CA1105339A - Solar energy collector - Google Patents
Solar energy collectorInfo
- Publication number
- CA1105339A CA1105339A CA288,358A CA288358A CA1105339A CA 1105339 A CA1105339 A CA 1105339A CA 288358 A CA288358 A CA 288358A CA 1105339 A CA1105339 A CA 1105339A
- Authority
- CA
- Canada
- Prior art keywords
- panel structure
- wall sections
- pair
- radiant energy
- multiplicity
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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- Laminated Bodies (AREA)
Abstract
A solar energy collector made up of laminated plastic sheet structure either in relatively rigid panel form or relatively flexible rolled mat form, the laminated sheet structure including a base layer providing a multiplicity of cooperating pairs of angularly related opaque walls, each cooperating pair of opaque walls diverging outwardly with respect to one another and defining an elongated channel of generally V-shaped cross-sectional configuration, all of the opaque walls defining a multiplicity of elongated channels disposed in generally parallel relation and a surface area greatly in excess of the area of the operative side of the laminated sheet structure, and a plurality of layers of transparent sheet material providing a plurality of transparent wall sections associated with each cooperating pair of opaque walls, the transparent wall sections associated with each cooperating pair of opaque walls including an inner transparent wall section extending between the pair of opaque walls sealingly enclosing the channel defined thereby, the transparent wall sections associated with each cooperating pair of opaque walls also defining an inner and outer insulating air space between the associated enclosed channel and the operative side of the laminated structure.
Description
~1~5339 . _ , ' ~ ' ' , `
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~. This invention relates to solar energy and j:: . more particularly to improved structure for collecting solar energy.
The capability o~ utilizi~g the energy which S comes from the sun.has received widespread attention in ~.
rece~t months, particularly since the now well-known n: "energy crisis". The basic prir.ciples of solar energy collection are known and there have been proposed many 1.;
` : ~:. different arrangements for accomplishing this basic purpose. ~7hile the need to utilize solar energy clearly . ... .. . . .
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~1~15;~39 - exists and the basic principles by which solar energy can be utilized are known, the actual utilization is minimal. The most common explanation is that while known solar energy collectors work and have the capability to efficiently operate in a very economical and highly favorable ecological manner, the initial costs are said to be prohibitive. The still existing need is for an effective collector which can be produced on a large scale basis at greatly reduced costs compared with those o~ known constructions.
- An object of the present invention is to provide a solar energy collector which will meet the above noted needs. In accordance with the principles of the present invention this objective is obtained by providing a solar energy collector which i5 of laminated sheet structure, the various layers of the laminated sheet structure being ~abricated by molding or extruding plastic material and effecting a simple assemblage thereof which is effective in operation.
Another object of the present invention is to provide a solar powered water or air heater which can be readily and easily recycled with minimum labor and energy consumption for purposes of materials conservation.
` Another object of the present invention is to -_`~ 25 provide a solar powered water or air heater which can be , .
. . ~.-: .:
shipped, stored,,and placed in seryLce with min~mum packaging and handling expense'xe~ultin~ in lo~'~nst~lled costs.
Another obj'ect o~ the'present ~n~ention concerns design fea`tures ahle'to regulate'the'internal system temper-ature thus preventing materials degradation in cas-e of fluid circulaton failure.
A further object of the present invention is to ` provide a solar powered air or water heater which collects '. more radiation than it emits by control of internal surface orientations.
Yet another object of this invention is to provide ;, a solar powered air or water heater which efficiently collects nearly all incident wave lengths and emits only a small amount of radiation by control of internal surface properties. ' t In accordance with one broad aspect, the invention relates to a radiant energy heat exchanger comprising:
a panel structure having sides of substantial area ', bounded by a thin periphery including opposed peripheral end '' portions, one of said sides being operable to face in a direction to receive radiant energy with the other side facing in opposed relation to said opera~le side, said panel structure including a base defining the other side of said panel structure and having a multiplicity of transversely spaced barrier walls extending longitudinally between the end portions of said panel structure, each of said barrier walls including outer portions disposed outwardly in a direction toward the operable side of said panel structure and extending longitudinally between the end portions thereof, adjacent pairs of barrier walls defining in said base a multiplicity of side-by-side ~r .
ll~S339 .
channels extending lon~itudinally between the'end portions of said p~neI structure,' an inner' sheet':~brm wall section sea'lin~l~ connected with each pai~ of ad~acent ~arrier walls at positions along the outer porti`ons thereof and extending transversely across the associated pair of adjacent ~arrier walls and longitudinally between the end portions of said panel structure so as to enclose the associated channel and thereby provide a plurality of inner fluid containing channel spaces extending longitu-dinally between the end portions of said panel structure, an outer sheet form wall section sealingly connected with each pair of adjacent barrier walls at positions along the outer portions thereof and extending transversely across r the associated pair of adjacent barrier walls outwardly of the associated inner wall and section longitudinally between the end portions of said panel structure, the exterior surfaces of said outer wall sections defining coextensive areas of the operable side of said panel structure, an intermediate sheet form wall section sealingly connected with each pair of adjacent barrier walls at positions along the outer portions thereof and extending across the associated pair of adjacent barrier walls between the associated inner and outer wall sections and longitudinally between the end portions of said panel structure so as to define a multiplicity of outer and intermediate fluid con-taining spaces in outwardly disposed relation with respect to said multiplicity of inner fluid containing channel spaces, said sheet form wall sections being constructed to ~acilitate the passage of radiant energy inwardly there-through so that a ~low of fluid directed through said inner - 4a -.,.
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fluid containing channel spaces from a position adjacent one end portion of said paneI structure to a position adjacent the other end portl'on o~ said paneL structure will result ~n radiant energy being received by the fluid flow only after such radiant ener~y passes inwardly through said sheet form wall secti~ons and said outer fluid containing spaces, said base being constructed to retard the passage of radiant energy therethrough.
TXese and other objects of the present invention will become more apparent during the course of the following :~ -detailed description and appended claims.
