US20120060830A1 - Solar thermal panels - Google Patents
Solar thermal panels Download PDFInfo
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- US20120060830A1 US20120060830A1 US13/227,606 US201113227606A US2012060830A1 US 20120060830 A1 US20120060830 A1 US 20120060830A1 US 201113227606 A US201113227606 A US 201113227606A US 2012060830 A1 US2012060830 A1 US 2012060830A1
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- Prior art keywords
- solar thermal
- panel
- fluid
- solar
- thermal
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- 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
- F24S10/502—Solar heat collectors using working fluids the working fluids being conveyed between plates having conduits formed by paired plates and internal partition means
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- 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
- F24S10/501—Solar heat collectors using working fluids the working fluids being conveyed between plates having conduits of plastic material
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- 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
- F24S10/55—Solar heat collectors using working fluids the working fluids being conveyed between plates with enlarged surfaces, e.g. with protrusions or corrugations
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- 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
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/20—Solar thermal
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- 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
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- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
- Y10T29/49355—Solar energy device making
Definitions
- the present disclosure relates generally to solar thermal panels and, more particularly, to systems and methods for manufacturing and sealing solar thermal panels.
- FIG. 1 is a diagram that shows one embodiment of a solar thermal system.
- FIG. 2 is a front profile view of a solar thermal panel.
- FIG. 3 is a side profile view of a solar thermal panel.
- FIG. 4 is a side profile view of a solar thermal panel being sealed.
- FIG. 5 is a perspective view of a solar thermal panel.
- the present disclosure teaches various systems and methods relating to solar thermal panels and solar thermal systems. Unlike conventional solar thermal panels, various embodiments of the inventive solar thermal panels are cost-effective to manufacture, thereby allowing for mass production of the solar thermal panels.
- a method of sealing a solar thermal panel is disclosed.
- the solar thermal panel is sealed by applying heat and pressure to one edge of the solar thermal panel, thereby melting the edge and forming a seal.
- a system is disclosed, in which a thermal-fluid-filled solar-thermal panel that has been sealed by applying heat to its edge to prevent leakage of the thermal fluid.
- inventive solar thermal panels and systems were developed, along with the corresponding processes for manufacturing these panels and systems.
- inventive solar thermal panel and its method of manufacture may appear simple, numerous failed attempts prior to the eventual success in building the disclosed working models demonstrate the non-trivial nature of the inventive solar thermal panels, systems, and methods. Consequently, one having ordinary skill in the art will appreciate the difficulties associated with manufacturing the disclosed solar thermal panels and systems.
- U.S. Pat. Nos. 4,114,597 and 4,178,914 describe headers for unitary solar collectors. These headers are separate components that are attached to the outside of the unitary solar collector. Attempting to attach separate headers to the outside of the solar thermal panel posed problems because the interface between the headers and the unitary solar collector, if not perfectly sealed, created points-of-failure where the thermal fluid escaped from the system. All attempts to externally seal the solar thermal panel with this separate and distinct component (such as a header or a pipe) resulted in incomplete seals, which consequently resulted in leakage of thermal fluid from the system. This occurred despite numerous attempts with many different types of sealants and adhesives. Thus, while it may appear trivial to externally seal the solar thermal panel, the reality of employing a separate component to achieve a leak-resistant seal proved to be unworkable.
- FIGS. 1 through 5 show preferred embodiments of a solar thermal panel, a solar thermal system employing the solar thermal panel, and methods for manufacturing the solar thermal panel.
- FIG. 1 is a diagram that shows one embodiment of a solar thermal system. While the system of FIG. 1 shows a closed loop that circulates thermal fluid 2 , it should be appreciated by those having skill in the art that the system may also be configured as an open-loop system.
- the system comprises a closed loop that circulates thermal fluid 2 .
- This closed loop includes a solar thermal panel 1 a , a control unit 5 , a storage tank 3 , and a first pump 4 .
- the solar thermal panel 1 a comprises a panel temperature gauge 7 , which measures the temperature of the fluid 2 within the solar thermal panel 1 a .
- the storage tank 3 comprises a fluid temperature gauge 6 , a heat exchanger 12 , a cold water inlet 11 , and a hot water pipe (not labeled).
