WO2017196188A1

WO2017196188A1 - Improvements to concentrating solar power systems, components therefore, and methods of manufacture and assembly

Info

Publication number: WO2017196188A1
Application number: PCT/NZ2017/050056
Authority: WO
Inventors: Kerry Hayes
Original assignee: Insolare Group Limited
Priority date: 2016-05-09
Filing date: 2017-05-09
Publication date: 2017-11-16

Abstract

The specification describes improvements to concentrating solar power systems, components therefore, and methods of manufacture and assembly.

Description

TITLE

IMPROVEMENTS TO CONCENTRATING SOLAR POWER SYSTEMS, COMPONENTS THEREFORE, AND METHODS OF MANUFACTURE OR ASSEMBLY

TECHNICAL FIELD The present invention relates to improvements to concentrating solar power systems, components therefore, and methods of manufacture or assembly.

BACKGROUND

Concentrating solar power ("CSP") systems are used to harness energy from the sun. The sun's rays are reflected using a reflector such as a mirror, onto a collector. The heat from the sun can then be used to generate electricity, or in another industrial process.

The collector is or includes a heat transfer assembly, which transports the heat to an apparatus or assembly for use. These heat transfer systems often include a thermal fluid such as water (in the form of steam) or other substance having a high specific heat. These substances are circulated through the assembly to capture the heat and facilitate its use. Alternatively, the heat transfer system may comprise a solid state media that transfer the heat so it can be used away from the reflector assembly.

The reflectors comprise a significant portion of the cost of a CSP system. A number of subcomponents contribute to the cost of these reflectors, including the support structures (often referred to as troughs), reflective surfaces, and collectors. A common type of trough is formed from a plurality of individual steel tubes. These are welded together to form a structure having sufficient rigidity to hold the reflective surface in position in the CSP system in-use. However, this method of manufacture is expensive due to the skill and labour required to assemble the tubes together.

In addition, the troughs produced using these methods have some inherent limitations which reduce their potential usefulness in CSP systems.

Attempts have been made to manufacture solar reflector panels using sandwich type construction techniques. See for example United States Patent No. 7077532. However, these types of solar panels all have their own inherent limitations. For instance, the invention described in United States Patent No. 7077532 is laborious to construct, requiring that a sheet of a core material is individually affixed to a casing layer and that a reflector must be subsequently affixed to the casing layer.

l In addition, it is unlikely that the core materials do not significantly contribute to the strength of the solar panel produced according to the teaching of United States Patent No. 7077532.

A further inherent problem identified in United States Patent No. 7077532 is that certain types of core materials were not able to cope with the heat experienced in use. Accordingly, the solar panels were not suitable for the intended use.

As a result of the foregoing, it is an object of the invention to provide a method of

manufacturing a support system for a CSP system which reduces the cost, labour, and/or skill involved in manufacturing CSP systems, particularly including support structures therefore. It is an object of the invention to provide an alternative support structure, or components therefore, for use in forming CSP systems.

In addition, it is an object of the invention to provide a method of assembling a CSP system.

Yet a further object of the invention is to provide a trough for a CSP system which is lighter weight than those available in the prior art. Yet a further object of the invention is to reduce the time and/or skill required to assemble a CSP system.

Yet a further object of the invention is to provide a support structure for a CSP system which is more rigid then the prior art troughs, while still achieving one or more of the other specified objectives. Alternatively, it is an object of the present invention to address the foregoing problems, or to at least provide the public with a useful choice.

DISCLOSURE OF INVENTION

A concentrating solar power ("CSP") system having at least one module, wherein the at least one module comprises a first layer, and wherein the first layer has a plurality of corrugations, a reflective layer, a second layer, wherein the first layer and the second layer are different materials to each other. A module for use in forming a power ("CSP") system, wherein the module includes: a first layer, and wherein the first layer has a plurality of corrugations, a reflective layer, a second layer, wherein the first layer and the second layer are different materials to each other. A concentrating solar power ("CSP") system, including at least a first module and a second module, at least a first tensioned connector that is positioned and arranged to hold the first module and the second module together.

A method of assembling a concentrating solar power ("CSP") system, the method including the steps of:

(a) positioning a first module;

(b) positioning a second module;

(c) positioning at least a first connector with respect to the first module and the second module; (d) tensioning the first connector to thereby cause it to hold the first module and the second module together.

A method of manufacturing a module for a solar collector, including:

(a) positioning a reflector in a mold;

(b) injecting or pouring a raw material into the mold; (c) curing the raw material.

A system configured for use in a method of manufacturing a module for a solar collector, including a molding station comprising at least one mold, an insert station, a delivery system; wherein the system is configured to in use: (a) position a reflective layer in the at least one mold of the molding station;

(b) inject or pour a raw material into the at least one mold;

(c) cure the raw material. A method of manufacturing a module for a solar collector, including the steps of:

(a) forming a corrugation in at least one sheet of metallic material to produce a

corrugated layer;

(b) securing a support truss to the corrugated layer; (c) securing a reflective layer to the corrugated layer.

A module for a solar collector, including a support material, a corrugated layer, and a reflective layer, and wherein the support material was formed directly to the corrugated layer and / or the reflective layer by pouring or injecting a raw material with respect to the corrugated layer and / or reflective layer and allowing the raw material to cure to form the support material.