The invention may best be understood with reference to the accompanying drawings, wherein an illustrative embodiment is shown.
In the drawings:
Figure 1 is a front elevational view of one form of a solar energy collector embodying the principles of the present invention;
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-` 111~5339 , Figure 2 lS an enlarged, fragmentary sectional view taken along the line 2-2 of Figure l;
Figure 3 is a fragmentary sectional view taken along the,line 3-3 of Figure l;
Figure 4 is an enlarged fragmentary sectional ,, view taken along the line 4-4 of Fi~ure l;
Flgure 5 is a fragmentary front elevational view , of another form of solar energy collector embodying the principles of the present invention;
Figure 6 is an enlarged fragmentary sectional - - view taken along the line 6-6 of Fi~ure 5;
~, Figure 7 is a view simila~r to Figure 6 showing i the manner in which the collector i~ rolled up for transportation and storage;
Figure 8 is a view simila,r to Figure 6 illustrating the component parts of the collecto,F shown in Figure 5 i~ in a position which they may assume during assembly; and Flgure 9 is a fragmentary sectional view illus-trating one configuration for manifl?lding the collector shown in Figure S.
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11(~`53~9 --~ Referring now more particularly to Figures 1-4 of the drawings, there is shown therein a panel form of a solar energy collector, generally indicated at 10, embody-ing the principles of the present invention. The solar energy cpllector panel L0 is formed essentially of laminated sheet structure from relatively inexpensive moldable plastic materials. As best shown in Figure 2, the laminated sheet structure of the collector 10 has a relatively rigid panel form providing an operative side of substantial area to be mounted in a position to receive the solar energy and an opposite coextensive side which may be regarded as a mounting side, both sides being bounded by a relatively thin periphery.
In the preferred embodiment shown the mounting side of the collector panel 10 is provided by a base layer 12, which may be regarded as a relatively thick sheet formation, preferably made from a suitable foamed plastic materlal, such as urethane, styrene or urea formaldehyde.
The base layer 12 is thus characterized by lightness of weight and rigidity. Moreover, by utilizing injection molding techniques to form the base layer 12 of foamed plastic material, the base layer 12 may be conveniently formed with configurations embodying the principles of the ~ present invention. As best shown, one side 14 of the base G 25 layer 12 is planar and this side defines the mounting side f'~~ of the collector panel 10. The opposite side of the base .
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~1~`5~39 ~2 _ layer 12 is formed with a multiplicity of cooperating pairs of angularly related inclined surfaces 1~, each pair of surfaces 16 diverging outwardly with respect to one another in a direction away from the planar side 14 to cooperatively define an elongated channel shape.
While it is within the contemplation of the present invention that the surfaces 16 of the foamed plastic of the base layer 12 provide both the heat retention function of the opaque walls and the fluid impervious function of fluid passages, it is preferred to adhere a barrier film 18 to these surfaces to pro-vide both functions. Desirably, the film 18 is initially vacuum formed and then held against the upper surface form of the mold as the plastic foam is added during the molding of the base layer 12. The ilm 18 is opaque and may be of any desired color. Suit-able plastic materials for the film 18 include polycarbonates,acrylics, polyvinyl chlorides, polyvinyl fluoride, rubber com-pounds, etc. It will also be understood that the barrier film 18 may provide only the fluid impervious function in which case a sprayed-on coating or integral skin may provide the opaque function.
The sheet formation of the collector panel is completed by the provisions of three transparent plastic sheets 20, 22 and 24 mounted over the base layer 12 and barrier \ \ film 18.
The lower film sheet 20 is bonded on the upper ~ .
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11(~5339 ridge portions of the walls provided by barrier film 18 in the configuration shown in Figure 2 to extend across each channel and define with the remaining unbonded portions of the barrier wall a closed fluid conveying channel 26.
Film 20 is bonded on the upper ridges of barrier layer 18 in any suitable-manner, such as by heat welding, solvent welding, or adhesive bonding techniques. A pre-ferred manner is to utilize the heat available from channel molds which hold film 18 to soften film 20 suffi-_ ciently to produce welding to barrier film 18 when the surfaces are joined under mold pressure. Sheets 22 and 24 are bonded along strips or lines at the ridge peaks in a similar manner. The lower surface of the sheet 22 extend-ing between each pair of adjacent peaks defines with the coextensive upper surface of the sheet 20 a lower insulating air space 28. Likewise, the upper surface portions of the sheet 22 define upper insulating air spaces 30 with the coextensive lower surface portions of the sheet 24. Sheet 22 is intentionally formed to the bridged surface shown, as is film sheet 20 for purposes of allowing for uneven expansion and contraction of the various members in response to climateological and application conditions. Upper sheet 24 is somewhat thicker than films 18, 20 and 22, and _ 25 is selected to offer protection from projectiles, hail, and r .
llC~S339 , ~ , other hazards, in addition to confining insulating air . ~ within space 30.
The collector panel 10 is preferably made to be a self-contained unit by manifolding the ends of the channels. 26 and the air spaces 28 and 30. This may be`
accomplished in any desired fashion, however a preferred mode, as illustrated in the drawings, embodies the provision of a tapered manifold trough surface at each end of the base layer 12 which is covered with the barrier film 18 to form a ta2ered manifold trough 32 . communicating with the associated end o, the channels 26.
Communication with each manifold trough 32 exteriorly of the panel 10 is provided by any suitable means, such as a plastic pipe section 34 which is either mounted within cavities molded in the base layer or provided in situ at the time the base layer is molded.
Any portion of the film 18 covering the adjacent end of each pipe 34 during assembly is simply cut away.
Each manifold trough 32 is preferably enclosed and sealed about the associated pipe 34 by means of the adjacent portions of the three sheets 20, 22 and 24. As best shown in Figure 4, the portions~ofthe sheets 20, 22 and 24 which overlie each manifold trough 32 are spaced -~ apart from each other and remain unsecured. The end _ 25 portions of the three sheets 20, 22 and 24 which overlie ~ .