- the control unit 5 is operatively coupled to the first pump 4 , the panel temperature gauge 7 , and the fluid temperature gauge 6 .
- the thermal fluid 2 circulates through the solar thermal panel 1 a , where the fluid 2 absorbs solar energy and heats up as a result.
- the thermal fluid 2 can reach temperatures up to 150 degrees Fahrenheit, which is typical for hot water heaters.
- the control unit 5 will either activate or deactivate the first pump 4 .
- the control unit 5 will activate the first pump 4 , which pumps the thermal fluid 2 from the tank 3 to the solar thermal panel 1 a.
- the storage tank 3 receives cold water through a cold water inlet 11 , and the cold water is pumped through the heat exchanger 12 . As the cold water travels through the heat exchanger 12 , the temperature difference between the cold water and the thermal fluid 2 causes the cold water to heat, while simultaneously causing the heated thermal fluid 2 to cool. The heated water exits through the hot water pipe (not labeled).
- the first pump 4 circulates the cooled thermal fluid 2 back to the solar thermal panel 1 a , where the fluid 2 absorbs solar energy and heats up, thereby repeating the cycle.
- the hot water pipe (not labeled) of the storage tank 3 is operatively coupled to a booster heater 13 , which includes a hot water outlet 14 .
- the hot water pipe (not labeled) provides the heated water to the booster heater, which further heats the water. That water can then be used by drawing it from the hot water outlet 14 .
- the system of FIG. 1 also shows a closed loop in which the thermal fluid 2 is used for space heating.
- An exemplary system for space heating comprises a booster heater 13 , a second pump 9 , an ambient temperature gauge 10 , and a hydronic heating system 8 .
- the second pump 9 and the ambient temperature gauge 10 are operatively coupled to the control unit 5 , which activates or deactivates the second pump 9 based on the reading of the ambient temperature gauge 10 .
- the control unit activates the second pump 9 , thereby circulating the heated thermal fluid 2 from the storage tank 3 to the booster heater 13 .
- the booster heater 13 further heats the thermal fluid 2 , which is then pumped through the hydronic heating system 8 via the second pump 9 .
- the fluid 2 travels through the hydronic heating system 8 , it cools as a result of heat transfer to the heated space.
- the cooled thermal fluid 2 is then pumped back to the storage tank 3 , where the cycle may repeat.
- the efficiency of the entire system depends in large part on the efficiency of the solar thermal panel 1 a , which allows the thermal fluid to collect and store the solar thermal energy. Having described the system, the solar thermal panel 1 a of FIG. 1 is described in greater detail with reference to FIGS. 2 through 5 .
- FIG. 2 is a front profile view of a preferred embodiment of the solar thermal panel 1 a of FIG. 1 .
- the solar thermal panel 1 a comprises horizontal layers 15 a , 15 b , 15 c (collectively 15 ), which horizontally separate the internal space within the solar thermal panel 1 a into top channels 17 and bottom channels 18 .
- these layers comprise clear polymer material that allows a large percentage of solar radiation to pass through the layers 15 .
- the solar thermal panel 1 a also comprises vertical ribs 16 , which vertically separate the internal space within the solar thermal panel 1 a into channels that carry the thermal fluid 2 through the solar thermal panel 1 a .
- the solar thermal panel 1 a is placed above a solid structure, such as a residential roof (not shown).
- the bottom of the solar thermal panel 1 a can be coated with an absorbing layer 19 , and the solar thermal panel 1 a can be placed above an insulating layer 20 .
- the solar thermal panel 1 a carries the thermal fluid 2 through its bottom channels 18 .
- the top channels 17 act as both a transmissive layer and an insulating layer. In other words, the air gap within the top channels 17 allow for transmission of solar radiation while simultaneously providing insulation to the bottom channels 18 .
- the top channels 17 can be evacuated to provide a partial vacuum, thereby improving the solar thermal panel's insulation properties.
- the solar thermal panel 1 a is sealed in such a way that the thermal fluid 2 does not undesirably leak out of the system. Attention is now turned to processes for manufacturing sealed solar thermal panels.
- FIG. 3 is a side profile view of a solar thermal panel as it is manufactured through an extrusion process.
- the solar thermal panel comprises an extruded polymer sheet 1 d .