A module for a solar collector, including a first corrugated layer that includes a plurality of apertures which extend from a first side of the first corrugated layer to a second side of the corrugated layer, a support material which extends through at least some of the apertures in the first corrugated layer and adheres to a surface of a reflective layer to secure the reflective layer to the first corrugated layer.

A method of assembling a solar collector, including the steps of: (a) positioning a first module;

(b) positioning a second module adjacent to the first module;

(c) attaching the first module and the second module to support structure(s);

(d) post-tensioning the first module and the second module together.

Embodiments of the invention are intended for use together. As a result, they will be described herein as such. However, it should be appreciated that the inventions may be used independently of each other. Therefore, the discussion herein should not be seen as limiting. In embodiments of the invention, the module(s) may have a parabolic shape, and therefore in use provide a parabolic reflector. In these embodiments, when viewed side on, the module(s) provides a reflective layer lying on a parabola. In use, the reflective layer reflects incident light to its focal point. This type of reflector is referred to as a parabolic reflector.

However, it should also be appreciated that the module may have other shapes and therefore provide supports for different CSP systems e.g. linear fresnal reflector systems, or a helio-stat solar power system.

Throughout the present specification, aspects of the invention will be described using terms such as width, length, depth, and thickness. It should be understood that these are relative terms. For convenience sake, in respect of a parabolic reflector embodiment, the following conventions will be used:

• Width, being the distance which a module extends along the directrix of the parabola.

• Height, being the distance which the module extends along the axis of symmetry.

• Depth, being the distance which the module extends along a plane normal to the directrix and the axis of symmetry.

• Thickness, being the distance between two opposed points measured in a plane substantially normal to the reflective surface.

The width, height, and depth of the module(s) will be discussed with reference to the reflective layer of the panel. It should be understood that the width and / or height are less than length of the reflective layer lying in that plane due to the curved shape of the reflective layer.

It is envisaged that the module(s) according to the invention may have a non-uniform thickness e.g., the thickness of the module varies across its length, depth, and / or width. In embodiments, in use, two or more of the modules according to the invention may be held in an operative position to provide a portion of a solar field for a CSP system e.g. may the modules be connected together to provide a solar collector of a desired length / dimensions. However, it is also envisaged that a single (one) module may be used, or that multiple modules may be positioned relative to each other. Throughout the present specification, reference will be made to the term "reflective layer". This should be understood as meaning a substance, substrate, or assembly of components which is capable of reflecting radiation e.g. sunlight.

In an embodiment, the reflective layer may be glass having a silvered backing. However, alternatives for the reflective layer are envisaged, including aluminium or metal films etc. In an embodiment, a sheet of glass providing the reflective layer may be any suitable thickness. For instance, the glass may have a thickness in the range of substantially 1 mm to substantially 3 mm.

In addition, reflective surfaces suitable for use with the invention may have different reflective efficiencies. However, to maximise the efficiency of the invention, the reflective layer should preferably have the highest reflective efficiency possible e.g. greater than 98%.

It is envisaged that the reflective layer may be an initially flat material, which is shaped to have a desired shape e.g. a parabola. This shaping may occur during attachment of the reflective layer to a sheet of material, or a partially formed module. Alternatively, the reflective layer may be pre-curved or shaped to correspond to a desired shape such as during forming of the reflective layer.

In an embodiment of the invention, layers used in the invention may be a metallic sheet material. For instance, the first layer may be formed form a sheet of 200 - 600 grade stainless steel, having a thickness in the range of approximately 0.5-2mm In addition, the metallic sheet materials may be pre-treated such as by galvanising, painting or other treatment process to provide beneficial properties, such as for example strength, corrosion resistance etc.

The thickness, strength and properties of metallic sheets used in the invention are not arbitrary. Instead, these characteristic of the components may have an important effect of the effectiveness of the invention. For instance, the preferred thickness and strengths may enable the sheets to be deformed to form a corrugated sheet, without breaking the sheet. In addition, the preferred could be important to providing sufficient strength and / or rigidity to a module according to the invention.

Reference throughout the present specification will be made to "corrugated". This should be understood as meaning a plurality of ridges which are separated by valleys.

In an embodiment, the ridges are orientated to extend along the width of a module, and reference will be made herein as such. However, the ridges may also extend along the depth of the module and therefore the discussion herein should not be seen as limiting.

In an embodiment, the ridges have a substantially trapezoidal shape when viewed end on e.g. along the length of the ridge. However, it is also envisaged that the ridges could have other shapes such as a rounded / curved shape, a triangular shape etc. Having ridges formed into the first layer may provide additional structural integrity to a module according to an embodiment of the invention as compared to comparable non- corrugated curved sheets.

In preferred embodiments a second layer of a module according to the invention is formed directly to the reflective layer by being positioned relative to the reflective layer e.g. such as by pouring or injecting a raw material, and subsequently allowing the raw material to cure. The process of curing allows the raw material to harden to provide rigidity to the reflective layer.

In an embodiment, the raw material may be a foam such as a polyurethane foam as should be known to one skilled in the art. Reference will be made as such, although this should not be seen as limiting. Alternatively, the foam may be any open or closed cell foam.

In addition, it is also envisaged that the raw material may be other materials which can be applied in a liquid / fluid / gas form and subsequently cured.

Pouring and / or injecting a foam relative to the reflective layer may allow it to infiltrate voids and / or through gaps and apertures, either as it is poured / injected or as it expands. This process may provide additional support for a module according to the invention as there is a comparatively greater support provided for the reflective layer.