, the end wall of the base layer 12 defining the associated 1~5~39 ; ~ manifold trough 32 are secured together in sealed relation.
and to the upper surface of the base layer. In this way, the portions of the sheets 20 and 22 overlying each manifold _ough 32 define a manifold space for the adjacent ends of . ~ the lower air~spaces 28, while the portions of the sheets 22 and 24 overlying each manifold trough define a manifold space for the adjacent ends of the upper air spaces 30.
Prevention against over-heating due to insufficient heat removal rates is an important consideration in instances where failure of the fl~id circulation system would allow ~ - system temperatures to exceed material or fabrication limits. Most applications involve placins the collector panels 10 on somewhat inclined surfaces. This facilitates gatherins maximum amounts of solar enersy, draining the system for cleaning and freeze protection, and for draining surface moisture following snow or rain showers. Pressure and temperature control for the air spaces 28 and 30 can he provided by the use o conventional valving illustrated : schematically in Figure 1 of the drawings at 36 and 38. In the schematic arrangement shown, an openins (not shown) is formed in the portion o the intermediate sheet 22 overlying the manifold trough and underlying the valve 36 so as to .
communicate the manifold spaces of both air spaces 28 and 30. It will be understood that the manifolds for the _ 25 air spaces 28 and 30 may be maintained separate and provided . ' ' .
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ll~S339 ~ ...................................................................... , with separate valves, if desired. Buoyant forces result-ing from heating air masses between the transparent films result in mass flow of the heated air out valve 36 as illustrated in Figure 1 when such valve is open. Control S of valve,36 can be provided by constructing the valve of .. ~, .
materials which have high thermal,expansion coefficients resulting in automatic opening at predetermined temperatures.
Another type of automatic control is to operate valve 36 ~- by solenoids and provide normally - c~losed - power - on functions with valve opening to occur in case of power _ failure or any other failure resulting in deficient fluid flow. The specific construction of valves operated by '~ material expansion-contraction forces or solenoids is well-known, and need not be further discussed in this dis-closure. Providing valves 38 at lower extremities to allow cool air to replace hot air passing through valve 36 thus enables maintenance of the system within design temper-ature. In areas where airborne dust prevails, filter strips over the vent valve inlet areas may be required to prevent build-up of dust on internal surfaces.
It will be understood that collector panels 10 in the unitized form described above are arranged to be installed with procedures normally utilized in installing `'- other types of wall or roofing panels with appropriate con-- 25 nections to the pipes 34 of the panels. Normally, the , ~; .
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ll~S339 ~- - panels lO will be regarded as add-on panels rather than panels which also serve as the exterior protective paneling as well. ~evertheless, such dual functioning is contemplated although other embodiments of the present invention herein-after described are preferred in such dual functioning situations~ Factory assembled panels including layers 12, 18, 20 and 22 may be utilized as a combination collector and membrane roof surface with a sheet 24 applied as a con-tinuous glazing for exclusion of water. Characteristic lG materials selection for the sheets or 'ilms 20, 22 and 24 _ are the same as those of film 18, namely, polycarbonates, acrylic, polyv1nyl chloride, polyvinyl fluoride, and rubber compounds.
Referring now more particularly to Figures 5-9, there is shown therein a second embodiment of the present invention which facilitates manufacture and application of ; relatively large collection areas. A rigid characteristic such as provided by the panel lO is not utilized but instead a rolled mat form, generally indicated at 40, which facilitates shi?ping and storage much like large carpets or sheet-like floor coverings. Production of 100' wide "continuous" lengths for purposes of reducing manufacturing and application costs is offered for large heat collection requirements. The thickness of the embodiment as shown in __ 25 the enlarged section of Figure 6 is typically less than 3/4".
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., , . ... -, ilCI-5339 . , , r ``` In its preferred form the rolled mat collector 40 is made up of two plastic extrusions 42 and 44 suitably bonded together in a manner hereinafter more fully explained. ~he extrusion 42 constitutes the base layer of the collector 40 similar to the base layer 12 and ~ilm 18 previously described of the panel 10. Extrusion 42 is formed of opaque plastic material, whereas extrusion 44 is formed of transparent plastic material. and is com-parable to the transparent sheets 20, 22 and 24 of the panel 10.
As best shown in Figures 6-8, opaque extrusion 42 has a cross-sectional configuration which provides cooperating pairs of walls 46 defining a ~-shape which diverge outwardly in a manner similar to the comparable walls of the film 18. The free edge of each leg of the V-shaped walls is integrally joined with the free edge.
o an adjacent leg of an adjacent pair of walls. Moreover, the lower apexes of adjacent V-shaped walls are integrally interconnected with inwardly foldable wall sections 48.
Extrusion 44 has a cross-sectional configuration which defines a series of side-by-side lower and upper : air spaces 50 and 52 similar to the air spaces 28 and 3 . . .
previously described, each of which is provided by lower, intermediate and upper thin wall sections 54, 56 and 58 integrally joined with each other along opposite edges . .
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l~S339 _, --~ and with adjacent opposite edges of adjacent wall sections 54, 56, and ~8.
Assembly of the upper transparent extrusion 44 on the lower opaque extrusion 42 is by heat ~onding in the configuration shown wherein the wall sections 54 extend across the wall sections 46 to form enclosed fluid channels 60 (Figure 6), similar to the channels 26 previously described. As best shown in Figure 5, the - bonaing is interrupted periodically along the length of the extrusions, as indicated by the phantom lines 62, for _ a purpose hereinafter to be more fully explained.
For shippins and storage a length of assembled extrusions 42 and 44, as for example 144 inches, is cut from the continuously formed and assembled extrusions.
Such length may contain 6 to 8 unbonded sections. The length is then rolled up like a rug with the assembly assuming the curvature as shown in Figure 7. It will be noted that the wall sections 48 fold inwardly to permit the rolling-up action. In application, the collector 40 is typically oriented with the water passageways or channels 60 extending along the slope of the surface that the collector i5 attached to. Unrolling the system while simultaneously stretching wall sections 48 rlat over the surface to which a suitable adhesive has been sprayed ~_ 25 produces a rigidized large area collector system. To ~ "~ .
