AU2004213524B2 - Absorber for a thermal collector of a solar system and method for the production thereof - Google Patents

Absorber for a thermal collector of a solar system and method for the production thereof Download PDF

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Publication number
AU2004213524B2
AU2004213524B2 AU2004213524A AU2004213524A AU2004213524B2 AU 2004213524 B2 AU2004213524 B2 AU 2004213524B2 AU 2004213524 A AU2004213524 A AU 2004213524A AU 2004213524 A AU2004213524 A AU 2004213524A AU 2004213524 B2 AU2004213524 B2 AU 2004213524B2
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Australia
Prior art keywords
metal sheets
absorber
adhesive
pipe system
heat transfer
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Expired - Fee Related
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AU2004213524A
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AU2004213524A1 (en
Inventor
Frieder Flamm
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Flamm GmbH
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Flamm GmbH
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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24SSOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S10/00Solar heat collectors using working fluids
    • F24S10/50Solar heat collectors using working fluids the working fluids being conveyed between plates
    • F24S10/503Solar heat collectors using working fluids the working fluids being conveyed between plates having conduits formed by paired plates, only one of which is plane
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24SSOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S10/00Solar heat collectors using working fluids
    • F24S10/50Solar heat collectors using working fluids the working fluids being conveyed between plates
    • F24S10/504Solar heat collectors using working fluids the working fluids being conveyed between plates having conduits formed by paired non-plane plates
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24SSOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S2025/601Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by bonding, e.g. by using adhesives
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/40Solar thermal energy, e.g. solar towers
    • Y02E10/44Heat exchange systems

Abstract

The invention relates to an absorber for a solar system comprising a pipe system for the heat transfer medium, which is disposed between two superimposed metal sheets, and a method for producing said absorber. Heat exchange between the absorber metal sheets and the pipe system is improved while production costs are reduced.