In addition, the forming process removes the need to separately form / shape the second layer. This infiltration may also assist in attaching the foam to the first layer. Therefore, the present invention may provide manufacturing efficiencies and cost savings as compared to prior art composite reflector panels.

In an embodiment, the raw material may at least partially attach a first layer to the reflective layer. That is, the raw material provides an adhesive which at least partially, and more preferably completely, secures the reflective layer and the first layer together. This may be possible due to the method of manufacturing the module described herein. For instance, a raw material is poured and / or injected with respect to the first layer, and allowed to infiltrate through holes in the first layer, to contact a surface of the reflective layer.

The raw material may also be allowed to rise (expand). This may facilitate the raw material coming into contact with the first layer and / or a surface of the reflective layer. As the raw material cures it adheres to the reflective layer and the first layer, to thereby secure the two together.

In preferred embodiments, sufficient of the raw material is poured / injected to provide rigidity to a module according to the invention. The rigidity may substantially contribute to the rigidity of a module, and form a composite panel comprising a reflective layer, a first layer, the foam, and other layers or components as described herein. This aspect of the invention should become clearer from the following description.

It should be understood that the use of raw material, for e.g. a foam, according to the invention differs to that in the prior art. For instance, the raw material is not pre-formed such as into a foam block, and subsequently secured to a reflective layer or casing layer. Instead, securing and shaping occurs concurrent to each other.

This may provide a number of advantages such as significantly reducing manufacturing time, improving accuracy of manufactured product, reducing labour and skill required to manufacture a module for a CSP system.

In an embodiment, a module according to the invention may include a third layer.

The raw material may at least partially, and preferably completely, adhere to the third layer. In this embodiment, the injection / pouring, and / or rising of the raw material causes it to contact the third layer. As the raw material cures, it adheres to the third layer. However, it is also envisaged that the third layer may be attached to the reflective layer (or other layers of a module) by other means such as a separate adhesive, rivets, and / or screws.

In an embodiment, the third layer may be corrugated e.g., the third layer may have a plurality of corrugations therein. The corrugations may be pre-formed into the layer such as by a deformation process prior to being secured to the first and / or second layer.

Providing the second layer with corrugations may make it stronger than a comparable non- corrugated sheet of material. Accordingly, the strength and / or rigidity of the panel may be increased.

However, it is also envisaged that the third layer may also be a non-corrugated curved sheet and therefore the foregoing should not be seen as limiting on the scope of the present invention.

In an embodiment, the third layer and the first layer may have different curves e.g., the layers lie on different parabolas. In this embodiment, it may provide a module according to the invention with a thickness that varies across its width. In an embodiment, a module according to the invention may include at least one conduit. Each conduit may be positioned and orientated to extend along the depth of the module. However, the conduits could also extend along the width of the modules.

The conduit(s) may provide a path through which a tensioning apparatus can extend. This could be particularly useful to facilitate connecting the tensioning apparatus to two or more adjacent modules to facilitate post-tensioning of the modules together.

In addition, the conduit(s) could contribute to the strength of a module according to an embodiment of the invention e.g. the conduit(s) may increase the rigidity and / or torsional strength of the module(s).

In an embodiment, a module may include a first conduit and a second conduit, and wherein the conduits are laterally spaced e.g. are spaced apart from each other across the width of the module.

For example, two conduits may be positioned at the same height of the module. However, it is also envisaged that two conduits may be positioned at different heights and therefore, the foregoing should not be seen as limiting. In an embodiment, the first conduit and the second conduit are spaced apart from each other along the height of the module. For instance, a conduit may be positioned at the vertex of the module, and another conduit may be positioned at the lateral margin of the module.

In an embodiment, the conduits may be symmetrically positioned in the module e.g. with respect to the vertex of the module. It is also envisaged that a module according to the invention could include three or more conduits, which are spaced apart from each other across the width of the module.

In an embodiment, a module may include webbing. The webbing can provide additional structure through which the raw material may pass such as when being poured, injected, and/or expand. The webbing may be formed integrally to, or secured to, the conduit(s).

Reference throughout the present specification to "tensioner" should be understood as meaning a component which can be tightened to draw two or more modules together.

The tensioner may include structure or components to engage one or more of the modules. This may facilitate the tensioner drawing the two modules together. In an embodiment, the tensioner may be a cable, wire rope, or flexible component. However, the tensioner could also be a rigid extrusion, rack and tooth arrangement etc. Therefore, the foregoing should not be seen as limiting on the scope of the present invention.

In an embodiment, the invention may include multiple tensioners. The tensioners are spaced apart from each other laterally and/or along the height of the panel(s).

However, it is also envisaged that the module(s) may include only a single tensioner positioned, such as e.g. at the vertex of the modules (s).

The use of a tensioner(s) may be useful in facilitating a more rigid and / or stable reflector for a CSP system. In addition, the tensioner(s) may facilitate provision of a post-tensioned reflector support for a CSP system. The post-tensioned support system may be easily constructed and a desired degree of rigidity can be provided.

The provision of a post-tensioned reflector support may be possible due to the embodiments of a panel as described herein. For instance, the use of a foam such as polyurethane, can provide a degree of rigidity and / or structural integrity to an individual panel. The panel can be subsequently connected to adjacent panel(s) using the tensioner(s).

