AU2012202676A1 - A solar collector - Google Patents

Abstract

Abstract A solar collect comprises a solar absorbing tube 3 containing elongate tube I I that extends out of one end of the solar absorbing tube 3 and into an end fitting 15 wherein an annular outer 5 passageway 13 of the elongate tube 11 communicates with a cold fluid inlet conduits 16 within the end fitting 15 and the inner passageway 14 of the elongate tube I1 communicates with a hot water outlet conduit 17 within the end fitting 15. Each end fitting 15 is provided with a receiving portion 22 extending orthogonally to the tubular passage 18 for receiving an end of the concentric elongated tube 11. The end fittings 15 are interconnected to provide fluid flow 10 paths without the need for a manifold. Any number of solar collector tubes can be interconnected in this way. The invention also applies solar collectors of the heat pipe type.

Description

AUSTRALIA Patents Act COMPLETE SPECIFICATION (ORIGINAL) Class Int. Class Application Number: Lodged: Complete Specification Lodged: Accepted: Published: Priority Related Art: Name of Applicant: Kingspan Holdings (IRL) Limited Actual Inventor(s): Richard Pelan, Boris Bauer, Paul Thomas McEntee, Patrick Robert Davis Address for Service and Correspondence: PHILLIPS ORMONDE FITZPATRICK Patent and Trade Mark Attorneys 367 Collins Street Melbourne 3000 AUSTRALIA Invention Title: A SOLAR COLLECTOR Our Ref: 941139 POF Code: 323361/473033 The following statement is a full description of this invention, including the best method of performing it known to applicant(s): -1- 2 "A solar collector" This application is a divisional application claiming priority from Australian Application 2008256262 filed 30 May 2008, the disclosure of which is incorporated herein by 5 reference. Field of the Invention The invention relates to a solar collector for converting solar radiation into heat and to 10 transfer the latter with the maximum possible efficiency to a fluid heat transferring means (e.g. water or air) whereby the heat can be utilised in a domestic or industrial application, for example to heat a domestic hot water or central heating system. Background to the Invention 15 A reference herein to a patent document or other matter which is given as prior art is not to be taken as an admission that that document or matter was known or that the information it contains was part of the common general knowledge as at the priority date of any of the claims. 20 Throughout the description and claims of this specification the word "comprise" and variations of that word, such as "comprises" and "comprising", are not intended to exclude other additives, components, integers or steps. 25 A solar collector typically comprises a number of elongate tubes containing a radiation absorbing plate for absorbing solar radiation in contact with a pipe through which the fluid to be heated can be passed or within which is contained a working fluid for transferring heat to the fluid to be heated. The radiation absorbing plate and at least a portion of the pipe are enclosed within an evacuated radiation transparent enclosure to prevent heat loss. 30 In one type of solar collector, known as the direct flow type, the fluid to be heated flows through the pipe in contact with the plate for direct conduction of heat between the plate and the fluid.