Description

02100-02 kk-ds ABSORBER FOR A THERMAL COLLECTOR OF A SOLAR SYSTEM AND METHOD FOR THE PRODUCTION THEREOF The present invention relates to an absorber for a thermal collector of a solar installation having an absorber wing for light and heat conversion and a pipe system for a heat transfer medium, the pipe system being positioned between two metal sheets, which lie one on top of the other, forming the absorber wing, the shape of the pipe system being introduced into at least one of the metal sheets and the metal sheets being bonded to one another.
Absorbers are components of solar installations. Solar installations principally comprise a solar receiving surface, generally referred to as a collector, the solar loop, and the heat accumulator. The collectors are typically mounted on the roof of a house and convert the incident solar radiation into heat. Pipelines, in which a heat transfer medium, such as a water-glycol mixture, is pumped in a loop, connect the collector to the heat accumulator. The pumps are automatically switched into the solar loop via a controller when a temperature sensor signals that the temperature at the collector is higher than that in the heat accumulator. The heat of the heat transfer agent is dissipated to the accumulator water in the heat accumulator.
In the private field of use, thermal collectors are used in particular. These are collectors which absorb the incident solar radiation and convert it directly into heat. The main component of every thermal collector is the absorber. This is a metallic, dark-colored plate which is also partially made of plastic. Since the solar radiation is not transmitted by the absorber and is also hardly reflected, it is largely converted into heat which drains off via the pipe system connected to the absorber. The heat transfer agent is located in the pipe system. The absorber, with the 2 associated pipe system, is located in a weatherproof housing having a glass cover. The air layer enclosed by the glass cover of the housing and the absorber is used as *a transparent thermal insulation in the direction of the incident solar radiation. An insulating layer attached below the absorber prevents heat losses via the housing floor. The pipe system positioned below the absorber plate is typically made of a meandering, pressure-resistant copper pipe, which is connected at each end to a collection line in order to connect multiple collectors to one another.
The heat transfer between the absorber plate and the absorber pipe occurs via a linear weld seam between the top of the absorber pipe and the absorber plate. The heat transfer via the linear weld seam is not optimal. For this reason, Solvis GmbH has developed a wide soldered connection between the absorber plate and the absorber pipe that is to cause improved heat transfer. The soldered connection extends over a graduated circle on the top of the absorber pipe; the soldered connection is produced by filling up the gusset between the pipe mantle and the bottom of the absorber with solder.
In addition to the higher costs of this connection, the heat transfer between absorber plate and absorber pipe is still not optimal. In addition, the manufacturing costs of typical collectors, which are high anyway, are disadvantageous, which is largely caused by the complex absorbers.
An absorber according to the species of a solar installation having a pipe system for a heat transfer medium, in which the pipe system is positioned between two metal sheets lying one on top of another in that form the absorber, the shape of the pipe system being introduced 00 8 into one of the metal sheets and the metal sheets being bonded to one another, is known from US 4,089,324.
SDE 195 46 100 Al and US 4,299,202 disclose absorbers for a solar collector whose metal sheets lying one on top of another, which form the absorber, are glued to one s another at the contact surfaces.
C Object of the Invention Cc It is the object of the present invention to substantially overcome or ameliorate C one or more of the disadvantages of the prior art.
C Summary of the Invention The present invention provides an absorber for a thermal collector of a solar installation having an absorber wing for light and heat conversion and a pipe system for a heat transfer medium, in which the pipe system is positioned between two metal sheets lying one on top of another that form the absorber wing, the shape of the pipe system being introduced into at least one of the metal sheets and the metal sheets being bonded to one another, wherein the metal sheets are bonded to one another using an adhesive and additionally in a formfitting way using clinching.
Because the shape of the pipe system is introduced into at least one, preferably both metal sheets of the absorber wing, a significantly larger transfer area is available for the incident heat.
The joining of the metal sheets through an adhesive significantly reduces the manufacturing costs, since soldering or welding work for manufacturing the absorber may be completely dispensed with.
A1121(1424861 I)ML.W 4 The joining of the sheets by an adhesive not only results in a significant cost reduction, but rather additionally improves the dimensional accuracy of the solar collector while simultaneously reducing the reject rate. The energy use is significantly reduced in gluing in relation to the current bonding technologies.
An adhesive from the group of silicone, epoxide, or phenol resin adhesives is preferably used as the adhesive.
Thermosetting adhesives based on modified epoxide resins particularly have a high long-term resistance to changing temperatures. Furthermore, these adhesives have favorable processing conditions and strength and resistance properties for metal/metal bonds.
