped forked parts may have more than three ends, for example 1 inlet and 3 outlets or 1 inlet and 4 outlets, in trident form, or for example 2 inlets and two outlets in "X" shape (equivalent to the joining of two "Y" parts at the center end thereof) and other alternatives that one skilled in the art may conceive.

[0029] In one embodiment, the "Y"-shaped forked parts are rotatably couplable to one another by said ends.

[0030] In one embodiment, the "Y"-shaped forked parts are couplable to one another by said ends,
in a continuously rotating manner, or
in a rotating manner, step by step, about a rotational symmetry axis of the ends.

[0031] In one embodiment, the kit described in the present disclosure may further comprise a plurality of rectilinear tubular shaped parts with two ends, connected through an airtight channel, produced by additive manufacturing for coupling to the forked parts, in particular for coupling to the forked parts in a rotating manner.

[0032] In one embodiment, the kit described in the present disclosure may further comprise a plurality of rectilinear tubular shaped terminal parts with a closed and rounded end, and another end for coupling to the forked parts, or where appropriate to the rectilinear tubular shaped parts, for closing open ends of the modular radiator parts.

[0033] In one embodiment, the plurality of terminal parts comprises a bore for connection to a supply network.

[0034] In one embodiment, said parts have a substantially circular cross-section or have a cross-section with rotational symmetry.

[0035] In one embodiment, the kit described in the present disclosure may further comprise a polymer sleeve for fluid-tight joining two parts together through said ends.

[0036] In one embodiment, the additive manufacturing is 3D printing, in particular liquid deposition modeling of ceramics.

[0037] In one embodiment, the parts have a minimum diameter of between 20 mm and 60 mm, preferably between 30 mm and 50 mm, more preferably 40 mm, and wherein the thickness of the part walls is between 3 mm and 8 mm, preferably between 3 mm and 5 mm, more preferably 4 mm.

[0038] In one embodiment, the finishing of the parts is in raw, glazed or with thermochromic paint.

[0039] In one embodiment, the kit described in the present disclosure may further comprise a part for the uniformity of the pressure exerted by the fluid.

[0040] Another aspect of the present embodiment relates to a method for manufacturing the kit/system described in the present embodiment which comprises the step of additive manufacturing of the parts.

[0041] In one embodiment, the additive manufacturing of parts is liquid deposition molding. Preferably, wherein the additive manufacturing is ceramic, metal or polymer additive manufacturing.

[0042] In one embodiment, although the modular system disclosed herein bases its production on the use of Liquid Deposition Modeling (LDM) technologies, mainly in ceramic material, due to the thermal inertia presented, its use is not linear in all situations, it being possible to manufacture all aforementioned parts with other materials without having to change them formally or technically. Thus, it is also possible to perform the entire system by additive manufacturing of metal or polymer, despite the fact that the latter has a mechanical response to requests quite different from the others, and its integral use in supporting elements is discarded.

[0043] In one embodiment, the system of the present embodiment may provide for the execution of hybrid solutions, with the coexistence of several materials in the same assembly, and may take advantage of the distinctive characteristics of each material based on the response to a specific problem.

[0044] In one embodiment, with respect to the geometry of each of the components, its shape is directly related to the process used in production, the additive manufacturing. Since being done by the successive addition of material, layer by layer, this has been taken into account during the design of the elements, given that for a sufficient material overlap at all times so that the integrity of the assembly is not affected, whenever there is a projection deviation (in the XY plane) from the top to the base, i.e. when the top and base of any volume are not perfectly aligned according to the Z axis, a smoothing of the generatrix is made, which defines the side surface joining the top and the base making the existing deviation to be substantially smaller, providing the part with greater carrying capacity while the material has no carrying capacity yet.

[0045] In one embodiment, the system of the present embodiment allows the construction of aggregates of quite different scales, this being dependent on the quantity and size of the elements used for the construction of the assembly. However, from the moment when the assembly assumes the large scale (agreed from 1.5 meters in height), if it is not attached to another supporting structure, acting as a supporting element, it is necessary to introduce additional levels, causing the measurement of the assembly in the direction perpendicular to the length of the plane to increase, and consequently it has a carrying capacity and responds positively to lateral demands.