3 In an alternative type of solar collector, known as the heat pipe type, the pipe forms a closed chamber and contains a working fluid, the pipe defining an evaporator section, in thermal contact with said radiation absorbing plate, and a condenser section remote from said plate, said plate and said evaporator section of said elongate tube being enclosed within the 5 evacuated radiation transparent enclosure to prevent heat loss. The condenser section is placed in thermal contact with the fluid to be heated to allow heat transfer between the working fluid and the fluid to be heated. The heat pipe type of collector utilises the phase change of the working fluid to achieve 10 greater efficiency. The energy which is required for the flow of the working fluid is provided by gravity so that no external pumping source is necessary. A known heat pipe type solar collector is disclosed in GB2103350. Both types of solar collector further comprise a heat collection manifold containing a 15 fluid to be heated and having at least one solar tube receiving aperture therein for insertion of on end of each elongate tube to enable the fluid to be heated to pass into and out of the pipe of each elongate tube, in the case of the direct flow type, or to permit heat transfer between the working fluid within the condenser section of the pipe and the fluid to be heated in the case of the heat pipe type. The manifold is typically provided with inlet and outlet connections. 20 The separate elongate tubes and the heat collection manifold of the solar collector need to be capable of being readily assembled on site and designed so that they are capable of taking up the tolerances which are usual in this field of the technology without risk of damage or leakages. In addition, it is necessary that these component parts be easily replaceable. To 25 date the traditional solar collector manifold has typically had a fixed number of receiving apertures as shown in Fig. 1. A traditional solar collector 1 comprises a manifold housing 2, a plurality of elongate tubes 3 and a support structure 4. The manifold is typically provided with an inlet port 5 and an outlet port 6 to allow the flow of the fluid to be heated. A plurality of inlet apertures 7 is also provided to allow the insertion of the elongate tubes 3 into the 30 manifold 2. The restrictive design of such traditional solar thermal collectors has limited the flexibility of the solar collector for various applications. Significant redesign of the heat collection manifold 2 is typically required in order to provide systems of variable size and energy generating capability. Traditional manifolds are fixed in their dimensions and the number of solar tubes that they can accommodate.

4 The present invention aims to address the limitations of current collector design by providing a solution that is sufficiently flexible to allow a collector to be constructed with any number of solar tubes and the size of which is not limited to the design and construction of the 5 manifold. The benefits of such an approach mean that the collector can be more accurately sized for its specific application or to fit confined or unusual spaces. 10 An additional aim of the present invention is to provide a solar collector having a high efficiency and which can be constructed cheaply, and can readily be assembled and overhauled, using less components than prior art devices. Statements of Invention 15 The present invention provides a solar collector comprising a heat pipe having a radiation absorbing means for absorbing solar radiation and an elongate tube for containing a heat transfer medium, the elongate tube having an evaporator section in thermal contact with the radiation absorbing means and a condenser section remote from the radiation absorbing 20 means, the radiation absorbing means and the evaporator section of said elongate tube being enclosed within an evacuated radiation transparent enclosure and the condenser section being located outside the transparent enclosure, and an end fitting providing fluid connection means for connecting with a corresponding end fitting of an adjacent heat pipe to permit passage of fluid between the end fittings without requiring a separate manifold, the end fitting comprising 25 an opening for reception of the condenser section of the heat pipe. In some embodiments, the end fitting is provided at one end of each elongate member. The end fitting preferably comprises a seal for sealing engaging the passageways of adjacent end fittings. More preferably, the end fitting comprises a groove or recess for receiving an 0 30 ring seal. In some embodiments, the opening to receive the condenser section extends substantially orthogonally to the fluid passageway.