- One particular type of multi-layered extruded polymer sheet is LEXAN®, a product from General Electric Company.
- the resulting sheet comprises multiple layers 15 a , 15 b , 15 c , which define top channels 17 and bottom channels 18 . Since the process of extruding multi-layered polymer sheets is well known in the art, further discussion of that particular process is omitted here.
- FIG. 4 is a side profile view of a solar thermal panel 1 c being sealed.
- the process of fabricating an extruded polymer sheet 1 d is widely known in the industry, the process of sealing the extruded polymer sheet 1 d is non-trivial.
- FIG. 4 shows one embodiment of a process for manufacturing a sealed extruded polymer panel 1 c.
- the extruded polymer panel 1 c is sealed as it emerges from the extrusion process.
- a heating die 21 is applied in a direction that is vertical to the extruded polymer panel 1 c , thereby creating an impact seal 23 , which melts the extruded polymer panel 1 c at the point of impact to create a sealed edge.
- the temperature of the heating die 21 , the heat distribution within the heating die 21 , and the speed at which the heating die 21 is applied should be controlled so as to provide a proper seal.
- the heating die 21 should be at a temperature that is slightly higher than the melting temperature of the polymer material, but not so high as to char or burn the polymer material.
- the heating die 21 should be uniformly heated in order to avoid non-uniform melting of the extruded polymer panel 1 c .
- the rate at which the heating die 21 is applied should be sufficiently slow enough that the extruded polymer panel 1 c melts, rather than being crushed by the weight of the heating die 21 .
- the heat-sealing of the extruded polymer panel 1 c can be done by other forms of conduction, convection heating, radiant heating, or various combinations thereof.
- a different manufacturing process using conduction, convection, or radiation may be employed to achieve the seal after the extrusion process.
- the polymer panel 1 c once sealed, now provides a base from which a functional solar thermal panel can be fabricated.
- One such panel is shown with reference to FIG. 5 .
- FIG. 5 is a perspective view of a functional solar thermal panel 1 b , which has been fabricated from the sealed extruded polymer panel 1 c of FIG. 4 .
- FIG. 5 shows a solar thermal panel 1 b , with a first set of holes 24 a associate with an inlet 25 a , and a second set of holes 24 b , associated with an outlet 25 b .
- the inlet 25 a and the outlet 25 b may be reversed, depending on the direction of the flow of the thermal fluid 2 .
- the first set of holes 24 a are drilled through the bottom channels 18 ( FIG.
- the second set of holes 24 b are drilled through the bottom channels 18 ( FIG. 2 ) near a proximal edge of the solar thermal panel 1 b , and an outlet 25 b is connected to the second set of holes 24 b .
- the holes 24 a , 24 b are located approximately one inch from their respective edges.
- the inlet 25 a allows for entry of thermal fluid 2 ( FIG. 2 ) into the solar thermal panel 1 b .
- the thermal fluid 2 Once the thermal fluid 2 enters the solar thermal panel through the inlet 25 a , the fluid travels through the bottom channels 18 ( FIG. 2 ) of the solar thermal panel 1 b .
- the fluid 2 fills the bottom channels 18 of the solar thermal panel 1 b and is expelled through the outlet 25 b.
- the fluid that gets pumped into the solar thermal panel 1 a by the first pump 4 will enter the solar thermal panel 1 a through the inlet 25 a . Consequently, once that fluid 2 has traveled through the solar thermal panel 1 a and has been heated by the solar radiation, the fluid 2 is expelled through the outlet 25 b and pumped to the storage tank 3 .
- the solar thermal panel 1 a can be attached to a residential roof, or mounted on walls, or can be used in any position that is consistent with the desired purpose.
- polymer materials such as LEXAN®, have an estimated life of 30 years.
- These types of solar thermal panels can be configured for use in existing structures, or as roofing materials for new structures.
- FIG. 1 shows an embodiment that employs pumps 4 , 9 to transport the fluid 2
- a wholly passive system that is based on thermal convection can be used to transport the thermal fluid 2 .