In an embodiment, the tensioner(s) are disposed within a conduit(s) in the module(s). This may assist with providing the tensioner(s) in a position to extend past, and draw together, multiple modules. In an embodiment, the module(s) may include an alignment mechanism.

Reference to the term "alignment mechanism" should be understood as meaning

component(s) or mechanism configured to assist with or facilitate aligning two modules with respect to each other. The alignment mechanism may therefore facilitate assembly of panel(s) according to embodiments of the invention to provide a reflector support for a CSP system.

In an embodiment, the alignment mechanism may comprise one or more pairs of mating components. For instance, each pair may comprises a first half and a second half. The first half and the second half are positioned respective ends of a module such that when two adjacent modules are aligned, the first half and the second half are aligned. It should be understood that each module (230) may include a first half at or towards a first end, and a second half at or towards a second end which distal to the first half. Each half is configured to engage with a corresponding half on an adjacent module in use. Each half forming part of an alignment mechanism may take different forms. For instance, a first half may be a male end configured to be disposed in an aperture forming the second half.

In a preferred embodiment, the alignment mechanism may be provided by ends of the conduits e.g., a first end of a conduit provides a first half and the distal end of the conduit provides a second half. In use, the first half and the second half each engage respective halves of adjacent panels in use.

It should be understood that aspects of the invention may selectively be used in combination with each other. Therefore, any reference to use of specific aspects together should not be seen as limiting on the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the invention should become clearer with reference to the attached Figures, in which:

Figure 1 is a schematic of a concentrating solar power ("CSP") electricity generation system according to the invention;

Figure 2 is a first end-on perspective view of a module according to the invention;

Figure 3 is an exploded view of a module according to the invention;

Figure 4 is a second-end perspective end on view of a module according to the invention; Figure 5 is a top perspective view of a module according to the invention;

Figure 6 is a first close up view of a module according to the invention;

Figure 7 is a second close up view of a section of a module according to the invention;

Figure 8 is a side cross sectional view of a module according to the invention;

Figure 9 is a side view of a reflector according to the invention in a first orientation; Figure 10 is a side view of a reflector according to the invention in a second orientation;

Figure 1 1 is a view comparing a reflector according to the invention in third orientations;

Figure 12 is a representative schematic of a manufacturing system according to an aspect of the invention Figure 13 is a side cross sectional view of a mold forming part of a manufacturing system according to the invention.

DETAILED DISCLOSURE

CSP System Referring first to Figure 1 , there is provided a concentrating solar power ("CSP") electricity generation system (100). The system (100) includes a solar field indicated as (200), and a generation system (300).

The solar field (200) includes a plurality of reflectors indicated as (210) each of which has an associated collector indicated as (220). Each reflector (210) is formed from at least one, and preferably a plurality of, modules (230) as are discussed in more detail below.

Each reflector (210) is mounted on an actuator arrangement which is represented in the Figures as a legs (21 1 ). For simplicity, components of the actuator arrangement other than legs (21 1 ) are not shown in the Figures. Each actuator arrangement is configured to rotate the respective reflector(s) (210) about an axis to facilitate tracking of the sun during its path through the sky. This facilitates the sun's rays being captured and subsequently used by the generation system (300). Representative positions for the reflector (210) are shown in Figures 9 and 10, while Figure 1 1 shows three representative positions for the reflector (210) relative to each other. It should be understood that the reflector (210) can be moved incrementally between each of the positions shown in Figure 1 1 .

A tracking and control system (not shown) is connected to the actuator arrangements to ensure that the position of the reflectors (210) is optimised at any given time.

The tracking and control system (not shown) may also include an emergency override function, which can bring the reflectors (210) off line (out of alignment with the sun's rays) if needed. This can provide an important safety function.

Each collector (220) is positioned to lie on the focal point of a respective reflector (210). This facilitates the reflectors (210) reflecting the sun's rays onto the collectors (220), and thereby heat from the sun being used by the generation system (300). Holding of the collector (220) in position may be achieved by mounting structures, e.g. in the form of rigid arms (213) as shown in the Figures. Each collector (220) is operatively connected to a heat transfer system indicated generally as (205). The heat transfer system (205) facilitates transport of the heat in sunlight incident on the collector (220) to the generation system (300). In the embodiment of Figure 1 , the heat transfer system (205) includes conduits (204) in fluid communication with the collectors (220). A pump (202) is configured to move a heat transfer fluid through the conduits (204) and the collectors (220). Accordingly, the heat transfer fluid can absorb heat from sunlight incident on the collector (220).

The heat transfer fluid may be any known fluid such as water / steam or other fluid having a high specific heat and / or other properties which make it suitable for use as a heat transfer fluid.

It is also envisaged that other embodiments for the heat transfer system (205) may be used such as molten salt or non-water / steam based system.

The heat transfer system (205) may be a direct to steam system e.g. steam exiting the collectors (220) enters the generation system (300). However, it is also envisaged that an exchanger (206) could be used to generate steam from a heat transfer fluid flowing through the collector (230).

In use, a comparatively cold heat transfer fluid enters the collector (230) and is heated by the sun's ray concentrated onto the collector (220) by the reflector (210) so that a comparatively hot heat transfer exits each collector (220) from where is subsequently used by the generation system (300). The direction of flow of the heat transfer fluid in the heat transfer system (205) is indicated by arrows in Figure 1 .

