CA2513822A1 - 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 PDFInfo
- Publication number
- CA2513822A1 CA2513822A1 CA002513822A CA2513822A CA2513822A1 CA 2513822 A1 CA2513822 A1 CA 2513822A1 CA 002513822 A CA002513822 A CA 002513822A CA 2513822 A CA2513822 A CA 2513822A CA 2513822 A1 CA2513822 A1 CA 2513822A1
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- CA
- Canada
- Prior art keywords
- metal sheets
- absorber
- adhesive
- pipe system
- heat transfer
- 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.)
- Abandoned
Links
- 239000006096 absorbing agent Substances 0.000 title claims abstract description 94
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 26
- 238000000034 method Methods 0.000 title claims description 16
- 229910052751 metal Inorganic materials 0.000 claims abstract description 62
- 239000002184 metal Substances 0.000 claims abstract description 62
- 230000001070 adhesive effect Effects 0.000 claims description 40
- 239000000853 adhesive Substances 0.000 claims description 36
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 9
- 238000004049 embossing Methods 0.000 claims description 7
- 238000009434 installation Methods 0.000 claims description 7
- 238000005304 joining Methods 0.000 claims description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 5
- 239000010949 copper Substances 0.000 claims description 5
- 229910052802 copper Inorganic materials 0.000 claims description 5
- 238000004381 surface treatment Methods 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 238000005260 corrosion Methods 0.000 claims description 4
- 230000007797 corrosion Effects 0.000 claims description 4
- 230000003647 oxidation Effects 0.000 claims description 4
- 238000007254 oxidation reaction Methods 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 229910000838 Al alloy Inorganic materials 0.000 claims description 3
- 230000001419 dependent effect Effects 0.000 claims description 3
- 239000006223 plastic coating Substances 0.000 claims description 3
- 238000006243 chemical reaction Methods 0.000 claims description 2
- 239000003822 epoxy resin Substances 0.000 claims description 2
- 238000010438 heat treatment Methods 0.000 claims description 2
- 239000005011 phenolic resin Substances 0.000 claims description 2
- 229920000647 polyepoxide Polymers 0.000 claims description 2
- 239000000463 material Substances 0.000 claims 1
- 229920002050 silicone resin Polymers 0.000 claims 1
- 239000000126 substance Substances 0.000 claims 1
- 239000010410 layer Substances 0.000 description 8
- 230000005855 radiation Effects 0.000 description 8
- 239000011521 glass Substances 0.000 description 5
- 230000006835 compression Effects 0.000 description 4
- 238000007906 compression Methods 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 238000007493 shaping process Methods 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- 238000004026 adhesive bonding Methods 0.000 description 2
- 239000012790 adhesive layer Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000011551 heat transfer agent Substances 0.000 description 2
- 238000005098 hot rolling Methods 0.000 description 2
- 230000002226 simultaneous effect Effects 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 239000004831 Hot glue Substances 0.000 description 1
- 240000007839 Kleinhovia hospita Species 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000005097 cold rolling Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 150000002118 epoxides Chemical class 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S10/00—Solar heat collectors using working fluids
- F24S10/50—Solar heat collectors using working fluids the working fluids being conveyed between plates
- F24S10/503—Solar heat collectors using working fluids the working fluids being conveyed between plates having conduits formed by paired plates, only one of which is plane
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S10/00—Solar heat collectors using working fluids
- F24S10/50—Solar heat collectors using working fluids the working fluids being conveyed between plates
- F24S10/504—Solar heat collectors using working fluids the working fluids being conveyed between plates having conduits formed by paired non-plane plates
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S2025/601—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by bonding, e.g. by using adhesives
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/40—Solar thermal energy, e.g. solar towers
- Y02E10/44—Heat 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
w 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 v 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 sola r 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 -~ into one of the metal sheets and the metal sheets being bonded to one another, is known from US 4,089,324.
DE 195 46 100 A1 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 another at the contact surfaces.
On the basis of this related art, the present invention is based on the object of providing an absorber having reduced manufacturing costs and improved dimensional accuracy while simultaneously having a reduced reject rate, in which strength losses of the bond between the metal sheets of the absorber occurring at high temperatures are compensated for. Furthermore, the present invention is based on the object of suggesting a method for manufacturing the improved absorber.