5 In some embodiments, the solar collector comprises a protective casing for receiving the end fitting and an end of the solar collector tube. Preferably, the end fitting and/or the end of the solar collector tube are releasably engageable in the protective casing. In this 5 embodiment, the protective casing preferably comprises a main protector body and a closure part which is movably mounted to or removable from the main protector body. For example, the protective casing can comprise a removable end cap. Preferably, the protective casing comprises a hinged or pivotal lid part. 10 In some embodiments, the protective casing comprises a receiver for receiving a locking clip for securely mounting the solar collector tube and/or the associated end fitting in the protective housing. Preferably, the protective casing comprises a support structure. The support structure is preferably integral with the protective housing. The support structures of adjacent protective casings are preferably interlinkable. In some embodiments, adjacent 15 support structures are interlocked by an interlink component. At least part of the interlink component can be integral with the support structure. In other forms, the interlink component is separate or separable from the support structure. In a second aspect, the present invention provides a solar collector assembly 20 comprising a plurality of similar solar collectors according to the first aspect of the present invention. Brief Description of the Drawings 25 Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of a prior art solar collector; 30 Fig. 2 is an exploded perspective view of part of a solar collector according to a first embodiment of the invention with a direct-flow type of tube and an end fitting; Fig. 3 is a cross-section on the line III - III of Fig. 2 of a solar collector tube of the direct flow type; 6 Fig. 4 is a perspective view of the connected solar tube and an end fitting in a first embodiment of the invention for the direct flow type of tube; 5 Fig. 5 is a cut-away cross-sectional view of Fig. 4; Fig. 6 is a planar cross-sectional view of the connected tube of the direct flow type with the end fitting; 10 Fig. 7 is an isometric view of two of the end fittings and tubes in a first embodiment of the connection technology; Fig. 8 is a cut-away partially cross-sectional view of the end-fittings and tubes of Fig. 7; 15 Fig. 9 is a cross section of the two end fittings and tubes of Figs. 7 and 8; Fig. 10 is a perspective view of two adjacent end fittings connected together with a resilient clip in place; 20 Fig. 11 is a perspective view of a single solar collector with a first embodiment of an outer protective casing; Fig. 11 A is an enlarged view of the outer protective casing part of Fig. 11; 25 Figs. 12 to 19 are perspective views illustrating the removal of a tube from the protective casing of Fig. 11; Fig. 20 is a perspective view of a number of tubes with the connection technology of 30 the invention when combined together; Fig. 21 is a plan view of a number of tubes connected together with protective casings in place; 7 Fig. 22 is a cut-away view of two adjacent tubes connected together with protective casings in place; Fig. 23 is a cross sectional view of the assembly of Fig. 22; 5 Fig. 24 is a view similar to Fig. 21 showing the tubes disconnected from each other; Figs. 25 to 27 are perspective views of connected tubes with various brackets/mountings; 10 Fig. 28 is a cross sectional view of an assembly of several tubes and end fittings with end connectors in situ; Fig. 29 is a perspective view of a second embodiment of the invention for the heat-pipe 15 type of tube; Fig. 30 is a cross-section on the line XXX - XXX of Fig. 29 of a solar tube of the heat pipe type; 20 Fig. 31 is a perspective view of the connected solar tube and an end fitting for the heat pipe type of tube; and Fig. 32 is a cross-sectional view of Fig. 31; 25 Detailed Description As illustrated in Fig. 2 to Fig. 28 a solar collector assembly according to a first embodiment of the present invention of the direct flow type comprises a solar absorbing tube 3 comprising an evacuated radiation transparent enclosure 8 enclosing an absorbing section 9, 30 comprising a radiation absorbing plate 10 for absorbing solar radiation and an elongate tube 11, containing a working fluid (heat transfer medium), in thermal contact with said radiation absorbing plate 10. The elongate tube 11 contains a concentrically positioned inner pipe 12 thereby forming two concentric internal flow passageways 13, 14 for the flow of a fluid to be heated. The elongate tube 11 extends out of one end of the solar absorbing tube 3 and into an 8 end fitting 15 wherein an annular outer passageway 13 of the elongate tube 11 communicates with a cold fluid inlet conduit stream 16 within the end fitting 15 and the inner passageway 14 of the elongate tube 11 communicates with a hot fluid outlet conduit stream 17 within the end fitting 15. Fluid passes from the annular outer passageway 13 to the inner passageway 14 via a 5 flow path provided at a distal end of the elongate tube 11. The end fitting 15 incorporates a tubular passage 18 having a central dividing wall 19 dividing the passage 18 into said cold fluid inlet conduit 16 and said hot fluid outlet conduit 17. The tubular passage 18 extends transversely across the end fitting 15 and is open at each 10 side of the end fitting whereby a fluid can flow between the tubular passages 18 of adjacent solar tubes 3. The open ends of the passages 18 comprise recesses to provide a circumferential seat 20 for an O-ring 21 or similar sealing means to provide a fluid-tight seal when adjacent end fittings 15 are connected together. 15 Each tubular passage 18 is provided with a receiving portion 22 extending orthogonally to the tubular passage 18 for receiving an end of the concentric elongated tube 11. One or more O-ring seals 23 are located within annular seats around the periphery of the pipe for providing a seal between the end of the pipe 11 and the pipe receiving portion 22. 20 The inner pipe 12 of the concentric elongate tube 11 defining said inner passageway 14 extends beyond the outer part to extend through an aperture 24 in the dividing wall 19 of the tubular passage 18 whereby the annular outer passageway 13 of the double walled pipe communicates with one side of the tubular passage 18, defining the cold fluid inlet stream 16, and the inner passageway 14 communicates with the other side of the tubular passage 18, 25 defining the hot fluid outlet stream 17. An end region of the outer wall of the double walled pipe 11 includes a flexible section 25 in the form of a corrugated or convoluted section of tube to provide a degree of flexibility to allow for slight misalignment of the pipe and to absorb shocks or impacts. 30 The end fitting 15 may be formed from a temperature resistant polymeric material, possibly by injection moulding.