[0046] In one embodiment, for the creation of these additional levels only the rotation of the channel divider elements relative to the parts to which it is connected is required. The degree of rotation of the different parts relative to the previous and subsequent parts is related to the section geometry, which may vary, although this variation may influence the thermal inertia of the elements. Although it may vary, the section governing the design of the assembly must take into account that in order for the system to function properly there must be one or more axes of symmetry in the generation of this base form. The circular section, which is illustrated in the figures accompanying this proposal, is the one that provides more possibilities for aggregation, as it is not limited to any specific angle.

[0047] In one embodiment, with respect to the connection between additively formed elements (linear, channel divisions and terminals), a thermoplastic sleeve is used to produce a structurally resistant watertight joint capable of accompanying and nullifying possible deformations coming from the additive manufacturing. The polymer joint that joins two parts is characterized by having only a change of state, which occurs soon after the material is exposed to a high temperature, i.e., reacts only once to thermal changes.

[0048] In one embodiment, the joining process comprises a joint of standard dimensions, also obtained by additive manufacturing, which will be applied to the joining of two parts of the circuit. When this element is subjected to a high temperature, there is a contraction that allows the adjustment to the shape of the parts intended to join. The sleeve tightens the parts from the inside and outside, overlapping the radiator part on both sides, this providing tightness. From the moment when the geometry changes due to the high temperature, the polymer stabilizes and remains with that geometry regardless of the thermal variations that may occur later. Although after this process the connection between elements has a good behavior towards mechanical stresses, its removal is relatively simple, it being only necessary to force the joint and then separate the radiator elements.

[0049] In one embodiment, the amount of heat that the system emanates is directly dependent on the heating system of the fluid and on the material selected for producing the assembly parts, in both cases, temperature and material, unrelated to this invention. On the other hand, the temperature range of the fluid, for the correct operation of the system taking into account the above designated material conditions, is between -10 °C and +80 °C, and for temperatures below 5 °C liquids with antifreeze characteristics should be used.

[0050] The present disclosure presupposes the creation of a modular system of planar architectural elements in ceramic material capable of radiating thermal energy through a fluid circuit that travels inside the constructed element.

[0051] In one embodiment, the system comprises the use of additive manufacturing in ceramics for the production of the three types of different tubular ceramic components required for the construction of the architectural assembly: (a) simple linear; (b) circuit dividing and (c) supply and end of network connection terminals. For the connection between the previous elements a polymeric joint is introduced.

[0052] In one embodiment, this system provides configurations from small-scale single panels solely for thermal energy radiation, to large-scale multi-plane complex constructions adding structural capacity to the assembly.

[0053] Basically, it points towards the development and execution of radiator walls constructed from the aggregation of small-scale ceramic elements.

Brief Description of the Drawings

[0054] For an easier understanding, figures are herein attached, which represent preferred embodiments which are not intended to limit the object of the present description.

Figure 1 - Plan, sectional and perspective view of the linear modular element of variable height.

Figure 2 - Plan, sectional and perspective view of the channel divider modular element. The channel divider element may distribute the circuit over two or more channels up to a maximum of 5.

Figure 3 - Plan, sectional and perspective view of the end and start circuit modular element.

Figure 4 - Section of the end-of-circuit part and connection to standard parts. The section of the terminal where the standard mains part will fit may vary in diameter.

Figure 5 - Diagram for the definition of the part wall geometry with top and base axial movements, relative to the XY Cartesian frame, promoting surface smoothing for better behavior during additive manufacturing.

Figure 6 - Two-part assembly diagram with varying connection angles. The possible angles are conditioned by the geometry of the shape generatrix section.

Figure 7 - Simple circuit diagram using all components (note - the lower and upper ends of the center ends of the forked parts are not shown).

Figure 8 - Radiator system with rotation of channel divider components.

Figure 9 - Polymer sleeve for connection of ceramic elements.

Figure 10 - Variation in the number of wall planes. The depth of the constructed assembly may vary according to user needs by successively adding simple planes.

Figure 11 - Digital template of a meeting of two wall planes formed by the system described herein.