This object is achieved in an absorber of the type cited at the beginning in that 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 metal sheets are bonded to one another using an adhesive and additionally in a formfitting way.
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.
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 v 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 sola r 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 -~ into one of the metal sheets and the metal sheets being bonded to one another, is known from US 4,089,324.
DE 195 46 100 A1 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 another at the contact surfaces.
On the basis of this related art, the present invention is based on the object of providing an absorber having reduced manufacturing costs and improved dimensional accuracy while simultaneously having a reduced reject rate, in which strength losses of the bond between the metal sheets of the absorber occurring at high temperatures are compensated for. Furthermore, the present invention is based on the object of suggesting a method for manufacturing the improved absorber.
This object is achieved in an absorber of the type cited at the beginning in that 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 metal sheets are bonded to one another using an adhesive and additionally in a formfitting way.
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.
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 Bola r loop under specific operating circumstances. In this case, temperatures of 200 °C - 220 °C 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 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 (A1 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.
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 °C.
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 temperature-dependent 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 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 A1 Mg Si 1 or A1 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 (e.g., 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 _ g _ 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 1a, 1b, 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, 11b.
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.
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 water-glycol 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.
List of reference numbers la,b metal sheets 2a,b coil 3a,b roller straightening machine 4a,b embossing station 5a,b 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
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 Bola r loop under specific operating circumstances. In this case, temperatures of 200 °C - 220 °C 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 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 (A1 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.
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 °C.
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 temperature-dependent 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 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 A1 Mg Si 1 or A1 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 (e.g., 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 _ g _ 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 1a, 1b, 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, 11b.
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.
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 water-glycol 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.
List of reference numbers la,b metal sheets 2a,b coil 3a,b roller straightening machine 4a,b embossing station 5a,b 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 (18)
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 (23) 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, characterized in that the metal sheets are bonded to one another using an adhesive (25) and additionally in a formfitting way (11a, b/12) using clinching.
2. The absorber according to Claim 1, characterized in that the additional bond (11a, b/12) between the metal sheets comprises multiple Tox points.
3. The absorber according to one of Claims 1 or 2, characterized in that the adhesive (25) is heat-resistant and impermeable to the vapor of the heat transfer medium up to at least 200 °C.
4. The absorber according to Claims 3, characterized in that the adhesive is a silicone or epoxide resin or phenol resin adhesive.
5. The absorber according to one of Claims 1 through 4, characterized in that at least the regions of the metal sheets forming the interior surfaces of the pipe system (23) are surface-treated.
6. The absorber according to Claim 5, characterized in that 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 one of Claims 1 through 6, characterized in that the material of the metal sheets (1a, 1b) is an aluminum alloy or steel or copper.
8. The absorber according to Claim 6 or 7, characterized in that the aluminum sheets are anodized.
9. The absorber according to Claim 6 or 7, characterized in that the sheet steel is provided with a copper or plastic coating.
10. The absorber according to one of Claims 1 through 9, characterized in that the metal sheets (1a, 1b) have a cold-formed pipe system (23).
11. A method for manufacturing absorbers according to Claims 2 through 11 from two metal sheets (1a, 1b) lying one on top of another, the shape of the pipe system (25) for the heat transfer medium being introduced into at least one of the metal sheets (1a) using cold forming, the two sheets (1a, 1b) being joined by an adhesive and additionally bonded to one another in a formfitting way at multiple locations using clinching.
12. The method for manufacturing absorbers according to Claim 11, characterized in that an adhesive is used for joining which is resistant to the heat transfer medium and maintains its adhesive properties at least in the temperature range between -30 °C and +200 °C.
13. The method for manufacturing absorbers according to Claim 11 or 12, characterized in that after straightening of the metal sheets (1a, 1b) to be joined, the shape of the pipe system for the heat transfer medium is introduced into at least one of the two metal sheets (1a).
14. The method for manufacturing absorbers according to one of Claims 11 through 13, characterized in that the shape of the pipe system for the heat transfer medium is introduced through embossing or deep drawing.