The generation system (300) can be any commercially known system which requires heat. For instance the generation system may be an electricity generating system such as a steam turbine or steam piston engine. In use, the generation system (300) uses heat from the collectors (220) to produce electricity.

The generation system (300) may also include a heat recovery unit (209), which is configured to in use capture heat from steam exiting a turbine / engine and before that steam again enters the exchanger (206). The use of a heat recovery unit (209) may contribute to the total efficiency of the system (100). First Embodiment of a Reflector

Referring now to Figures 2 to 8. Each reflector (210) is formed from at least one module (230), such as between 1 to 100 modules (230). The number of modules (230) may be selected according to factors such as a desired length for the reflector (210), the strength of the actuator arrangement (e.g. legs (21 1 )) and support structures such as foundations (not shown), or the required shape and configuration of the solar field (200). For simplicity the number of modules (230) will not be discussed herein. However, one skilled in the art would appreciate that the invention is not limited to a specific number of modules (230) for the reflector (210). In the Figures, only several of the modules which form the reflector (210) are noted.

All of the modules (230) used to form the reflector (210) are identical to each other.

Accordingly, only one module will be discussed herein. Throughout the Figures, like numerals refer to like components.

Each module (230) is a composite sandwich panel structure which in a preferred form includes a first corrugated layer (232), a second corrugated layer (234), and a support material (236) in the form of a polyurethane foam.

The first corrugated layer (232) and the second corrugated layer (234) form part of (or are) a housing to retain / encase the support material (236).

The module (230) includes at least one member and preferably two or more member which extend along the width of the module. In the embodiment shown in the Figures, five members (240, 242, 244, 246, and 248) are used.

Each member (240, 242, 244, 246, and 248) includes a first flange (250), a second flange (252), and a body portion (254). The body portion (254) is shape to define an aperture which is indicated as (256).

Each member (240, 242, 244, 246, and 248) includes a conduit (258). The conduit may be secured to the member (240, 242, 244, 246, and 248) or formed integrally thereto e.g. in the form of an extrusion. The conduit may be positioned at various locations such at or adjacent the first flange (250), at or adjacent the second flange (252), or intersecting the body portion (254) as is shown in the Figures.

Each member (240, 242, 244, 246, and 248) includes a male end indicated generally as (260) and a female end indicated generally as (262). The male end (260) and the female end (262) are configured to engage with a corresponding male end (260) and a female end (262) respectively on laterally adjacent modules (230). When two modules (230) are assembled to form a reflector (210), the male end (260) extends into the female end (262). The interaction of the male end (260) and the female end (262) may also assist to align laterally adjacent modules (230), which may assist in assembling the reflector (210). It is envisaged that the members (240, 242, 244, 246, 248) may be identical to each other or differ from one or more of the other members in at least one respect. For instance, one of the members may have a different shaped body portion (254), apertures (256), presence of conduit (258), and / or flanges (250, 252). Therefore, the members (240, 242, 244, 246, 248) may be customized to provide desirable features such as strength and rigidity to a particular portion of the module (230).

A flexible component (264) may be disposed in the conduits (258). The flexible component (264) may be a length of material such as a wire rope or other suitable component(s). A first locking element (not shown in the Figures) is secured to an end of the flexible component (264). The flexible component (264) is tensioned and a second locking element (not shown in the Figures) is secured to a second end of the flexible component (254). The locking elements (not shown in the Figures) prevent the tension in the flexible component (264) reducing. The locking elements (not shown in the Figures) and flexible component (264) hold two or more modules (230) together and substantially prevent them moving away from each other in a direction along the length of the conduits (258). The first corrugated layer (232) has a series or corrugations having a generally trapezoidal cross section. Each corrugation comprises a peak (270) and a trough (272). Each peak (270) is connected to a trough (272) by a pair of corrugation side walls (274, 276).

The peaks (270) provide a bearing surface which is in contact with a back surface of a reflective layer (278). The first corrugated layer (232) has apertures (not shown in the Figures) which extend from a first side of the first corrugated layer (232) to a second side of the first corrugated layer (234). The support material (236) extends through the apertures in the first corrugated layer (232) and is in contact with a rear surface of the reflective layer (278).

The support material (236) acts as an adhesive to secure the reflective layer (278) to the first corrugated layer (232).

The first corrugated layer (232) curves about an axis, which defines the focal point for the module (230) and thereby also the reflective layer (278). Accordingly, when the reflector (210) is assembled an in use, the collector (220) lies on the axis about which the bearing surface defined by the peaks (270) curves. In the embodiment shown in the Figures, the length of the corrugations (defined by the peaks (270) and the troughs (272) is substantially perpendicular to the width of the reflector (210).

The curve of the first corrugated layer (232) preferably corresponds to the shape of the reflective layer (278), such as on a parabola. However, it may have any desired shape.

The second corrugated layer (234) has a series of corrugations having a generally trapezoidal shape. Each corrugation has a peak (280) and a trough (282). Each peak (280) is connected to adjacent troughs (282) by corrugation side walls (284, 286).

The second corrugated layer (234) also curves about an axis (not noted in the Figures). The axis is orientated to extend along the length of the reflector (210), and in use is parallel to the length of the collector (220). Therefore, the peaks (280) and troughs (282) extend substantially perpendicular to the length of the reflector (210).