Abstract
Systems and methods for employing solar thermal energy for heating are disclosed. In some embodiments, a system is disclosed, in which a thermal-fluid-filled solar-thermal panel that has been sealed to prevent leakage of the thermal fluid. In other embodiments, a method of sealing a solar thermal panel is disclosed. In one preferred embodiment, the solar thermal panel is sealed by applying heat to one edge of the solar thermal panel, thereby melting the edge and forming a seal.
Description
- This application claims the benefit of U.S. provisional patent application Ser. No. 61/381,545, having the title “Solar Thermal System,” filed 2010 Sep. 10, which is incorporated herein by reference in its entirety.
- The present disclosure relates generally to solar thermal panels and, more particularly, to systems and methods for manufacturing and sealing solar thermal panels.
- Collecting the sun's energy with solar panels for use in home heating and water heating is a concept that has previously been explored and implemented. However, most currently-existing designs focus on efficiency, rather than cost. As a result, solar thermal panels have not gained widespread use. Thus, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies.
- Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
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FIG. 1 is a diagram that shows one embodiment of a solar thermal system. -
FIG. 2 is a front profile view of a solar thermal panel. -
FIG. 3 is a side profile view of a solar thermal panel. -
FIG. 4 is a side profile view of a solar thermal panel being sealed. -
FIG. 5 is a perspective view of a solar thermal panel. - Reference is now made in detail to the description of the embodiments as illustrated in the drawings. While several embodiments are described in connection with these drawings, there is no intent to limit the disclosure to the embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all alternatives, modifications, and equivalents.
- Brief Overview
- The present disclosure teaches various systems and methods relating to solar thermal panels and solar thermal systems. Unlike conventional solar thermal panels, various embodiments of the inventive solar thermal panels are cost-effective to manufacture, thereby allowing for mass production of the solar thermal panels. In some embodiments, a method of sealing a solar thermal panel is disclosed. In one preferred embodiment, the solar thermal panel is sealed by applying heat and pressure to one edge of the solar thermal panel, thereby melting the edge and forming a seal. In other embodiments, a system is disclosed, in which a thermal-fluid-filled solar-thermal panel that has been sealed by applying heat to its edge to prevent leakage of the thermal fluid.
- Previous Failed Attempts and Eventual Success
- Before describing the various embodiments of the invention, it is worthwhile to understand how the inventive solar thermal panels and systems were developed, along with the corresponding processes for manufacturing these panels and systems. Although the inventive solar thermal panel and its method of manufacture may appear simple, numerous failed attempts prior to the eventual success in building the disclosed working models demonstrate the non-trivial nature of the inventive solar thermal panels, systems, and methods. Consequently, one having ordinary skill in the art will appreciate the difficulties associated with manufacturing the disclosed solar thermal panels and systems.
- A particularly challenging problem related to properly sealing the panel to prevent leakage of the thermal fluid from the solar thermal panel. As one can imagine, in order to maximize the heat capacity within the solar thermal system, much (if not all) of the thermal fluid should be maintained within the solar thermal panel. Unfortunately, if there are leaks in the solar thermal panel, then the thermal fluid can escape, taking with it any heat that is stored in the thermal fluid.
- Sealing the solar thermal panel posed a particularly difficult problem that was not easily overcome. For example, U.S. Pat. Nos. 4,114,597 and 4,178,914 describe headers for unitary solar collectors. These headers are separate components that are attached to the outside of the unitary solar collector. Attempting to attach separate headers to the outside of the solar thermal panel posed problems because the interface between the headers and the unitary solar collector, if not perfectly sealed, created points-of-failure where the thermal fluid escaped from the system. All attempts to externally seal the solar thermal panel with this separate and distinct component (such as a header or a pipe) resulted in incomplete seals, which consequently resulted in leakage of thermal fluid from the system. This occurred despite numerous attempts with many different types of sealants and adhesives. Thus, while it may appear trivial to externally seal the solar thermal panel, the reality of employing a separate component to achieve a leak-resistant seal proved to be unworkable.