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conduits, the collector is cut along the center of the unbonded sections 62 which upper and lower e~trusions 42 and 44 produce two flaps of bonding over per orated inlet S and outlqt tubing 64 as is clearly illustrated in Figure 9. For widths less than the manufactured-width, the collector 40 may be cut-along any water channel line and sealed at each end. Thus rectangular areas of nearly any width and length dimensions can be accommodated with the rolled mat collector 40.
In operation, both embodiments employ the multiple layers of plastic material to reduce heat loss fron! the water within the channels. The upper transparent sheets or thin wall sections produce a layer of stagnant air between it -15 and the inner sheets or wall sections, thus preventing wind cooling of the inner collector materials. The middle sheet or wall section reaches a temperature more or less equal to the water channel material and thus blocks radiation from the water channel to the cool portions of the sky around the sun. The air spaces next to the water channels insulate with the middle film promoting equalization of water channel and middle film temperatures. In applications where surface winds are minimized by architectural features or landscaping, the middle sheet 22 or wall sections 56 __ 25 may be omitted without serious loss in collection efficiency.
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The extended surface represen,ed by the wetted area of the lower channel deLining walls of the embodimer.ts provides an opa~ue absorber for radia~ion passins through the transparen, fil~s and water wi.hin the channels.
Lisht rays not totally absorbed ana converted into heat are rerlected toward opposite walls thereby considerably increasing (compared to conventional fla, plate scnemes) conversion of available insolen/ce in'o heat energy. ~adia-tion from the opaque wetLed surfaces are at infrared wave-lengths which are efCiciently absorbed by the water in the channels. Hea'L loss through radiation is li.~i,ed by the relatively small transparent area perper.dicular to a coole.
sink. Thus, the system operates as a radiation trap havir.s a collection area ef ectively larger ~han its loss area by the ratio oL the wetted opaque area to ~he wetted transparent area. Essentially the same a~alysis ap~lies to the opaque portion with respec' to transparent ~ortion where the medium being heated wi.hin the channel is air instead 0c waLer.
Relative di~ensions including ,he inc uded anc,le between the wetted walls defining the channels, the l~r.gtn ol wetted wall compared to dry walls, and film ~hicknesses can be emperically optimized for minimum total costs.
Resulting configurations which utilize polycarbonate ma.er,al selections included angles between 30 a~d 60 with 1/16"
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S;~39 minimum air spacings between the transparent films. Increas-ing the minimum air spacing and~or decreasing the included angle increases the water temperatures achievable. However, overheating the plastic film may result during fluid circula-tion , failures unless outside sprinklers, shade, or venting of the stagnant air layers are provided to prevent operation beyond design temperatures. Utilization of glass or other high temperature material selections for the transparent members would increase the acceptable design temperatures but long useful lives have been achieved for water temperatures of 170F
in embodiments using polycarbonate transparent films. Thus, external sprinkling to prevent operation beyond design limits and for purposes of rinsing the system to maintain dust free transparent surfaces has proved preferable to more expensive material selections.
Improvement of low sun angle collection compared to flat glazed flat plate collectors is also offered by thermo-forming upper sheets or thin wall sections. Optimum curvatures and lens profiles differ with the angle of inclincation to the sun and with the chosen included angle. It is intended that local manufacturers of the invention provide optimized curvature of upper sheet 24 or upper wall sections 58 for local conditions of low angle collection. In relatively cool ~orthern ambients where relatively high humidities pre-vail, the included angle may be 30 and sections of sheet 24 .
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or wall sections 58 may be c~rved on a 1" radius. In hot dry climates the included angle may be 60 and the sheet 24 or wall sections 58 may be curved on a 2" radius.
; ~ , It thus will be seen that~the objects of this invention have been fully and effectively accomplished. It will be realized, however, that the foregoing preferred specific embodiment has been shown and described for the purpose of illustrating the functional and structural prin-ciples of this invention and is subject to change without departure .rom such principles. Therefore, this invention ~ includes all modifications encompassed within the spirit and scope of the following claims.
, . .
.~
:
: .
.` ,:: ;~`
f :; .
~. This invention relates to solar energy and j:: . more particularly to improved structure for collecting solar energy.
The capability o~ utilizi~g the energy which S comes from the sun.has received widespread attention in ~.
rece~t months, particularly since the now well-known n: "energy crisis". The basic prir.ciples of solar energy collection are known and there have been proposed many 1.;
` : ~:. different arrangements for accomplishing this basic purpose. ~7hile the need to utilize solar energy clearly . ... .. . . .
~ : - 2 ~
,~
. ..
~1~15;~39 - exists and the basic principles by which solar energy can be utilized are known, the actual utilization is minimal. The most common explanation is that while known solar energy collectors work and have the capability to efficiently operate in a very economical and highly favorable ecological manner, the initial costs are said to be prohibitive. The still existing need is for an effective collector which can be produced on a large scale basis at greatly reduced costs compared with those o~ known constructions.
- An object of the present invention is to provide a solar energy collector which will meet the above noted needs. In accordance with the principles of the present invention this objective is obtained by providing a solar energy collector which i5 of laminated sheet structure, the various layers of the laminated sheet structure being ~abricated by molding or extruding plastic material and effecting a simple assemblage thereof which is effective in operation.
Another object of the present invention is to provide a solar powered water or air heater which can be readily and easily recycled with minimum labor and energy consumption for purposes of materials conservation.
` Another object of the present invention is to -_`~ 25 provide a solar powered water or air heater which can be , .
. . ~.-: .:
shipped, stored,,and placed in seryLce with min~mum packaging and handling expense'xe~ultin~ in lo~'~nst~lled costs.
Another obj'ect o~ the'present ~n~ention concerns design fea`tures ahle'to regulate'the'internal system temper-ature thus preventing materials degradation in cas-e of fluid circulaton failure.
A further object of the present invention is to ` provide a solar powered air or water heater which collects '. more radiation than it emits by control of internal surface orientations.