Side edge caps are (288, 290) are secured to the side edges of the first module (230). In the embodiment of the Figures, the side edge caps (288, 290) form part of a housing which encapsulates the support material (236). However, it is also envisaged that the side edge caps (288, 290) may not be included, and instead that the first corrugated layer (232) and / or the second corrugated layer (234) may be deformed to perform the side function as the side edge caps (288, 290).

Manufacturing System Referring now to Figure 12 which is a schematic of a representative system (600) configured for use in manufacturing modules (230) according to the invention. The system (600) can be configured to manufacture any of the modules described herein. However, only manufacture of a module (230) will be specifically discussed. It should be appreciated that the

configuration of system (600), and the steps / processes which it performs, will be adjusted to manufacture a module (230).

The system (600) includes a feed station (602), a deforming station (604), an assembly station (606), and a control apparatus (608).

The control apparatus (608) is in communication with components in the system (600) and is able to control their operation. The feed station (602) includes at least one decoiler, such as (61 OA, 610B) as shown in Figure 12. The decoilers (61 OA, 610B) each contain a coil of a stainless steel sheet (612A, 612B). The decoilers (61 OA, 61 OB) are configured to rotate to feed the stainless steel into the deforming station (604).

A cutting station (613) is configured to cut the stainless steel on the decoilers (61 OA, 61 OB) into individual lengths. The cutting station (613) may include at least one, and preferably two, cutting apparatus (615A, 615B) as is shown in the Figures.

The individual lengths of steel cutting by the cutting apparatus (615A, 615B) will each be referred to herein as a "sheet". The length and width of the sheets can be varied according to parameters entered into control apparatus (608), and the cutting apparatus (615A, 615B) are configured to cut the steel accordingly. The dimensions of the sheet of material are selected according to a desired size of panel to be manufactured using system (600). The size of module is selected according to the dimensions of reflective layer (278).

The deforming station (604) includes at least one roll former, such as two roll formers (614A, 614B) as shown in the Figures. Each roll former (614A, 614B) is configured to deform t stainless steel to create corrugations therein.

The shape, orientation of the corrugations can be varied according to parameters of the module being constructed by system (600). For instance, the corrugations can correspond to those discussed above in relation to Figures 2 to 8.

As shown in the Figures, the deforming station (604) is after the cutting station (613) and therefore deforms the sheet(s) of material after they have been cut from the coils of steel on the decoilers (612A, and / or 612B). However, the deforming station (604) may be positioned before the cutting station (613), and therefore deform the sheet(s) of material before they have been cut from the coils of steel on the decoilers (612A, and / or 612B)

The roll formers (614A, 614B) may also be configured to otherwise deform the stainless steel. For instance, the deformers (614A, 614B) also form a curve in the stainless steel. The curve may be determined according to parameters of a module (230) to be constructed by the system (600), and / or such as what part of the module (230) the steel sheet is to provide e.g. a first corrugated layer (232) or a second corrugated layer (234).

The system (600) may also include a perforating unit (616) which is configured to create a plurality of apertures in the sheet(s) of material which are deformed by the roll former (614A). As shown in the Figures, the perforating unit (616) is provided as part of the deforming station as an attachment to the roll former (614A). Lengths exiting roll formers (614A, 614B) are moved to store (618) which forms part of the assembly station (606).

The assembly station (606) includes a mold (620), an actuator unit (622), and a delivery system (624). The mold (620) has a curved bearing surface (not shown in the Figures). The curved bearing surface (not shown) has a shape corresponding to the shape for the reflective layer (278) of a module (230) to be produced by the system (630) use. For instance, the curved bearing surface (not shown) may have a parabolic shape, a shape corresponding to the shape of a fresnal reflector, or any other desired shape for a reflective layer (278). The actuator unit (622) is positioned near the store (618). The store (618) holds sheets of a reflective material such as sheets of a silvered mirror. The sheets of reflective material can be pre-curved. Alternatively, the sheets of reflective material may be flat and subsequently deformed / bent to a desired shape during assembly of a module (230) e.g. by being applied to the curved bearing surface (not shown) of the mold (620). Method of Manufacture

Additional aspects of the system (600) should become clearer from following description of a method of manufacture according to the invention. It should also be appreciated that the steps of the method need not be completed using a system (600) such as described herein. For instance, it is also possible that other apparatus of process can be used to manufacture a module according to the invention.

To manufacture a module (230), the desired parameters for the module (230) are entered into the control apparatus (608).

The control apparatus (608) calculates parameters for sheets and communicates instructions to the components of the system (600) to perform the following steps. The decoilers (61 OA, 610B) are engaged to feed out the rolls of stainless steel. The cutting apparatus (615A, 615B) are engaged to cut the steel into individual sheets (not shown).

The deforming station (604) deforms the individual sheets (not shown) to forms corrugations and curves therein, to thereby form the first corrugated layer (232) and / or the second corrugated layer (234). As a sheet(s) exit the roller formers (614A), the perforating unit (616) creates apertures in at least one of the first corrugated layer (232) and the second corrugated layer (234). The actuator unit (622) is engaged to move components of the module (230) into the store (618). A reflective layer (278) is placed on the curved bearing surface (not shown) and spacer elements (not shown) are placed on a rear surface of the reflective layer (278).

The actuator unit is engaged to move a first corrugated sheet (232) to bear down on the spacer elements (not shown).