9 Figs. 7 to 9 show the connection of two end-fittings 15 connected to two solar tubes 3 of the direct flow type. The inlet flow channel 16 of one of the end fittings 15 communicates with the inlet flow channel 16 of the adjacent end fitting 15. In addition, the manner in which the outlet flow channel 17 communicates with the outlet flow channel in the adjacent end 5 fitting 15 is also shown. The flow is illustrated in Fig. 9 in which the dotted line arrow indicates hot fluid flow and the full line arrow indicates cold fluid flow. Fig. 10 illustrates one way for securing adjacent tubes 3 to one another during the installation of a collector using the current invention. A resilient clip 32 is located into two 10 channels 33 on one side of the end fitting 15 that engage with a circumferential inclusion 34 on the opposite end of an adjacent end fitting 15 to provide a secure locking mechanism to withstand the high-pressure conditions that are normal in this field. Various other connection technologies that may be utilised include a twist lock fitting where an inclusion on one end fitting 15 engages with a protrusion on an adjacent end fitting, or a clamp that engages with 15 circumferential inclusions or protrusions on opposite faces of adjacent end-fittings in order to secure the two end fittings together. In one embodiment of the invention the end fitting 15 is encased in a protective enclosure 26 as shown in Figs. 11 to 27. In a first embodiment of the protective enclosure 26 20 this consists of a main body enclosure 27 that has an integral support structure 28. Additionally the protective enclosure is provided with a removable end-cap 29 and an inlet port 30 and outlet port 31 to allow for the insertion of the end-fitting 15. A plurality of solar collector tubes incorporating the end fitting 15 and the protective enclosure 26 of the present invention are shown in Fig. 20. 25 Figs. 11 to 19 show by way of an example a schematic of a single tube of a first embodiment of the invention. When assembled the direct flow type and the heat pipe type will have the same external aesthetic appearance. The finished tube comprises an upper fitting 50, a solar tube 3 and a lower fitting 51. Preferentially both upper fitting 50 and lower fitting 51 30 are provided with channels 52 to allow for the insertion of supporting structures. Figs. 20 to 28 further show the assembly of a number of tubes using the present invention to construct a solar collector.

10 The end fitting 15 fits into a protective enclosure 26 that comprises; a main body enclosure 27 (that includes an integrated structure for supporting the tube when installed), a top cover 60 and an end-cap 29. A retaining clip 61 is provided to secure the tube into the end enclosure 26. 5 A tube 3, end fitting 15, and protective enclosure 26 are assembled as follows. Referring initially to Fig. 19 the end fitting 15 is located into position in the main body enclosure 27. The fitting 15 is inserted with the tube receiving port 22 facing upwards and sliding the end fitting 15 horizontally into position in the main body enclosure 27 (see Fig. 10 18). Once the end fitting 15 is in position it is rotated through -90 degrees (see Fig. 16) until the tube receiving port 22 is facing the tube 3. The end fitting 15 will preferentially clip / lock into position by this 90 degree rotation action during assembly in the factory. The tube is then inserted into the large open end of the main body enclosure 27 so that 15 the flexible neck / condenser of the tube fits into the end fitting 15. Once the tube is inserted it is secured in position by the retaining clip 61. The retaining clip 61 engages with a convolution of the flexible bellow either on a direct flow or heat pipe tube when it is inserted to hold it in place. Once the retaining clip 61 is secured in place the tube cannot be removed from the main body enclosure 26 as the clip 61 is secured against an internal planar face of the 20 main body enclosure thereby stopping the tube being removed. Once the tube is secured in position the top cover 60 (see Fig. 14) is put in place and pivots to a closed secure position as illustrated in Fig. 13. The top cover 60 pivots so that should a tube 3 need to be removed at a later stage the top cover 60 can pivot to an open 25 position, thereby allowing access to the retaining clip 61 (so that is can be disengaged / removed) to allow the tube 3 to be removed from the main body enclosure 26. When the top cover 60 is in a closed position as shown in Fig. 13 the end cap 29 can then be attached as illustrated in Fig. 12. The end cap 29 twist-locks into position and secures 30 the top cover 60 in its closed position. The end cap 29 can be readily removed to aid access to the internal retaining clip 61 to allow for tube removal and replacement.