Yet another object of this invention is to provide ;, a solar powered air or water heater which efficiently collects nearly all incident wave lengths and emits only a small amount of radiation by control of internal surface properties. ' t In accordance with one broad aspect, the invention relates to a radiant energy heat exchanger comprising:
a panel structure having sides of substantial area ', bounded by a thin periphery including opposed peripheral end '' portions, one of said sides being operable to face in a direction to receive radiant energy with the other side facing in opposed relation to said opera~le side, said panel structure including a base defining the other side of said panel structure and having a multiplicity of transversely spaced barrier walls extending longitudinally between the end portions of said panel structure, each of said barrier walls including outer portions disposed outwardly in a direction toward the operable side of said panel structure and extending longitudinally between the end portions thereof, adjacent pairs of barrier walls defining in said base a multiplicity of side-by-side ~r .
ll~S339 .
channels extending lon~itudinally between the'end portions of said p~neI structure,' an inner' sheet':~brm wall section sea'lin~l~ connected with each pai~ of ad~acent ~arrier walls at positions along the outer porti`ons thereof and extending transversely across the associated pair of adjacent ~arrier walls and longitudinally between the end portions of said panel structure so as to enclose the associated channel and thereby provide a plurality of inner fluid containing channel spaces extending longitu-dinally between the end portions of said panel structure, an outer sheet form wall section sealingly connected with each pair of adjacent barrier walls at positions along the outer portions thereof and extending transversely across r the associated pair of adjacent barrier walls outwardly of the associated inner wall and section longitudinally between the end portions of said panel structure, the exterior surfaces of said outer wall sections defining coextensive areas of the operable side of said panel structure, an intermediate sheet form wall section sealingly connected with each pair of adjacent barrier walls at positions along the outer portions thereof and extending across the associated pair of adjacent barrier walls between the associated inner and outer wall sections and longitudinally between the end portions of said panel structure so as to define a multiplicity of outer and intermediate fluid con-taining spaces in outwardly disposed relation with respect to said multiplicity of inner fluid containing channel spaces, said sheet form wall sections being constructed to ~acilitate the passage of radiant energy inwardly there-through so that a ~low of fluid directed through said inner - 4a -.,.
....
fluid containing channel spaces from a position adjacent one end portion of said paneI structure to a position adjacent the other end portl'on o~ said paneL structure will result ~n radiant energy being received by the fluid flow only after such radiant ener~y passes inwardly through said sheet form wall secti~ons and said outer fluid containing spaces, said base being constructed to retard the passage of radiant energy therethrough.
TXese and other objects of the present invention will become more apparent during the course of the following :~ -detailed description and appended claims.
The invention may best be understood with reference to the accompanying drawings, wherein an illustrative embodiment is shown.
In the drawings:
Figure 1 is a front elevational view of one form of a solar energy collector embodying the principles of the present invention;
- 4b - -,.
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-` 111~5339 , Figure 2 lS an enlarged, fragmentary sectional view taken along the line 2-2 of Figure l;
Figure 3 is a fragmentary sectional view taken along the,line 3-3 of Figure l;
Figure 4 is an enlarged fragmentary sectional ,, view taken along the line 4-4 of Fi~ure l;
Flgure 5 is a fragmentary front elevational view , of another form of solar energy collector embodying the principles of the present invention;
Figure 6 is an enlarged fragmentary sectional - - view taken along the line 6-6 of Fi~ure 5;
~, Figure 7 is a view simila~r to Figure 6 showing i the manner in which the collector i~ rolled up for transportation and storage;
Figure 8 is a view simila,r to Figure 6 illustrating the component parts of the collecto,F shown in Figure 5 i~ in a position which they may assume during assembly; and Flgure 9 is a fragmentary sectional view illus-trating one configuration for manifl?lding the collector shown in Figure S.
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11(~`53~9 --~ Referring now more particularly to Figures 1-4 of the drawings, there is shown therein a panel form of a solar energy collector, generally indicated at 10, embody-ing the principles of the present invention. The solar energy cpllector panel L0 is formed essentially of laminated sheet structure from relatively inexpensive moldable plastic materials. As best shown in Figure 2, the laminated sheet structure of the collector 10 has a relatively rigid panel form providing an operative side of substantial area to be mounted in a position to receive the solar energy and an opposite coextensive side which may be regarded as a mounting side, both sides being bounded by a relatively thin periphery.
In the preferred embodiment shown the mounting side of the collector panel 10 is provided by a base layer 12, which may be regarded as a relatively thick sheet formation, preferably made from a suitable foamed plastic materlal, such as urethane, styrene or urea formaldehyde.
The base layer 12 is thus characterized by lightness of weight and rigidity. Moreover, by utilizing injection molding techniques to form the base layer 12 of foamed plastic material, the base layer 12 may be conveniently formed with configurations embodying the principles of the ~ present invention. As best shown, one side 14 of the base G 25 layer 12 is planar and this side defines the mounting side f'~~ of the collector panel 10. The opposite side of the base .
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~1~`5~39 ~2 _ layer 12 is formed with a multiplicity of cooperating pairs of angularly related inclined surfaces 1~, each pair of surfaces 16 diverging outwardly with respect to one another in a direction away from the planar side 14 to cooperatively define an elongated channel shape.
While it is within the contemplation of the present invention that the surfaces 16 of the foamed plastic of the base layer 12 provide both the heat retention function of the opaque walls and the fluid impervious function of fluid passages, it is preferred to adhere a barrier film 18 to these surfaces to pro-vide both functions. Desirably, the film 18 is initially vacuum formed and then held against the upper surface form of the mold as the plastic foam is added during the molding of the base layer 12. The ilm 18 is opaque and may be of any desired color. Suit-able plastic materials for the film 18 include polycarbonates,acrylics, polyvinyl chlorides, polyvinyl fluoride, rubber com-pounds, etc. It will also be understood that the barrier film 18 may provide only the fluid impervious function in which case a sprayed-on coating or integral skin may provide the opaque function.