[0055] Although the invention disclosed herein may assume various configurations, either in the aggregation of parts or in parts as a single element, the drawings presented only present one of the possible solutions for an easy understanding and exposure of the premises on which it is based.

Detailed Description of the Invention

[0056] The modular system of the present description was designed to be a modular system for the construction of elements capable of thermal radiation and can be applied in any situation as a carrying wall or only as a radiator panel.

[0057] The present disclosure therefore pertains to the field of manufacturing modular systems, notably for the construction of elements that allow thermal energy to be radiated through an internal water circuit or other equivalent fluid.

[0058] In one embodiment, the aggregation assembly (radiator) is constructed from the assembly of three types of elements, a linear element 1, a channel divider 2 and an end-of-circuit element 3.

[0059] In one embodiment, the simple linear element 1 serves to linearly connect on the Z axis through its top 4 and its base 5 to matching elements of the same section 6 through connecting parts 7 constructed of thermoplastic material. This linear element 1 can vary in size at Z 8 (Z1), from a minimum of 200 mm to a maximum value of 800 mm, twice the maximum Z-dimension of channel divider element 2, set at 400 mm.

[0060] In one embodiment, channel divider 2 divides a terminal 9 and two or more channels 10 and 11, allowing the displacement of the construction in the three Cartesian dimensions (X, Y and Z) by the angle formed by the wall of the part 12. The maximum number of divisions possible with this part is limited to five, also taking into account the plasticity of the production material which will influence the maximum angle at which components can be produced by additive manufacturing.

[0061] In one embodiment, the circuit terminals 3 have the functions of connecting to the fluid supply network and closing the channel in specific situations, namely start 13 and end 14 of circuit. This part allows the connection to standard elements 15 commonly used in this type of system through threaded mechanical connections at the top of terminal 16, where the part is purposely drilled so that the standard connection element or a closing element can be integrated, without formal changes being required.

[0062] In one embodiment, the connecting element 7 of the above-mentioned three types of parts 1, 2 and 3 consists of a polymer which when exposed to high temperatures retracts and ties the two parts 17 and 18 on both sides, inner 19 and outer 20 sides, providing a watertight and sturdy joint. This connector, also produced by additive manufacturing, preferably has the ability to change state only once, that is, only retracts after the first heating after having been formed. From that moment on the material stabilizes and ensures the firm connection of the elements.

[0063] In one embodiment, the maximum dimensions on the Z axis 21 (Z2) and 22 (Z3) of division modules 2 and terminals 3 shall not exceed 400 mm. As for the X and Y axes, the maximum dimensions shall be based on the angle formed by the hypotenuse 23 of the triangle drawn by the centers of the inlet section 24, outlet 25 and the projection of the inlet on the XY plane 26, which shall not, in the case of ceramics, be less than 55° relative to the XY plane.

[0064] In one embodiment, the dimension of the tubular element section 4, 5, 9, 10 and 11 and 27 may vary in response to the necessary matching of the pressure exerted by the circuit fluid on the part walls. In order to avoid circuit constraints at certain times, particularly with regard to channel divider elements 2, the dimension of the inlet section 9 must invariably be equal to the sum of the areas of outlet sections 10 and 11, in the illustrated case.

[0065] With respect to the geometry of each of the components their shape is directly related to the production process used for manufacturing. The use of additive manufacturing for the production of the parts being conceived, the later are formed by the successive addition of material, layer by layer. For a sufficient material overlap to be ensured at all times so that the integrity of the assembly is not affected, whenever there is a projection deviation, Figure 5, (in the XY plane) from the top 24 to the base 25, i.e. when the top 24 and base 25 of any volume are not perfectly aligned according to the Z axis, a smoothing of the generatrix 28 is made, which defines the side surface joining the top 24 and the base 25 making the existing deviation to be substantially smaller.