11 Fig. 1 Ia shows how the finished tube would leave the factory. O-rings 21 would also be fitted in the grooves of 31 (see Fig. 9). It is also an option to ship tubes 3 pre-assembled in groups of 2 or more (ideally 5 or more). 5 Figs. 25 to 27 show how the tube may be connected together during installation as follows: Fig. 25 shows how the tubes can be twist-locked together making use of protrusions / inclusions on the end-fitting 15. A twisting through approx. 20 degrees may be used to lock 10 the tubes together. Fig. 26 shows tubes being installed onto a rail support 65. The tubes slide along the support rail and are secured together with a clip mechanism 32 as shown in Fig. 10. 15 Fig. 27 shows how the tubes can be pre-assembled and secured together either by a twist-lock securing mechanism or a clip mechanism 32 and a support rail 66 is then inserted through a passageway 67 in the support 28 for the main body enclosure 27. Fig. 20 shows a multitude of tubes connected together - the product could leave the 20 factory pre-assembled as shown in Fig. 20 or as individual tubes that are assembled on-site in this manner by the installer. Tubes can be connected together in any quantity of 2 or more. Fig. 24 show a plurality of tubes before they are connected together and Fig. 21 shows the same tubes after they are 25 connected. Fig. 28 shows the flow paths through the end fittings / tube when one or more tubes are connected. In addition, the black areas 70, 71 at either end indicates end fittings fitted to ensure that the flow characteristics are as required with only one flow channel in and one flow 30 channel out. The end fitting 70 is a male end connector and the end fitting 71 is a female end connector. The end fitting 70 leaves an inlet port 72 for inlet of cold fluid (heavy arrows) and the end fitting 71 leaves an outlet port 73 for flow of hot fluid (light arrows).

12 As illustrated in the Fig. 29 to Fig 32, a second embodiment of the invention for use with solar collectors of the heat-pipe type comprises an end fitting 15 provided with a tubular passage 18 provided with a pipe receiving portion 22 extending orthogonally to the tubular passage 18 modified for receiving the condenser 35 and the sealing plug 36 of a heat-pipe type 5 solar collector tube 3. Each heat tube solar tube 3 comprises an evacuated radiation transparent tube 8 enclosing a radiation absorbing plate 10 in thermal contact with an evaporator section 38 of a heat pipe 37, in thermal contact with said radiation absorbing plate 10. The evaporator section 10 38 is enclosed within the evacuated radiation transparent enclosure 8 to prevent heat loss. Each heat pipe solar tube 3 contains a suitable working fluid. Each heat pipe includes a condenser section 35 at a distal end of the elongate tube 3 remote from the evaporator section 37, wherein the vaporised working fluid evaporated in the 15 evaporator section 37 is condensed before draining back down into the evaporator section 37. The condenser section 35 of each heat pipe tube 3 is inserted into a receiver 22 of an end fitting 15, whereby heat transfer can take place between the condenser sections 35 of the heat pipes 3 and a heat transfer fluid (e.g. water) flowing via the flow path 18 in the end-fitting 20 15. The end fitting 15 includes inlet and outlet openings 39, 40 on either side of the end fitting 15 to allow the heat transfer fluid in the end fitting 15 to be circulated through the chambers of adjacent tubes. As shown schematically in Fig. 29 and Figs. 30 to 32, the end fitting 15 includes an 25 opening 41 to allow the condenser section 35 to enter the end fining 15 to be immersed in the fluid contained therein. An O-ring seal 36 or similar resilient sealing means is provided around an end of the heat pipe 3 to form a fluid light seal in said opening 41. Alternatively the condenser section 35 may be placed in thermal contact with a wall section of the end fitting 15. 30 The solar tubes of the heat pipe type can be mounted into protective casings and interconnected, disconnected as described above.