The sheet formation of the collector panel is completed by the provisions of three transparent plastic sheets 20, 22 and 24 mounted over the base layer 12 and barrier \ \ film 18.
The lower film sheet 20 is bonded on the upper ~ .
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.
11(~5339 ridge portions of the walls provided by barrier film 18 in the configuration shown in Figure 2 to extend across each channel and define with the remaining unbonded portions of the barrier wall a closed fluid conveying channel 26.
Film 20 is bonded on the upper ridges of barrier layer 18 in any suitable-manner, such as by heat welding, solvent welding, or adhesive bonding techniques. A pre-ferred manner is to utilize the heat available from channel molds which hold film 18 to soften film 20 suffi-_ ciently to produce welding to barrier film 18 when the surfaces are joined under mold pressure. Sheets 22 and 24 are bonded along strips or lines at the ridge peaks in a similar manner. The lower surface of the sheet 22 extend-ing between each pair of adjacent peaks defines with the coextensive upper surface of the sheet 20 a lower insulating air space 28. Likewise, the upper surface portions of the sheet 22 define upper insulating air spaces 30 with the coextensive lower surface portions of the sheet 24. Sheet 22 is intentionally formed to the bridged surface shown, as is film sheet 20 for purposes of allowing for uneven expansion and contraction of the various members in response to climateological and application conditions. Upper sheet 24 is somewhat thicker than films 18, 20 and 22, and _ 25 is selected to offer protection from projectiles, hail, and r .
llC~S339 , ~ , other hazards, in addition to confining insulating air . ~ within space 30.
The collector panel 10 is preferably made to be a self-contained unit by manifolding the ends of the channels. 26 and the air spaces 28 and 30. This may be`
accomplished in any desired fashion, however a preferred mode, as illustrated in the drawings, embodies the provision of a tapered manifold trough surface at each end of the base layer 12 which is covered with the barrier film 18 to form a ta2ered manifold trough 32 . communicating with the associated end o, the channels 26.
Communication with each manifold trough 32 exteriorly of the panel 10 is provided by any suitable means, such as a plastic pipe section 34 which is either mounted within cavities molded in the base layer or provided in situ at the time the base layer is molded.
Any portion of the film 18 covering the adjacent end of each pipe 34 during assembly is simply cut away.
Each manifold trough 32 is preferably enclosed and sealed about the associated pipe 34 by means of the adjacent portions of the three sheets 20, 22 and 24. As best shown in Figure 4, the portions~ofthe sheets 20, 22 and 24 which overlie each manifold trough 32 are spaced -~ apart from each other and remain unsecured. The end _ 25 portions of the three sheets 20, 22 and 24 which overlie ~ .
, the end wall of the base layer 12 defining the associated 1~5~39 ; ~ manifold trough 32 are secured together in sealed relation.
and to the upper surface of the base layer. In this way, the portions of the sheets 20 and 22 overlying each manifold _ough 32 define a manifold space for the adjacent ends of . ~ the lower air~spaces 28, while the portions of the sheets 22 and 24 overlying each manifold trough define a manifold space for the adjacent ends of the upper air spaces 30.
Prevention against over-heating due to insufficient heat removal rates is an important consideration in instances where failure of the fl~id circulation system would allow ~ - system temperatures to exceed material or fabrication limits. Most applications involve placins the collector panels 10 on somewhat inclined surfaces. This facilitates gatherins maximum amounts of solar enersy, draining the system for cleaning and freeze protection, and for draining surface moisture following snow or rain showers. Pressure and temperature control for the air spaces 28 and 30 can he provided by the use o conventional valving illustrated : schematically in Figure 1 of the drawings at 36 and 38. In the schematic arrangement shown, an openins (not shown) is formed in the portion o the intermediate sheet 22 overlying the manifold trough and underlying the valve 36 so as to .
communicate the manifold spaces of both air spaces 28 and 30. It will be understood that the manifolds for the _ 25 air spaces 28 and 30 may be maintained separate and provided . ' ' .
-- 10 -- , .... .
ll~S339 ~ ...................................................................... , with separate valves, if desired. Buoyant forces result-ing from heating air masses between the transparent films result in mass flow of the heated air out valve 36 as illustrated in Figure 1 when such valve is open. Control S of valve,36 can be provided by constructing the valve of .. ~, .
materials which have high thermal,expansion coefficients resulting in automatic opening at predetermined temperatures.
Another type of automatic control is to operate valve 36 ~- by solenoids and provide normally - c~losed - power - on functions with valve opening to occur in case of power _ failure or any other failure resulting in deficient fluid flow. The specific construction of valves operated by '~ material expansion-contraction forces or solenoids is well-known, and need not be further discussed in this dis-closure. Providing valves 38 at lower extremities to allow cool air to replace hot air passing through valve 36 thus enables maintenance of the system within design temper-ature. In areas where airborne dust prevails, filter strips over the vent valve inlet areas may be required to prevent build-up of dust on internal surfaces.
It will be understood that collector panels 10 in the unitized form described above are arranged to be installed with procedures normally utilized in installing `'- other types of wall or roofing panels with appropriate con-- 25 nections to the pipes 34 of the panels. Normally, the , ~; .
'' ' .;
- , . .
ll~S339 ~- - panels lO will be regarded as add-on panels rather than panels which also serve as the exterior protective paneling as well. ~evertheless, such dual functioning is contemplated although other embodiments of the present invention herein-after described are preferred in such dual functioning situations~ Factory assembled panels including layers 12, 18, 20 and 22 may be utilized as a combination collector and membrane roof surface with a sheet 24 applied as a con-tinuous glazing for exclusion of water. Characteristic lG materials selection for the sheets or 'ilms 20, 22 and 24 _ are the same as those of film 18, namely, polycarbonates, acrylic, polyv1nyl chloride, polyvinyl fluoride, and rubber compounds.