As already noted at the beginning, there is no circulation of the heat transfer medium in the solar loop under specific operating circumstances. In this case, temperatures of 200 'C 220 oC may occur in the absorber with appropriate solar radiation. In order to be able to compensate for strength losses of the adhesive bond occurring at these temperatures, the two metal sheets of the absorber wing are additionally bonded to one another in a formfitting way. Multiple Tox points between the metal sheets have been shown to be the preferred additional bond.
The Tox points are produced through clinching of the two metal sheets. This connection may be automated especially easily and therefore manufactured cost-effectively.
Vaporization of the heat transfer medium is particularly connected to the standstill of the normal loop. This results in elevated corrosion or oxidation on the interior walls of the pipe system if the typical water-glycol mixture is used in particular.
In order to ensure sufficient stability of the absorber, the metal sheets are provided at least in the region 5 forming the inner surfaces of the pipe system with a coating that inhibits corrosion and/or oxidation. However, the metal sheets are preferably coated completely and on both sides. Aluminum sheets are preferably anodized, while sheet steel is particularly provided with a copper or plastic coating. The coating ensures the desired longevity of the solar collectors.
A roll bond method for manufacturing evaporator plates is known from a brochure of Showa Aluminum Corporation, Osaka, Japan 1993, in which metal sheets lying one on top of another are welded to one another through hot rolling and finally cold rolled to the final thickness. The separating agent of the channel regions left out of the welding, which is applied in the screen printing method, is blown out using compressed air before the metal sheets are divided into the individual evaporator plates. This method has the disadvantage of the metal sheet thickness change during hot rolling and in the subsequent cold rolling step, since this results directly in corresponding metal sheet length changes. Problems result from this which result in a high reject rate in the following work steps. The evaporators must be manufactured from pure aluminum (Al 99.5) in order to allow the introduction of the channels.
The absorber according to the present invention does not, however, necessarily have to be made of pure aluminum and nonetheless may be manufactured easily in a large piece count. In addition, in interest of cost reduction, a method for mass production of absorbers with a low reject rate is to be suggested that requires little energy and opens up a large design freedom in regard to the design of the pipe system. These requirements are not fulfilled by the known roll bond method, so that it is less suitable for manufacturing the absorbers of collectors for solar installation.
6 According to the present invention, the metal sheets forming the absorber are bonded to one another using an adhesive. In particular, one-component or two-component adhesives are used, which are resistant to the heat transfer medium and maintain their adhesive properties at least in the temperature range between -30 °C and +200 oC.
In a preferred embodiment of the manufacturing method according to the present invention, the adhesive is not first applied after the shaping of the pipe system, but rather already to the starting material of the absorber, which is particularly strip-shaped. Strips coated in this way may be wound up like uncoated strips into a coil without sticking to one another if it is a temperaturedependent hot melt adhesive. The adhesive effect only sets in after heating to a specific temperature.
The joining of the metal sheets through an adhesive allows the use of metal sheets having the final thickness and final strength, which has advantageous effects on the dimensional accuracy of the absorber while simultaneously reducing the reject rate. The energy use is significantly reduced in gluing in relation to typical bonding technologies, such as soldering or welding. For planar application to the join surfaces, the adhesive may be rolled on using rollers or spread on using a tool similar to a doctor blade or spatula. Alternatively to the planar application, the adhesive may also be sprayed on in lines, the quantity being metered in such way that no excess adhesive penetrates into the pipe system after the joining of the metal sheets to be glued.
The shape of the pipe system is introduced through cold shaping, particularly through deep drawing or embossing, through which high cross-sectional reproduction precision and flexible arrangement of the heat transfer pipes in the metal sheets of the absorber lying one on top of another 7 may be achieved on one side, on both sides, or on alternate sides as required.
The introduction of the pipe system through deep drawing or embossing allows the use of aluminum alloys when manufacturing absorbers instead of the pure aluminum currently used. Suitable aluminum alloys are, for example, the aluminum wrought alloys cited in the following: Al Mg 3 Al Mg Si 1 or Al Cu Mg 1.
In an advantageous embodiment of the present invention, at least the areas of the metal sheets to be glued are subjected to a surface treatment. If aluminum sheets are used, an anodized coating is recommended, which is generated through anodic oxidation of the aluminum sheet.
