Composite Solar Mirror Panels for Low Slope Error Manufacturing
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Solution Overview
Problem
The high cost and inefficiency of solar thermal power plants due to the significant influence of individual mirror panel costs, which require precise manufacturing to achieve high accuracy and minimize slope errors for optimal energy concentration.
Innovation Solution
The development of solar mirror panels comprising a sheet-like reflective member, a stiffening member, and a spacer member made of resin bonded wood composite, with a manufacturing process using a mould and temperature gradient control to achieve an average slope error of less than 1 milliradian, allowing for high accuracy and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used for solar mirror panels, then production cost is reduced, but manufacturing precision and slope error control deteriorate
Solution Approach 1:
The panel is divided into multiple layers (reflective member, stiffening members, spacer members) that can be manufactured separately and then bonded together. This segmentation allows each layer to be optimized independently for precision while using cost-effective materials and manufacturing processes, achieving low slope errors without prohibitively high costs.
Solution Approach 2:
The invention uses composite panel construction with different materials (glass or polymer reflective members, metal stiffening members, resin bonded wood composite spacer members) bonded together. Each material contributes specific properties that collectively achieve high precision with controlled costs, resolving the contradiction between manufacturing precision and ease of manufacture.
2Reliability
If high precision manufacturing is implemented to minimize slope errors, then energy concentration efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The panel layers are pre-formed with specific geometries and properties before assembly. The mould defines the precise curved surface geometry in advance, and layers are pre-cut and prepared, reducing the complexity of the final assembly process while ensuring high precision and energy concentration efficiency.
Solution Approach 2:
The invention controls critical parameters such as layer thicknesses, material properties, and bonding conditions to achieve the desired precision. By optimizing these parameters within reasonable ranges, high energy concentration efficiency is achieved without requiring excessively complex manufacturing processes.
3Productivity
If individual mirror panels are manufactured with high accuracy, then focal area is minimized and efficiency is maximized, but production cost increases
Solution Approach 1:
The multi-layer panel design serves multiple functions simultaneously: the reflective member provides optical functionality, stiffening members provide structural support, and spacer members maintain precise spacing. This multi-functionality reduces the need for additional components and processes, lowering overall panel cost while maintaining high energy collection efficiency.
Solution Approach 2:
The invention uses cost-effective materials such as resin bonded wood composite for spacer members and standard glass or polymer for reflective members, rather than expensive specialized materials. These materials can be easily replaced if needed, reducing the cost per panel while maintaining the precision required for high energy collection efficiency.
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 solution enables the production of solar mirror panels with high accuracy and reduced costs, improving the efficiency and cost-effectiveness of solar thermal power plants by minimizing slope errors and optimizing panel manufacturing processes.
Implementation Method 1
The manufacture of panels utilises a process that generates a temperature gradient through the various members of the panel as the members of panel are being adhered to each other
Implementation Method 2
generates a temperature gradient through the various members of the panel as the members of panel are being adhered to each other
Implementation Method 3
Mirrors are moved to track the sun with either single or dual axes of movement, focussing light to a receiver where some sort of energy collection or conversion process is carried out
Data Source
AI summary
A solar mirror panel (10) has a first sheet-like stiffening member (12) having a reflective surface, a second sheet-like stiffening member (18), and a spacer member (16) of resin bonded wood composite located between the first and second members (12, 16).