Referring now more particularly to Figures 5-9, there is shown therein a second embodiment of the present invention which facilitates manufacture and application of ; relatively large collection areas. A rigid characteristic such as provided by the panel lO is not utilized but instead a rolled mat form, generally indicated at 40, which facilitates shi?ping and storage much like large carpets or sheet-like floor coverings. Production of 100' wide "continuous" lengths for purposes of reducing manufacturing and application costs is offered for large heat collection requirements. The thickness of the embodiment as shown in __ 25 the enlarged section of Figure 6 is typically less than 3/4".
'`'' - ' .
., , . ... -, ilCI-5339 . , , r ``` In its preferred form the rolled mat collector 40 is made up of two plastic extrusions 42 and 44 suitably bonded together in a manner hereinafter more fully explained. ~he extrusion 42 constitutes the base layer of the collector 40 similar to the base layer 12 and ~ilm 18 previously described of the panel 10. Extrusion 42 is formed of opaque plastic material, whereas extrusion 44 is formed of transparent plastic material. and is com-parable to the transparent sheets 20, 22 and 24 of the panel 10.
As best shown in Figures 6-8, opaque extrusion 42 has a cross-sectional configuration which provides cooperating pairs of walls 46 defining a ~-shape which diverge outwardly in a manner similar to the comparable walls of the film 18. The free edge of each leg of the V-shaped walls is integrally joined with the free edge.
o an adjacent leg of an adjacent pair of walls. Moreover, the lower apexes of adjacent V-shaped walls are integrally interconnected with inwardly foldable wall sections 48.
Extrusion 44 has a cross-sectional configuration which defines a series of side-by-side lower and upper : air spaces 50 and 52 similar to the air spaces 28 and 3 . . .
previously described, each of which is provided by lower, intermediate and upper thin wall sections 54, 56 and 58 integrally joined with each other along opposite edges . .
.
.;, - - - , ~ , -. .. ........ . .
l~S339 _, --~ and with adjacent opposite edges of adjacent wall sections 54, 56, and ~8.
Assembly of the upper transparent extrusion 44 on the lower opaque extrusion 42 is by heat ~onding in the configuration shown wherein the wall sections 54 extend across the wall sections 46 to form enclosed fluid channels 60 (Figure 6), similar to the channels 26 previously described. As best shown in Figure 5, the - bonaing is interrupted periodically along the length of the extrusions, as indicated by the phantom lines 62, for _ a purpose hereinafter to be more fully explained.
For shippins and storage a length of assembled extrusions 42 and 44, as for example 144 inches, is cut from the continuously formed and assembled extrusions.
Such length may contain 6 to 8 unbonded sections. The length is then rolled up like a rug with the assembly assuming the curvature as shown in Figure 7. It will be noted that the wall sections 48 fold inwardly to permit the rolling-up action. In application, the collector 40 is typically oriented with the water passageways or channels 60 extending along the slope of the surface that the collector i5 attached to. Unrolling the system while simultaneously stretching wall sections 48 rlat over the surface to which a suitable adhesive has been sprayed ~_ 25 produces a rigidized large area collector system. To ~ "~ .
.: , . .. -~ ~! facilitate connection of the collector to inlet and outlet . . ~
conduits, the collector is cut along the center of the unbonded sections 62 which upper and lower e~trusions 42 and 44 produce two flaps of bonding over per orated inlet S and outlqt tubing 64 as is clearly illustrated in Figure 9. For widths less than the manufactured-width, the collector 40 may be cut-along any water channel line and sealed at each end. Thus rectangular areas of nearly any width and length dimensions can be accommodated with the rolled mat collector 40.
In operation, both embodiments employ the multiple layers of plastic material to reduce heat loss fron! the water within the channels. The upper transparent sheets or thin wall sections produce a layer of stagnant air between it -15 and the inner sheets or wall sections, thus preventing wind cooling of the inner collector materials. The middle sheet or wall section reaches a temperature more or less equal to the water channel material and thus blocks radiation from the water channel to the cool portions of the sky around the sun. The air spaces next to the water channels insulate with the middle film promoting equalization of water channel and middle film temperatures. In applications where surface winds are minimized by architectural features or landscaping, the middle sheet 22 or wall sections 56 __ 25 may be omitted without serious loss in collection efficiency.
.~,. ..
.. . ... .
. ,, .. ~ ~, 11~5~39 ~ .
The extended surface represen,ed by the wetted area of the lower channel deLining walls of the embodimer.ts provides an opa~ue absorber for radia~ion passins through the transparen, fil~s and water wi.hin the channels.
Lisht rays not totally absorbed ana converted into heat are rerlected toward opposite walls thereby considerably increasing (compared to conventional fla, plate scnemes) conversion of available insolen/ce in'o heat energy. ~adia-tion from the opaque wetLed surfaces are at infrared wave-lengths which are efCiciently absorbed by the water in the channels. Hea'L loss through radiation is li.~i,ed by the relatively small transparent area perper.dicular to a coole.
sink. Thus, the system operates as a radiation trap havir.s a collection area ef ectively larger ~han its loss area by the ratio oL the wetted opaque area to ~he wetted transparent area. Essentially the same a~alysis ap~lies to the opaque portion with respec' to transparent ~ortion where the medium being heated wi.hin the channel is air instead 0c waLer.
Relative di~ensions including ,he inc uded anc,le between the wetted walls defining the channels, the l~r.gtn ol wetted wall compared to dry walls, and film ~hicknesses can be emperically optimized for minimum total costs.
Resulting configurations which utilize polycarbonate ma.er,al selections included angles between 30 a~d 60 with 1/16"
( ) . .
.. .. .
S;~39 minimum air spacings between the transparent films. Increas-ing the minimum air spacing and~or decreasing the included angle increases the water temperatures achievable. However, overheating the plastic film may result during fluid circula-tion , failures unless outside sprinklers, shade, or venting of the stagnant air layers are provided to prevent operation beyond design temperatures. Utilization of glass or other high temperature material selections for the transparent members would increase the acceptable design temperatures but long useful lives have been achieved for water temperatures of 170F
in embodiments using polycarbonate transparent films. Thus, external sprinkling to prevent operation beyond design limits and for purposes of rinsing the system to maintain dust free transparent surfaces has proved preferable to more expensive material selections.