- Moving away from a separate header that attached to the outside of the solar thermal panel, attempts were also made to seal the solar thermal panel by removing a portion of the inner channel to create a cavity, and then friction-fitting a pipe in the resulting cavity and sealing the interface between the pipe and the wall of the solar thermal panel. Although intuition suggests that both friction and a commercial sealant, when used in conjunction, would provide a leak-resistant seal, all of the attempts to achieve a leak-resistant seal in this manner also failed. The point of failure was, again, the interface between the solar thermal panel and the inner pipe. Again, all attempts using a separate and distinct component resulted in incomplete seals, which again resulted in leakage of thermal fluid from the system. Despite numerous attempts with varying combinations of pipe sizes and sealants, a leak-resistant seal was never achieved. In other words, employing this separate internal component did not achieve a leak-resistant seal. Mainly, the seals were the points-of-failure because the entire length of the solar thermal panel needed to maintain the seal. Thus, over multiple heating-cooling cycles, the solar thermal panel would expand and contract, thereby causing the adhesive (which expanded and shrank at a different rate) to fail and no longer maintain a leak-resistant seal.
- Many other attempts were made to create a leak-resistant seal, those also failed.
- Insofar as sealing the solar thermal panel with a separate component resulted in failures, despite the numerous permutations of pipe sizes and sealing compounds, efforts were directed to finding ways to seal the solar thermal panel without the use of separate components. Eventually, attempts were made to achieve a leak-resistant seal by melting the open ends of the solar thermal panel, rather than employing separate and distinct sealing components. Early attempts included melting the edge of the solar thermal panel by applying heat to the edge. While applying heat to the edge of the solar thermal panel may seem trivial, even this method posed challenges. For example, finding the right conditions under which a proper seal would form was not a trivial task.
- In terms of heat exposure, prolonged exposure caused not only the edge of the solar thermal panel to melt, but also caused the internal ribs and layers to melt, thereby resulting in an internal leakage of thermal fluid from one layer to another. In terms of finding the correct temperature, if the applied heat was insufficient, then the edges would not melt together. Conversely, if the applied heat was too high, then undesirable effects were seen, such as the melting of the internal ribs and layers as well as material breakdown. Additionally, when there was uneven heat distribution, this resulted in non-uniform melting of the edges, thereby creating an unsightly solar thermal panel.
- Persistence in view of all of those failures eventually led to a redirection of research efforts to the panels, methods, and systems that are described with reference to
FIGS. 1 through 5 . In other words, the embodiments of the invention, as herein described, are the result of numerous failures and difficulties, all of which may appear trivial in hindsight, but which were in reality extraordinarily difficult to overcome. - With these difficulties in mind, attention is turned to
FIGS. 1 through 5 , which show preferred embodiments of a solar thermal panel, a solar thermal system employing the solar thermal panel, and methods for manufacturing the solar thermal panel. -
FIG. 1 is a diagram that shows one embodiment of a solar thermal system. While the system ofFIG. 1 shows a closed loop that circulatesthermal fluid 2, it should be appreciated by those having skill in the art that the system may also be configured as an open-loop system. - The system, as shown in
FIG. 1 , comprises a closed loop that circulatesthermal fluid 2. This closed loop includes a solarthermal panel 1 a, acontrol unit 5, astorage tank 3, and afirst pump 4. The solarthermal panel 1 a comprises apanel temperature gauge 7, which measures the temperature of thefluid 2 within the solarthermal panel 1 a. Thestorage tank 3 comprises afluid temperature gauge 6, aheat exchanger 12, acold water inlet 11, and a hot water pipe (not labeled). Thecontrol unit 5 is operatively coupled to thefirst pump 4, thepanel temperature gauge 7, and thefluid temperature gauge 6. - In operation, the
thermal fluid 2 circulates through the solarthermal panel 1 a, where thefluid 2 absorbs solar energy and heats up as a result. Thethermal fluid 2 can reach temperatures up to 150 degrees Fahrenheit, which is typical for hot water heaters. Based on the readings of thepanel temperature gauge 7 and thefluid temperature gauge 6, thecontrol unit 5 will either activate or deactivate thefirst pump 4. For example, when the reading of thepanel temperature gauge 7 is higher than the reading of thefluid temperature gauge 6, thecontrol unit 5 will activate thefirst pump 4, which pumps thethermal fluid 2 from thetank 3 to the solarthermal panel 1 a. - The
