Solar Collector Absorber Sheet Coating for Low-Cost Low-Emission Production
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Solution Overview
Problem
Existing methods for producing absorber sheets for solar collectors, such as those using Physical Vapor Deposition (PVD) or Chemical Vapor Deposition (CVD) processes, are costly due to high investment requirements and do not efficiently minimize thermal radiation emission, leading to energy losses.
Innovation Solution
A coil coating process is used to apply a highly selective coating with thin functional layers, including an adhesion promoter layer and sol-gel-based layers, utilizing paint rollers and functional particles like nanoparticles, which allows for precise control of layer thickness and improved adhesion, reducing costs and energy emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If PVD or CVD processes are used to produce highly selective coating, then absorption efficiency is improved, but production cost increases significantly
Solution Approach 1:
The patent replaces expensive PVD/CVD vacuum coating systems with a cost-effective coil coating process using conventional painting equipment. The highly selective coating is applied as a thin layer (5-20 micrometers) through spray or roller coating, eliminating the need for costly vacuum chambers and complex ion bombardment equipment, thereby dramatically reducing production costs while maintaining low thermal radiation emission properties
Solution Approach 2:
The patent changes the coating application method from vacuum-based physical/chemical deposition to conventional liquid coating processes. By controlling coating parameters such as layer thickness (5-20 micrometers), solvent content, and curing temperature, the patent achieves the same optical properties (high absorption, low emission) at a fraction of the equipment and operational cost
2Loss of energy
If PVD or CVD processes are used to produce highly selective coating, then absorption efficiency is improved, but investment outlay increases
Solution Approach 1:
The patent replaces expensive PVD/CVD vacuum coating systems with a cost-effective coil coating process using conventional painting equipment. The highly selective coating is applied as a thin layer (5-20 micrometers) through spray or roller coating, eliminating the need for costly vacuum chambers and complex ion bombardment equipment, thereby dramatically reducing production costs while maintaining low thermal radiation emission properties
Solution Approach 2:
The patent substitutes complex vacuum-based physical vapor deposition or chemical vapor deposition equipment with simple mechanical coil coating equipment. The coating is applied using conventional spray guns or rollers that move along the continuously fed metal strip, replacing sophisticated vacuum systems with basic mechanical application devices, thus reducing investment outlay
3Loss of energy
If thick coating layers are applied to minimize thermal radiation, then energy loss is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies thin coating layers (5-20 micrometers) instead of thick layers, achieving sufficient thermal radiation control with minimal material. This partial action approach reduces manufacturing complexity by eliminating the need for multiple thick coating passes and complex thickness control systems, while still achieving the required optical performance through optimized coating composition and thin-film interference effects
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coil coating process significantly reduces production costs and energy losses by achieving high absorption efficiency with low thermal radiation emission, using aluminum or aluminum alloys, and allows for embossing to enhance absorption surface area without cracking, resulting in a cost-effective and efficient absorber sheet.
Implementation Method 1
the strip is coated with a highly selective coating using a coil coating process
Implementation Method 2
which are usually produced using a 'Physical Vapor Deposition' (PVD) process or a 'Chemical Vapor Deposition' (CVD) process
Implementation Method 3
the absorber, which converts the light energy of the sun into heat
Implementation Method 4
the heat absorbed is not emitted again in the form of radiation
Data Source
Figure 1
AI summary
The invention relates to a method for the production of an absorber sheet metal plate (1) for solar collectors made of a band of metal, particularly aluminum or an aluminum alloy. The invention further relates to an absorber sheet metal plate (1) for solar collectors and an advantageous use of the absorber sheet metal plate (1). The object to provide a method for the production of an absorber sheet metal plate for solar collectors, wherein the method enables the cost-effective production of an absorber sheet metal plate having a highly selective coating (2, 3, 4), is achieved by painting the band with a highly selective coating by means of a coil-coating process, the coating having excellent absorption properties for sunlight and low heat emission.