[0066] In one embodiment, this modular system allows the creation of quite different scale aggregations, however when it reaches dimensions greater than 1.5 meters on the Z axis it is necessary to increase the base of the wall so that it maintains responsiveness to lateral stresses as illustrated in the assembly of figure 8, element 28. For the creation of this base increase in the direction perpendicular to the wall plane it is necessary to rotate the channel divider elements 29 relative to the parts to which it is connected 30. The rotation of the above designated elements is conditioned by the section geometry of the components 4, 5, 9, 10, 11 and 27 and in the design of that section there must be one or more axes of symmetry. In the illustrated case, with a circular cross-section, any angle of rotation can be performed on the part fittings.

[0067] In a further embodiment the wall thicknesses of components 1, 2 and 3 depend on the material used for the production of these components. In the case of the use of the ceramic material the thickness of the aforementioned components is related to the Z dimension they can reach.

[0068] In one embodiment the parts with Z height alternating between 100 mm and 300 mm, the thickness of layer 31, 32 and 33 should be from 3 mm to 5 mm. For components with Z axis-related dimension between 300 mm and 400 mm the thickness of layer 31, 32 and 33 is about 5 mm to 8 mm. For components with a dimension larger than 400 mm, a condition only possible for linear element 1, the thickness of the layer is about 8 mm, and the thickness of the element to which it is attached, whether it is a channel divider 2 or a terminal 3, must match their thickness with that of the linear element 1.

[0069] The embodiments described are combinable with each other. The present invention is of course in no way restricted to the embodiments described herein and a person of ordinary skill in the art can foresee many possibilities of modifying it and replacing technical features with equivalents depending on the requirements of each situation as defined in the appended claims. The term "comprises" or "comprising" when used herein is intended to indicate the presence of the features, elements, integers, steps and components mentioned, but does not preclude the presence or addition of one or more other features, elements, integers, steps and components, or groups thereof.

Claims

1. Kit for modular radiator for fluid circulation in additive manufacturing comprising:

a plurality of Y-shaped forked parts with three ends connected by a fluid-tight channel, produced by additive manufacturing,

wherein said parts are couplable to one another by said ends; and

a plurality of terminals for enclosing open ends of the modular radiator parts.

2. Kit according to the preceding claim wherein the "Y"-shaped forked parts are rotatably couplable to one another by said ends.

3. Kit according to the preceding claim wherein the "Y"-shaped forked parts are couplable to one another, by said ends,

in a continuously rotating manner, or

in a rotating manner, step by step, about a rotational symmetry axis of the ends.

4. Kit according to any one of the preceding claims further comprising a plurality of rectilinear tubular shaped parts with two ends, connected through an airtight channel, produced by additive manufacturing, for coupling to the forked parts, in particular for coupling to the forked parts in a rotating manner.

5. Kit according to any one of the preceding claims further comprising a plurality of rectilinear tubular shaped terminal parts with a closed and rounded end, and another end for coupling to the forked parts, or where appropriate to the rectilinear tubular shaped parts, for closing open ends of the modular radiator parts.

6. Kit according to the preceding claim, wherein the plurality of terminal parts comprises a bore for connection to a supply network.

7. Kit according to any one of the preceding claims wherein said parts have a substantially circular cross-section or have a cross-section with rotational symmetry.

8. Kit according to any one of the preceding claims further comprising a polymer sleeve for fluid-tight joining two parts together through said ends.

9. Kit according to any one of the preceding claims wherein the additive manufacturing is 3D printing, in particular liquid deposition modeling of ceramics.

10. Kit according to any one of the preceding claims wherein the parts have a minimum diameter of between 20 mm and 60 mm, preferably between 30 mm and 50 mm, more preferably 40 mm, and wherein the thickness of the part walls is between 3 mm and 8 mm, preferably between 3 mm and 5 mm, more preferably 4 mm.

11. Kit according to any one of the preceding claims wherein the finishing of the parts is in raw, glazed or with thermochromic paint.

12. Kit according to any one of the preceding claims, further comprising a part for the uniformity of the pressure exerted by the fluid.

13. Method for manufacturing the kit of any one of the preceding claims comprising the step of additive manufacturing of the parts.

14. Method according to the preceding claim wherein the additive manufacturing of the parts is liquid deposition modeling.

15. Method according to claims 14 or 15, wherein the additive manufacturing is ceramic, metal or polymer additive manufacturing.

Drawing