Members (220, 222, 224, 226, 228) are positioned to bear against a surface of the first corrugated layer (232) distal to the spacer elements (not shown).

A second corrugated layer (234) is positioned to bear on the members (220, 222, 224, 226, 228). Side edge caps (288, 290) are positioned to surround side edges of the first and second corrugated layers (232, 234).

A mold cover (not shown in the figures) may be positioned to close the mold (620).

Delivery system (624) is engaged to inject a raw material such as a polyurethane into a gap between the first corrugated layer (232) and the second corrugated layer (234). The polyurethane foam is allowed to expand so that it expands through apertures (not shown), and completely fills the gap between the first corrugated layer (232) and the second corrugated layer (234). In addition, the polyurethane foam expands through the apertures in the first corrugated layer (232) and comes into contact with a back surface of the reflective layer (278). The polyurethane foam is cure. This may involve moving the mold (620) to enable the above steps to be repeated using additional molds which are identical to mold (620).

The system (600) may include components or otherwise be configured to promoted curing of the polyurethane. For instance, a heating apparatus (not shown) may be included to promote or assist in curing of the polyurethane. Various embodiment to the heating apparatus envisaged. For instance, the heating apparatus may be incorporated into the mold (620), e.g., in the curved bearing surface and / or the mold cover. Alternatively, the heating apparatus may be provided as an additional component.

Curing of the polyurethane secures the first corrugated layer (23) and the second corrugated layer (234) and the side edge caps (288, 290) together, thereby encapsulating the members (220, 222, 224, 246, 248). The polyurethane foam also acts as an adhesive to secure the reflective layer (278) to the first corrugated layer (232).

The curing of the polyurethane foam forms a composite panel which provides the module (230). The above process can be repeated to produce a desired number of modules (230).

In addition, the system (600) may include more than one mold (620). This may enable the production of modules (230) to be optimised, e.g. a plurality of modules (230) can be concurrently and / or sequentially produced as described herein. The number of supports (620) can be selected to optimise production by the system (600) according to a cycle time to produce one module (230).

It should also be understood that the orientation of the components in the support (620) can be reversed e.g. the curved bearing surface (not shown) may be convex (rather than concave). As a result, in such embodiments, the order in which components of the module (230) are added to the mold (620) is reversed, with the reflective layer (278) being added after the first corrugated layer (232).

It would be understood by one skilled in the art that the system (600) and the method of manufacture can be adjusted to form a module (230) by omission of a second corrugated layer (234). In such embodiment, other elements such as a mold lid (not shown) may be utilised to assist in controlling expansion and /or shaping of the polyurethane foam to facilitate that curing in a desired shape.

In addition, the steps of the method (and therefore components of the system (600)) may be changed without departing from the scope of the present invention.

Method of Assembling a Concentrating Solar Power System

The invention provides a method of constructing at least a reflector (100) to thereby portion at least a portion of a concentrating solar power system (100) such as that shown in Figure 1 .

To construct the reflector (210), a first module (230) is positioned.

If required, a second module (230) can be positioned adjacent the first module (230). The first module (230) and / or second module (230) are moved relative to each other to cause a male end(s) (260) on the first module (230) to engage a female end(s) (262) on the second module (230) to thereby align the modules and facilitate connecting them together. Additional modules (230) may be positioned and connected to the first modules (230) and / or second module (230) so as to provide a reflector (210) having a desired length. Again, male and female connectors on the modules are caused to engage each other.

Additional fasteners (not shown in the Figures) may be used to connect the modules (230) together if required

The module(s) (230) may be mounted to an actuator assembly (such as legs (21 1 )) which is connected to the tracking and control system (not shown in the Figures).

The above steps may be performed in any order to optimise the efficiency and ease of construction of the solar field (200). The modules (230) are post-tensioned together by tensioning flexible components (264) disposed in the conduits (258). This pulls the module(s) (230) together.

The flexible components (264) in the conduits(s) (230) are separated from each other across the width the module(s) (230). According, post- tensioning of the modules (230) together creates a composite beam having a web height equivalent to the greatest distance between the conduits (258). This may provide rigidity to the reflector (210) when constructed.

While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the invention may be embodiment in other specific forms without departing from the essential characteristics therefore. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and range or equivalency of the claims are therefore intended to be embraced therein.

It should also be appreciated that aspects of the embodiments described herein can be combined to produce yet further embodiments of the invention. Accordingly, the description herein should not be seen as limiting on the scope of the invention.

Claims

WHAT IS CLAIMED IS:

A concentrating solar power ("CSP") system having at least one module, wherein the at least one module includes a first layer, and wherein the first layer has a plurality of corrugations, a reflective layer, a second layer, wherein the first layer and the second layer are different materials to each other. The CSP system as claimed in claim 1 , wherein the first layer is stainless steel.

The CSP system as claimed in claim 2, wherein the stainless steel is galvanised.

The CSP system as claimed in either one of claims 2 or 3, wherein the stainless steel is selected from the grades of:

The CSP system as claimed in any one of claims 1 to 4, wherein the corrugations provide a bearing surface to which the reflective layer is secured.

The CSP system as claimed in any one of claims 1 to 5, wherein the corrugations have a substantially trapezoidal cross section.

The CSP system as claimed in any one of claims 1 to 6, wherein first layer has a pre-formed curve.