storage tank 3 receives cold water through acold water inlet 11, and the cold water is pumped through theheat exchanger 12. As the cold water travels through theheat exchanger 12, the temperature difference between the cold water and thethermal fluid 2 causes the cold water to heat, while simultaneously causing the heatedthermal fluid 2 to cool. The heated water exits through the hot water pipe (not labeled). Thefirst pump 4 circulates the cooledthermal fluid 2 back to the solarthermal panel 1 a, where thefluid 2 absorbs solar energy and heats up, thereby repeating the cycle. - For some embodiments, such as the one shown in
FIG. 1 , the hot water pipe (not labeled) of thestorage tank 3 is operatively coupled to abooster heater 13, which includes ahot water outlet 14. For those embodiments, the hot water pipe (not labeled) provides the heated water to the booster heater, which further heats the water. That water can then be used by drawing it from thehot water outlet 14. - In addition to using the
thermal fluid 2 to heat water for use, the system ofFIG. 1 also shows a closed loop in which thethermal fluid 2 is used for space heating. An exemplary system for space heating comprises abooster heater 13, a second pump 9, anambient temperature gauge 10, and ahydronic heating system 8. The second pump 9 and theambient temperature gauge 10 are operatively coupled to thecontrol unit 5, which activates or deactivates the second pump 9 based on the reading of theambient temperature gauge 10. - In operation, when the reading of the
ambient temperature gauge 10 is below a set thermostat temperature, the control unit activates the second pump 9, thereby circulating the heatedthermal fluid 2 from thestorage tank 3 to thebooster heater 13. Thebooster heater 13 further heats thethermal fluid 2, which is then pumped through thehydronic heating system 8 via the second pump 9. As thefluid 2 travels through thehydronic heating system 8, it cools as a result of heat transfer to the heated space. The cooledthermal fluid 2 is then pumped back to thestorage tank 3, where the cycle may repeat. - As one can appreciate, the efficiency of the entire system depends in large part on the efficiency of the solar
thermal panel 1 a, which allows the thermal fluid to collect and store the solar thermal energy. Having described the system, the solarthermal panel 1 a ofFIG. 1 is described in greater detail with reference toFIGS. 2 through 5 . -
FIG. 2 is a front profile view of a preferred embodiment of the solarthermal panel 1 a ofFIG. 1 . - As shown in
FIG. 2 , the solarthermal panel 1 a compriseshorizontal layers thermal panel 1 a intotop channels 17 andbottom channels 18. Preferably, these layers comprise clear polymer material that allows a large percentage of solar radiation to pass through the layers 15. The solarthermal panel 1 a also comprisesvertical ribs 16, which vertically separate the internal space within the solarthermal panel 1 a into channels that carry thethermal fluid 2 through the solarthermal panel 1 a. Preferably, the solarthermal panel 1 a is placed above a solid structure, such as a residential roof (not shown). To increase the heat absorption by thethermal fluid 2, and also to reduce heat loss from a residential structure, the bottom of the solarthermal panel 1 a can be coated with an absorbinglayer 19, and the solarthermal panel 1 a can be placed above an insulatinglayer 20. - Given this multi-layered structure, the solar
thermal panel 1 a carries thethermal fluid 2 through itsbottom channels 18. Thetop channels 17 act as both a transmissive layer and an insulating layer. In other words, the air gap within thetop channels 17 allow for transmission of solar radiation while simultaneously providing insulation to thebottom channels 18. For some embodiments, thetop channels 17 can be evacuated to provide a partial vacuum, thereby improving the solar thermal panel's insulation properties. Once the solar radiation reaches the absorbinglayer 19, the solar radiation is converted to thermal energy. The thermal energy is then absorbed by thethermal fluid 2, which is carried in thebottom channels 18 adjacent to the absorbinglayer 19. The heated thermal fluid then circulates through a solar thermal system, similar to that shown inFIG. 1 . - As one having skill in the art can appreciate, the solar
thermal panel 1 a is sealed in such a way that thethermal fluid 2 does not undesirably leak out of the system. Attention is now turned to processes for manufacturing sealed solar thermal panels. -
FIG. 3 is a side profile view of a solar thermal panel as it is manufactured through an extrusion process. Specifically, the solar thermal panel comprises an extrudedpolymer sheet 1 d. One particular type of multi-layered extruded polymer sheet is LEXAN®, a product from General Electric Company. As shown inFIG. 3 , when the extrudedpolymer sheet 1 d is extruded in accordance with known methods, the resulting sheet comprisesmultiple layers top channels 17 andbottom channels 18. Since the process of extruding multi-layered polymer sheets is well known in the art, further discussion of that particular process is omitted here. -
FIG. 4 is a side profile view of a solarthermal panel 1 c being sealed. As noted above, although the process of fabricating anextruded polymer sheet 1 d is widely known in the industry, the process of sealing the extrudedpolymer sheet 1 d is non-trivial.FIG. 4 shows one embodiment of a process for manufacturing a sealed extrudedpolymer panel 1 c. - In a preferred embodiment, the extruded