Improvement of low sun angle collection compared to flat glazed flat plate collectors is also offered by thermo-forming upper sheets or thin wall sections. Optimum curvatures and lens profiles differ with the angle of inclincation to the sun and with the chosen included angle. It is intended that local manufacturers of the invention provide optimized curvature of upper sheet 24 or upper wall sections 58 for local conditions of low angle collection. In relatively cool ~orthern ambients where relatively high humidities pre-vail, the included angle may be 30 and sections of sheet 24 .
5;~3~
or wall sections 58 may be c~rved on a 1" radius. In hot dry climates the included angle may be 60 and the sheet 24 or wall sections 58 may be curved on a 2" radius.
; ~ , It thus will be seen that~the objects of this invention have been fully and effectively accomplished. It will be realized, however, that the foregoing preferred specific embodiment has been shown and described for the purpose of illustrating the functional and structural prin-ciples of this invention and is subject to change without departure .rom such principles. Therefore, this invention ~ includes all modifications encompassed within the spirit and scope of the following claims.
, . .
Claims (5)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A radiant energy heat exchanger comprising a panel structure having sides of substantial area bounded by a thin periphery including opposed peripheral end portions, one of said sides being operable to face in a direction to receive radiant energy with the other side facing in opposed relation to said operable side, said panel structure including a base defining the other side of said panel structure and having a multiplicity of transversely spaced barrier walls extending longitudinally between the end portions of said panel structure, each of said barrier walls including outer portions disposed outwardly in a direction toward the operable side of said panel structure and extending longi-tudinally between the end portions thereof, adjacent pairs of barrier walls defining in said base a multiplicity of side-by-side channels extending longitudinally between the end portions of said panel structure, an inner sheet form wall section sealingly connected with each pair of adjacent barrier walls at positions along the outer portions thereof and extending transversely across the associated pair of adjacent barrier walls and longitu-dinally between the end portions of said panel structure so as to enclose the associated channel and thereby provide a plurality of inner fluid containing channel spaces extending longitudinally between the end portions of said panel structure, an outer sheet form wall section sealingly connected with each pair of adjacent barrier walls at positions along the outer portions thereof and extending transversely across the associated pair of adjacent barrier walls outwardly of the associated inner wall and section longitudinally between the end portions of said panel structure, the exterior surfaces of said outer wall sections defining coextensive areas of the operable side of said panel structure, an intermediate sheet form wall section sealingly connected with each pair of adjacent barrier walls at positions along the outer portions thereof and extending across the associated pair of adjacent barrier walls between the associated inner and outer wall sections and longitu-dinally between the end portions of said panel structure so as to define a multiplicity of outer and intermediate fluid containing spaces in outwardly disposed relation with respect to said multiplicity of inner fluid containing channel spaces, said sheet form wall sections being constructed to facilitate the passage of radiant energy inwardly there-through so that a flow of fluid directed through said inner fluid containing channel spaces from a position adjacent one end portion of said panel structure to a position adjacent the other end portion of said panel structure will result in radiant energy being received by the fluid flow only after such radiant energy passes inwardly through said sheet form wall sections and said outer fluid containing spaces, said base being constructed to retard the passage of radiant energy therethrough.
2. A radiant energy heat exchanger as defined in claim 1 wherein each of said outer sheet form wall sections is of concavo-convex cross-sectional configuration with the convex surface thereof facing outwardly so as to (1) provide a multiplicity of side-by-side arches on the operable side of said panel structure which serve to enhance the load bearing capabilities thereof; (2) provide a multiplicity of side-by-side convex surfaces on the operable side of said panel structure which serve to enhance the range of the angle of incidence of radiant energy passable therethrough; and (3) provide a multiplicity of side-by-side lenses on the operable side of said panel structure which serve to concentrate the radiant energy passing therethrough.
3. A radiant energy heat exchanger as defined in claim 2 wherein each of said barrier walls is formed by a pair of sheet form oppositely inclined wall sections con-verging outwardly to define one of the aforesaid outer edges, the arrangement being such that said panel structure can be displaced from an operative condition wherein the inner edges of each pair of inclined wall sections are spaced laterally apart a predetermined distance and a collapsed condition wherein the inner edges of each pair of inclined wall sections are disposed closer together than said predetermined distance.
4. A radiant energy heat exchanger as defined in claim 3 wherein the inner edges of each pair of inclined wall sections are interconnected by a wall section having a central fold movable in a direction toward the outer edge of the associated pair of inclined wall sections.
5. A radiant energy heat exchanger as defined in claim 1 wherein manifold means is provided at each end portion of said panel structure in communicating relation with the associated ends of said inner fluid containing channel spaces for directing the flow of fluid therethrough, and selectively operable means for admitting a cooling fluid into said intermediate fluid containing spaces at a position adjacent one end portion of said panel structure and for allowing said cooling fluid to flow through said intermediate fluid con-taining spaces and outwardly thereof at a position adjacent the other end portion of said panel structure whereby over-heating of said panel structure can be prevented in the event that the flow of fluid through said inner fluid containing channel spaces is stopped during a period in which said panel structure is receiving radiant energy of an intensity sufficient to effect such overheating.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA288,358A CA1105339A (en) | 1977-10-07 | 1977-10-07 | Solar energy collector |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA288,358A CA1105339A (en) | 1977-10-07 | 1977-10-07 | Solar energy collector |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1105339A true CA1105339A (en) | 1981-07-21 |
Family
ID=4109720
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA288,358A Expired CA1105339A (en) | 1977-10-07 | 1977-10-07 | Solar energy collector |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1105339A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4505264A (en) * | 1983-12-27 | 1985-03-19 | Universite Laval | Electromagnetic wave concentrator |
-
1977
- 1977-10-07 CA CA288,358A patent/CA1105339A/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4505264A (en) * | 1983-12-27 | 1985-03-19 | Universite Laval | Electromagnetic wave concentrator |
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