For sheet steel, a copper or plastic coating may be applied as a corrosion protection. Additionally or alternatively, further mechanical and/or thermal surface treatments may be performed on the areas to be glued. Mechanical surface treatments brushing) remove contamination and roughen the surface, which may have advantageous effects on the strength of the adhesive bond for specific adhesives.
The thermal surface treatment degreases the surface.
The joined metal sheets, which are cut to absorber size, are additionally bonded to one another in a formfitting way. This additional bonding fixes the metal sheets until reaching a minimum hardness of the adhesive and unloads the adhesive bond during operation of the collector at high temperatures of the heat transfer medium. For this purpose, formfitting bonds active in the absorber plane are generated at multiple locations distributed uniformly on the absorber area using clinching (toxing), which maintain the fixing of the metal sheets required for the adhesive 8 curing and the stabilization of the absorber under all operating conditions. The absorbers fixed in this way may leave the press for the joining procedure again immediately and, if necessary, pass through a curing furnace or cure to the required adhesive final strength under normal ambient conditions.
Depending on the adhesive used, it may be necessary for the metal sheets mechanically fixed in this way to be additionally pressed and/or heated on one another. For this purpose the plates are laid on one another with elastic intermediate layers to form a stack in order to then cure for the required time under the pressure of a press and/or the simultaneous effect of temperature.
After completing curing, any necessary post-processing follows, such as stamping, bending, flanging, and lacquering.
A production line for manufacturing an absorber according to the present invention is illustrated in a side view and a top view in Figures la, lb. Figures 2 shows a schematic section through a collector having absorbers according to the present invention: The exemplary embodiment shows a two-train production line in which two metal sheets la, lb are processed in parallel.
The strip-shaped metal sheets la, lb, which are each uncoiled from a coil 2a, 2b, are, after straightening in a roller straightening machine 3a, 3b, fed to embossing stations 4a, 4b, which introduce the shape for the pipe system through embossing in both metal sheets. If the absorber pipes are only to be embossed on one side, one of the embossing stations 4a or 4b may be dispensed with; in this case, a flat metal sheet is joined to an embossed metal sheet.
9 The adhesive application is subsequently performed in both trains using a roller 5a, 5b positioned above the line shape in each case. Only after the adhesive is rolled on are the strip-shaped metal sheets la, lb cut to the size of the absorber 8 to be manufactured using shears 6a, 6b in cutting stations 7a, 7b.
Subsequently, the metal sheets la, lb, manufactured in the two parallel manufacturing trains and cut to the size of the absorbers, are joined in a compression mold 9 and fixed in their position to one another using clinching (toxing) in a formfitting bond 13 active in the metal sheet plane on at least two locations lla, llb.
The absorbers thus fixed leave the compression mold 9 again immediately and reach a curing station 13 in which they cure under the pressure of a press 14 and the simultaneous effect of temperature in batches up to the required adhesive final strength. Elastic intermediate layers 15 are located between the curing absorbers 8, which prevent damage of the absorber pipes embossed on both sides in the curing station 13. If the capacity of the curing station 13 may not absorb all absorbers 8 which may be manufactured from the two coils 2a, 2b, multiple curing stations may be provided to ensure a continuous production flow.
The transport of the metal sheets la, lb between the cutting stations 7a, 7b, the compression mold 9, and the curing station 13 is advantageously performed automatically, for example, using conveyor means and clocked gripping and lifting devices, which are not shown in the figures for reasons of clarity.
The schematic construction of the absorber manufactured using the manufacturing train shown in Figure 1 results from the sectional illustration of a collector shown in Figure 2.
10 The flat collector, identified as a whole with 16, comprises a weatherproof housing 17 having a glass cover 18, through which the solar radiation 19 is incident on the surface 21 of the absorber 22. The preferably dark-colored surface 21 largely converts the incident solar radiation 19 into heat, which is dissipated via the pipe system 23 integrated into the absorber 22, of which only two absorber pipes are shown in cross-section. The shape of the absorber pipes is introduced through cold shaping into the metal sheets, which are bonded to one another via an adhesive layer 25. The heat transfer medium, a frostproof waterglycol mixture, circulates in the absorber pipes.
An insulation layer 24 positioned below the absorber prevents heat losses via the floor of the housing 17, while the air layer enclosed by the glass cover 18 in the absorber 22 acts as a radiation-transparent thermal insulation on the top of the absorber.
11 List of reference numbers la,b metal sheets 2a,b coil 3a,b roller straightening machine 4a,b embossing station roller 6a,b shears 7a,b cutting stations 8 absorber 9 compression mold lla,b locations 12 formfitting bond 13 curing station 14 press elastic intermediate layer 16 flat collector 17 housing 18 glass cover 19 solar radiation 21 surface of collector 22 absorber 23 pipe system 24 insulation layer adhesive layer