polymer panel 1 c is sealed as it emerges from the extrusion process. As the extrudedpolymer panel 1 c passes over abottom die 22, aheating die 21 is applied in a direction that is vertical to the extrudedpolymer panel 1 c, thereby creating animpact seal 23, which melts the extrudedpolymer panel 1 c at the point of impact to create a sealed edge. - As described above, the temperature of the heating die 21, the heat distribution within the heating die 21, and the speed at which the heating die 21 is applied should be controlled so as to provide a proper seal. Specifically, the heating die 21 should be at a temperature that is slightly higher than the melting temperature of the polymer material, but not so high as to char or burn the polymer material. Also, the heating die 21 should be uniformly heated in order to avoid non-uniform melting of the extruded
polymer panel 1 c. Finally, the rate at which the heating die 21 is applied should be sufficiently slow enough that the extrudedpolymer panel 1 c melts, rather than being crushed by the weight of the heating die 21. Insofar as all of these factors depend on the characteristics of the polymer material, and insofar as one having skill in the art can calculate these factors, further discussion of applying the heating die 21 is omitted here. It should also be appreciated by those skilled in the art that the heat-sealing of the extrudedpolymer panel 1 c can be done by other forms of conduction, convection heating, radiant heating, or various combinations thereof. Thus, for example, should the extruded polymer panel not be sealed immediately after extrusion, a different manufacturing process using conduction, convection, or radiation may be employed to achieve the seal after the extrusion process. - The
polymer panel 1 c, once sealed, now provides a base from which a functional solar thermal panel can be fabricated. One such panel is shown with reference toFIG. 5 . -
FIG. 5 is a perspective view of a functional solarthermal panel 1 b, which has been fabricated from the sealed extrudedpolymer panel 1 c ofFIG. 4 . Specifically,FIG. 5 shows a solarthermal panel 1 b, with a first set ofholes 24 a associate with aninlet 25 a, and a second set ofholes 24 b, associated with anoutlet 25 b. One can readily appreciate that theinlet 25 a and theoutlet 25 b may be reversed, depending on the direction of the flow of thethermal fluid 2. The first set ofholes 24 a are drilled through the bottom channels 18 (FIG. 2 ) near a distal edge of the solarthermal panel 1 b, and theinlet 25 a is connected to the first set ofholes 24 a. The second set ofholes 24 b are drilled through the bottom channels 18 (FIG. 2 ) near a proximal edge of the solarthermal panel 1 b, and anoutlet 25 b is connected to the second set ofholes 24 b. In preferred embodiments, theholes - In operation, the
inlet 25 a allows for entry of thermal fluid 2 (FIG. 2 ) into the solarthermal panel 1 b. Once thethermal fluid 2 enters the solar thermal panel through theinlet 25 a, the fluid travels through the bottom channels 18 (FIG. 2 ) of the solarthermal panel 1 b. Eventually, thefluid 2 fills thebottom channels 18 of the solarthermal panel 1 b and is expelled through theoutlet 25 b. - Placing this in the context of
FIG. 1 , the fluid that gets pumped into the solarthermal panel 1 a by thefirst pump 4 will enter the solarthermal panel 1 a through theinlet 25 a. Consequently, once thatfluid 2 has traveled through the solarthermal panel 1 a and has been heated by the solar radiation, thefluid 2 is expelled through theoutlet 25 b and pumped to thestorage tank 3. - As shown in
FIG. 1 , the solarthermal panel 1 a can be attached to a residential roof, or mounted on walls, or can be used in any position that is consistent with the desired purpose. Typically, polymer materials, such as LEXAN®, have an estimated life of 30 years. These types of solar thermal panels can be configured for use in existing structures, or as roofing materials for new structures. - Variants
- Although exemplary embodiments have been shown and described, it will be clear to those of ordinary skill in the art that a number of changes, modifications, or alterations to the disclosure as described may be made. For example, while a residential roofing system has been described with reference to the solar thermal panels, it should be appreciated that the system can be used in residential, commercial, or industrial settings. Additionally, one having skill in the art will understand that the system of
FIG. 1 can be configured to be wholly programmable and automated, or can require manual input by a user. Also, one having skill in the art will understand that the thermal fluid can be water, glycol, or other fluid that has desired heat capacity properties. Furthermore, one having skill in the art will appreciate that the absorbinglayer 19 can comprise tar paper, paint, or other substance that is conducive to absorbing solar energy. Finally, it should be appreciated that, whileFIG. 1 shows an embodiment that employspumps 4, 9 to transport thefluid 2, a wholly passive system that is based on thermal convection can be used to transport thethermal fluid 2. - All such changes, modifications, and alterations should therefore be seen as within the scope of the disclosure.