15. The method for manufacturing absorbers according to one of Claims 11 through 14, characterized in that the metal sheets (1a, 1b) are cut to absorber size before or after the application of the adhesive.
16. The method for manufacturing absorbers according to one of Claims 11 through 15, characterized in that a temperature-dependent adhesive is applied to both metal sheets (1a, 1b), 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 one of Claims 11 through 16, characterized in that at least the areas of the metal sheets (1a, 1b) 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 one more of Claims 1 through 10.
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 |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2513822A1 true CA2513822A1 (en) | 2004-09-02 |
Family
ID=32891753
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002513822A Abandoned CA2513822A1 (en) | 2003-02-19 | 2004-01-22 | Absorber for a thermal collector of a solar system and method for the production thereof |
Country Status (10)
Country | Link |
---|---|
US (1) | US20060137679A1 (en) |
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) |
Families Citing this family (10)
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DE102006003096B4 (en) * | 2006-01-20 | 2012-05-31 | Hydro Aluminium Deutschland Gmbh | Modular solar panel |
DE102007013919A1 (en) * | 2007-03-20 | 2008-09-25 | Werner Fischer | Heat exchanger for solar thermal energy |
DE102008052010B4 (en) * | 2008-10-10 | 2014-06-18 | Joma-Polytec Gmbh | Solar absorber module and heat exchanger |
DE102009022059A1 (en) * | 2009-05-20 | 2010-11-25 | Schott Solar Ag | Radiation-selective absorber coating and absorber tube with radiation-selective absorber coating |
DE102009043986B3 (en) * | 2009-09-11 | 2011-01-27 | Hydro Aluminium Deutschland Gmbh | Process for the production of solar collectors |
AT509018B1 (en) | 2009-10-29 | 2012-04-15 | Dtec Gmbh | FLAT ABSORBER |
DE102010017269B3 (en) * | 2010-06-08 | 2011-12-08 | Andreas Martin Hofer | Heat collector module for mounting on a roof plate on the top |
DE102011007616B4 (en) * | 2011-04-18 | 2014-09-04 | Sandvik Materials Technology Deutschland Gmbh | Solar flat collector, method for producing a solar flat collector and solar thermal system |
DE102011050993A1 (en) * | 2011-06-09 | 2012-12-13 | ETA 86 Solar Steel AG | Process for the production of a heat exchanger, heat exchanger and manufacturing plant |
CN107160133A (en) * | 2017-06-28 | 2017-09-15 | 江苏哈工药机科技股份有限公司 | A kind of solar thermal collector production clamps pushing equipment with frame |
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-
2003
- 2003-02-19 DE DE10306930A patent/DE10306930B3/en not_active Expired - Fee Related
-
2004
- 2004-01-22 DK DK04704203T patent/DK1606565T3/en active
- 2004-01-22 EP EP04704203A patent/EP1606565B1/en not_active Expired - Lifetime
- 2004-01-22 ES ES04704203T patent/ES2278299T3/en not_active Expired - Lifetime
- 2004-01-22 AU AU2004213524A patent/AU2004213524B2/en not_active Expired - Fee Related
- 2004-01-22 WO PCT/EP2004/000474 patent/WO2004074749A1/en active IP Right Grant
- 2004-01-22 US US10/545,431 patent/US20060137679A1/en not_active Abandoned
- 2004-01-22 CA CA002513822A patent/CA2513822A1/en not_active Abandoned
- 2004-01-22 AT AT04704203T patent/ATE348988T1/en not_active IP Right Cessation
- 2004-01-22 DE DE502004002374T patent/DE502004002374D1/en not_active Expired - Fee Related
- 2004-01-22 PT PT04704203T patent/PT1606565E/en unknown
Also Published As
Publication number | Publication date |
---|---|
ES2278299T3 (en) | 2007-08-01 |
DK1606565T3 (en) | 2007-01-29 |
EP1606565A1 (en) | 2005-12-21 |
ATE348988T1 (en) | 2007-01-15 |
EP1606565B1 (en) | 2006-12-20 |
US20060137679A1 (en) | 2006-06-29 |
AU2004213524B2 (en) | 2008-11-06 |
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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