Claims (20)

1. An absorber for a thermal collector of a solar installation having an absorber wing for light and heat conversion and a pipe system for a heat transfer medium, in which the pipe system is positioned between two metal sheets lying one on top of another that form the absorber wing, the shape of the pipe system being introduced into at r least one of the metal sheets and the metal sheets being bonded to one another, wherein Mc, the metal sheets are bonded to one another using an adhesive and additionally in a N formfitting way using clinching. l0
2. The absorber according to Claim 1, wherein the additional bond C between the metal sheets comprises multiple Tox points.
3. The absorber according to Claim 1 or 2, wherein the adhesive is heat- resistant and impermeable to the vapor of the heat transfer medium up to at least 200 0 C.
4. The absorber according to Claim 3, wherein the adhesive is a silicone or Is epoxide resin or phenol resin adhesive.
The absorber according to any one of Claims 1 to 4, wherein at least the regions of the metal sheets forming the interior surfaces of the pipe system are surface- treated.
6. The absorber according to Claim 5, wherein the metal sheets are provided with a coating that inhibits corrosion and/or oxidation at least in the region forming the interior surfaces of the pipe system.
7. The absorber according to any one of Claims 1 to 6, wherein the material of the metal sheets is an aluminum alloy or steel or copper.
8. The absorber according to Claim 6 or 7, wherein the aluminum sheets are anodized.
9. The absorber according to Claim 6 or 7, wherein the sheet steel is provided with a copper or plastic coating.
The absorber according to any one of Claims 1 to 9, wherein the metal sheets have a cold-formed pipe system.
11. A method for manufacturing absorbers according to any one of Claims 2 to 10 from two metal sheets lying one on top of another, the shape of the pipe system for the heat transfer medium being introduced into at least one of the metal sheets using cold forming, the two sheets being joined by an adhesive and additionally bonded to one another in a formfitting way at multiple locations using clinching. A121(1424861 I):MLW 00
12. The method for manufacturing absorbers according to Claim 11, r wherein an adhesive is used for joining which is resistant to the heat transfer medium and Smaintains its adhesive properties at least in the temperature range between -30'C and +200 0 C.
13. The method for manufacturing absorbers according to Claim 11 or 12, wherein after straightening of the metal sheets to be joined, the shape of the pipe system Sfor the heat transfer medium is introduced into at least one of the two metal sheets. c
14. The method for manufacturing absorbers according to any one of SClaims 11 to 13, wherein the shape of the pipe system for the heat transfer medium is introduced through embossing or deep drawing.
The method for manufacturing absorbers according to any one of Claims 11 to 14, wherein the metal sheets are cut to absorber size before or after the application of the adhesive.
16. The method for manufacturing absorbers according to any one of Claims 11 to 15, wherein a temperature-dependent adhesive is applied to both metal sheets, the adhesive effect of the temperature-dependent adhesive only setting in after heating to a defined temperature.
17. The method for manufacturing absorbers according to any one of Claims 11 to 16, wherein at least the areas of the metal sheets to be glued are subjected to a mechanical and/or thermal and/or chemical surface treatment.
18. A thermal collector for a solar installation having an absorber according to any one of Claims 1 to
19. An absorber substantially as described herein with reference to the accompanying drawings. 2s
20. A method for manufacturing absorbers substantially as described herein with reference to the accompanying drawings. Dated 26 September 2008 Flamm AG Patent Attorneys for the Applicant/Nominated Person SPRUSON FERGUSON AH21(1424861 ):ML\W
AU2004213524A 2003-02-19 2004-01-22 Absorber for a thermal collector of a solar system and method for the production thereof Expired - Fee Related AU2004213524B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10306930.5 2003-02-19
DE10306930A DE10306930B3 (en) 2003-02-19 2003-02-19 Absorber for a thermal collector of a solar system and method for its production
PCT/EP2004/000474 WO2004074749A1 (en) 2003-02-19 2004-01-22 Absorber for a thermal collector of a solar system and method for the production thereof

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AU2004213524B2 true AU2004213524B2 (en) 2008-11-06

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EP (1) EP1606565B1 (en)
AT (1) ATE348988T1 (en)
AU (1) AU2004213524B2 (en)
CA (1) CA2513822A1 (en)
DE (2) DE10306930B3 (en)
DK (1) DK1606565T3 (en)
ES (1) ES2278299T3 (en)
PT (1) PT1606565E (en)
WO (1) WO2004074749A1 (en)

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ES2278299T3 (en) 2007-08-01
DK1606565T3 (en) 2007-01-29
EP1606565A1 (en) 2005-12-21
CA2513822A1 (en) 2004-09-02
ATE348988T1 (en) 2007-01-15
EP1606565B1 (en) 2006-12-20
US20060137679A1 (en) 2006-06-29
PT1606565E (en) 2007-03-30
DE10306930B3 (en) 2004-10-14
WO2004074749A1 (en) 2004-09-02
AU2004213524A1 (en) 2004-09-02
DE502004002374D1 (en) 2007-02-01

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