The CSP system as claimed in claim 7, wherein the pre-formed curved is a parabola.

The CSP system as claimed in any one of claims 1 to 8, wherein the reflective layer is glass.

The CSP system as claimed in claim 9, wherein the glass is a silvered glass.

1 1 . The CSP system as claimed in any one of claims 1 to 10, wherein the second layer is a polyurethane foam.

12. The CSP system as claimed in claim 1 1 , wherein the polyurethane foam extends through apertures in the first layer and adheres to a back surface of the reflective layer.

13. The CSP system as claimed in claim 12, wherein the adherence of the

polyurethane foam to the back surface of the reflective layer secures the reflective layer and the first layer together.

14. The CSP system as claimed in any one of claims 1 to 1 1 , including a third layer.

15. The CSP system as claimed in claim 12, wherein the third layer has a plurality of corrugations.

16. The CSP system as claimed in claim 15, wherein the corrugations have a

trapezoidal cross-sectional shape.

17. The CSP system as claimed in either one of claims 14 or 15, wherein the third layer has a pre-formed curve.

18. The CSP system as claimed in any one of claims 1 to 17, including a second module.

19. The CSP system as claimed in claim 18, wherein the first module and the second module are post-tensioned together.

20. The CSP system as claimed in either one of claims 18 or 19, wherein the first module and the second module each include a male connector and a female connector, and further

wherein the male end of the first module engages with the female end of the second module.

21 . The CSP system as claimed in any one of claims 1 to 20, wherein at least the first module is connected to an actuator configured to rotate the first module about an axis to follow the sun's path of movement through the sky.

22. The CSP system as claimed in any one of claims 1 to 21 , including a collector positioned and arranged so that the sun's rays incident on the reflective layer are reflected onto the collector.

23. A CSP module for use in forming a concentrating solar power ("CSP") system, wherein the module includes a first layer, and wherein the first layer has a plurality of corrugations, a reflective layer, a second layer, wherein the first layer and the second layer are different materials to each other.

24. The CSP module as claimed in claim 23, wherein the first layer is stainless steel.

25. The CSP module as claimed in claim 24, wherein the stainless steel is galvanised.

26. The CSP module as claimed in any one of claims 23 to 25, wherein the

corrugations in the first layer provide a bearing surface to which the reflective layer is secured.

27. The CSP module as claimed in any one of claims 23 to 26, wherein the

corrugations in the first layer have a substantially trapezoidal cross-sectional shape.

28. The CSP module as claimed in any one of claims 23 to 27, wherein first layer has a pre-formed curve.

29. The CSP module as claimed in claim 28, wherein the pre-formed curve is a

parabola.

30. The CSP module as claimed in any one of claims 23 to 29, wherein the reflective layer is glass.

31 . The CSP module as claimed in claim 30, wherein the glass is a silvered glass.

32. The CSP module as claimed in any one of claims 23 to 31 , wherein the second layer is a polyurethane foam.

33. The CSP module as claimed in claim 32, wherein the polyurethane foam extends through apertures in the first layer and adheres to a back surface of the reflective layer.

34. The CSP module as claimed in claim 33, wherein the adherence of the

35. The CSP module as claimed in any one of claims 23 to 34, including a third layer.

36. The CSP module as claimed in claim 35, wherein the third layer has a plurality of corrugations.

37. The CSP module as claimed in claim 36, wherein the corrugations have a

trapezoidal cross-sectional shape.

38. The CSP module as claimed in either one of claims 36 or 37, wherein the third layer has a pre-formed curve.

39. The CSP module as claimed in any one of claims 32 to 34, wherein the

polyurethane foam is formed to the first layer.

40. The CSP module as claimed in any one of claims 23 to 39, including at least one conduit.

41 . The module as claimed in claim 40, including a first conduit and a second conduit which are spaced apart from each other across the module's width.

42. The module as claimed in any one of claims 23 to 43, including at least one

member.

43. The module as claimed in any one of claims 23 to 42, including at least a first member and a second member which are laterally spaced relative to each other across the module's width.

44. The module as claimed in either one of claims 42 or 43, wherein at least one of the members has a web.

45. A concentrating solar power ("CSP") system including a module as claimed in any one of claims 23 to 44.

46. A method of constructing a concentrating solar power ("CSP") system, including the steps of:

(a) positioning a first module as claimed in any one of claims 23 to 45;

(b) positioning a collector to lie on the focal point of the module so that the sun's rays incident on the reflective layer are reflected onto the collector;

(c) connecting the collector to a generation system so that heat in the sun's rays reflected onto the collector can be used.

47. The method as claimed in claim 46, including the step of mounting the first module to an actuator assembly configured to in use rotate the module.

48. The method as claimed in either one of claims 46 or 47, including the step of connecting the actuator assembly to a control system.

49. The method as claimed in any one of claims 46 to 48, including the step of

positioning a second module adjacent to the first module.

50. The method as claimed in claim 49, including the step of connecting the first module and the second module together.

51 . The method as claimed in claim 50, wherein the step of connecting the first

module and the second module together involves causing a male end on the first module to engage with a female end on the second module.

52. The method as claimed in any one of claims 46 to 51 , including the step of

positioning a third module relative to the first module or the second module.

53. The method as claimed in claim 52, including the step of connecting the third module to the first module or the second module.

54. The method as claimed in any one of claims 46 to 53, including the step of post- tensioning the modules together.