Claims (8)
1. A method of manufacturing a solar thermal panel, comprising the steps of:
extruding a polymer panel comprising layers, the polymer panel further comprising an open edge; and
melting the open edge to form a sealed edge.
2. The method of claim 1 , wherein the melting step comprises the steps of:
pressing the top of the polymer panel with a heated die, thereby causing the layers to melt together to form a seal.
3. The method of claim 1 , wherein the melting step comprises the steps of:
heating the open edge with a radiative heat source.
4. The method of claim 1 , wherein the melting step comprises the steps of:
heating the open edge with a convective heat source.
5. The method of claim 1 , wherein the melting step comprises the steps of:
heating the open edge with a conductive heat source.
6. A solar thermal panel manufactured using the method of claim 1 .
7. A solar thermal panel comprising:
a bottom channel for carrying thermal fluid, the bottom channel having a bottom-channel seal to prevent leakage of the thermal fluid from the bottom channel;
a first hole located near a first edge of the bottom channel, the first hole for receiving the thermal fluid from an external source;
a second hole located near a second edge the bottom channel, the second hole for expelling the thermal fluid from the solar thermal panel; and
a top channel located above the bottom channel, the top channel having a top-channel seal.
8. The panel of claim 7 , further comprising:
an inlet attached to the first hole; and
an outlet attached to the second hole.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/227,606 US20120060830A1 (en) | 2010-09-10 | 2011-09-08 | Solar thermal panels |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US38154510P | 2010-09-10 | 2010-09-10 | |
US13/227,606 US20120060830A1 (en) | 2010-09-10 | 2011-09-08 | Solar thermal panels |
Publications (1)
Publication Number | Publication Date |
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US20120060830A1 true US20120060830A1 (en) | 2012-03-15 |
Family
ID=45805446
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US13/227,606 Abandoned US20120060830A1 (en) | 2010-09-10 | 2011-09-08 | Solar thermal panels |
Country Status (1)
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US (1) | US20120060830A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2019129539A1 (en) | 2017-12-27 | 2019-07-04 | Basf Se | A composition, its preparation process, and the use of the composition as a waterproofing coat |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4480635A (en) * | 1980-05-08 | 1984-11-06 | Rav Shemesh B.M. | Solar heater |
US5846620A (en) * | 1997-02-06 | 1998-12-08 | W. R. Grace & Co.-Conn. | High strength flexible film package |
-
2011
- 2011-09-08 US US13/227,606 patent/US20120060830A1/en not_active Abandoned
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4480635A (en) * | 1980-05-08 | 1984-11-06 | Rav Shemesh B.M. | Solar heater |
US5846620A (en) * | 1997-02-06 | 1998-12-08 | W. R. Grace & Co.-Conn. | High strength flexible film package |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2019129539A1 (en) | 2017-12-27 | 2019-07-04 | Basf Se | A composition, its preparation process, and the use of the composition as a waterproofing coat |
US11434379B2 (en) | 2017-12-27 | 2022-09-06 | Basf Se | Composition, its preparation process, and the use of the composition as a waterproofing coat |
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