13 Various modifications and variations to the described embodiments of the inventions will be apparent to those skilled in the art without departing from the scope of the invention as defined in the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should 5 not be unduly limited to such specific embodiments.

Claims (20)

1. A solar collector comprising a heat pipe having a radiation absorbing means for absorbing solar radiation and an elongate tube for containing a heat transfer medium, 5 the elongate tube having an evaporator section in thermal contact with the radiation absorbing means and a condenser section remote from the radiation absorbing means, the radiation absorbing means and the evaporator section of said elongate tube being enclosed within an evacuated radiation transparent enclosure and the condenser section being located outside the transparent enclosure, and an end fitting providing fluid 10 connection means for connecting with a corresponding end fitting of an adjacent heat pipe to permit passage of fluid between the end fittings without requiring a separate manifold, the end fitting comprising an opening for reception of the condenser section of the heat pipe. 15

2. A solar collector as claimed in claim I wherein said end fitting is provided at one end of each elongate member.

3. A solar collector as claimed in claim 1 or 2 wherein the end fitting comprises a seal for sealing engaging the passageways of adjacent end fittings. 20

4. A solar collector as claimed in claim 3 wherein the end fitting comprises a groove or recess for receiving an O-ring seal.

5. A solar collector as claimed in any of claims I to 4 wherein the opening to receive the 25 condenser section extends substantially orthogonally to the fluid passageway.

6. A solar collector as claimed in any of claims 1 to 5 comprising a protective casing for receiving the end fitting and an end of the solar collector tube. 30

7. A solar collector as claimed in claim 6 wherein the end fitting and/or the end of the solar collector tube are releasably engageable in the protective casing.

8. A solar collector as claimed in claim 7 wherein the protective casing comprises a main protector body and a closure part which is movably mounted to or removable from the 35 main protector body. 15

9. A solar collector as claimed in claim 8 wherein the protective casing comprises a removable end cap.

10. A solar collector as claimed in claim 8 or 9 wherein the protective casing comprises a 5 hinged or pivotal lid part.

11. A solar collector as claimed in any of claims 6 to 10 wherein the protective casing comprises a receiver for receiving a locking clip for securely mounting the solar collector tube and/or the associated end fitting in the protective housing. 10

12. A solar collector as claimed in any of claims 6 to 11 wherein the protective casing comprises a support structure.

13. A solar collector as claimed in claim 12 wherein the support structure is integral with 15 the protective housing.

14. A solar collector as claimed in claim 12 or 13 wherein the support structures of adjacent protective casings are interlinkable. 20

15. A solar collector as claimed in claim 14 wherein adjacent support structures are interlocked by an interlink component.

16. A solar collector as claimed in claim 15 wherein at least part of the interlink component is integral with the support structure. 25

17. A solar collector as claimed in claim 15 wherein the interlink component is separate or separable from the support structure.

18. A solar collector substantially as hereinbefore described with reference to Figs. 29 to 30 32 of the accompanying drawings.

19. A solar collector assembly comprising a plurality of similar solar collectors as claimed in any preceding claim. 35

20. A solar collector assembly substantially as hereinbefore described with reference to the accompanying drawings.