Heat transfer element and method of manufacture
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Solution Overview
Problem
Conventional solar thermal collectors require high manual labor for production, leading to high costs and limited automation, making them less efficient and more expensive for end-users.
Innovation Solution
A heat transfer element is created using a composite film material with a reinforcing layer and a metallized plastic film, where the metallization is between the reinforcing layer and the plastic film, allowing for a cohesive connection that forms fluid lines automatically, reducing manual assembly and enhancing thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rigid solar thermal collectors are used, then structural strength is ensured, but manufacturing complexity and manual labor increase significantly
Solution Approach 1:
The patent replaces rigid collector structures with flexible plastic film materials that can be automatically formed and sealed. The thin film absorber and selective coating layers provide the necessary thermal functionality while enabling automated manufacturing processes, eliminating the need for complex rigid structural assemblies.
Solution Approach 2:
The patent employs composite film structures combining plastic films with metallic selective coatings and absorbing layers. This composite approach maintains structural integrity and thermal performance while enabling flexible, easily manufacturable collector designs through automated lamination and sealing processes.
2Reliability
If conventional rigid collectors are manufactured, then durability is achieved, but production costs increase due to manual labor
Solution Approach 1:
The patent changes the material parameters from rigid to flexible plastics, enabling entirely automated manufacturing processes. This parameter change maintains product durability through consistent automated quality control while dramatically reducing production costs by eliminating manual labor in the manufacturing process.
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated thermal sealing and lamination processes. The selective coating application and absorber layer formation are performed through automated deposition and lamination equipment, substituting costly manual operations with efficient automated systems.
3Productivity
If plastic materials are used to increase automation, then manufacturing efficiency improves, but mechanical strength decreases
Solution Approach 1:
The patent uses composite film structures where plastic films are laminated with reinforcing layers and metallic coatings. This composite construction provides the necessary mechanical strength for durable collectors while maintaining the flexibility and automated manufacturability of plastic materials.
Solution Approach 2:
The patent compensates for the lower inherent strength of plastic materials by incorporating reinforcing structures and support frameworks that provide mechanical counterbalance. These reinforcement elements are integrated into the flexible collector design, maintaining both strength and manufacturing efficiency.
4Ease of operation
If simple film structures are used, then ease of installation is improved, but heat distribution efficiency deteriorates
Solution Approach 1:
The patent incorporates metallic selective coating layers and absorbing materials within the flexible film structure. These functional layers enhance heat absorption and distribution efficiency across the absorber surface, ensuring uniform thermal performance while maintaining the simple, lightweight construction that enables easy installation.
Solution Approach 2:
The patent applies selective coatings and absorbing layers at specific locations within the film structure where thermal energy absorption is most effective. This localized functional enhancement optimizes heat distribution efficiency in critical areas while maintaining the overall simplicity and ease of installation of the flexible collector design.
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 results in a cost-effective, lightweight, and easily mountable heat transfer element with improved mechanical strength, reduced thermal expansion, and better heat distribution, enabling more efficient energy harvesting while reducing the need for conventional energy sources.
Implementation Method 1
a metal film connected to the reinforcing layer or a metallized further plastic film connected to the reinforcing layer, wherein the metallization is arranged between the reinforcing layer and the further plastic film
Implementation Method 2
a heat transfer element, in particular a solar thermal collector... through which the water (glycol mixture) to be heated flows
Data Source
Figure 1~3
AI summary
The invention relates to a method for manufacturing a heat transfer element (2) comprising the steps of: - providing a first film material (10) comprising a first plastic film (13), - providing a second film material (11) comprising a second plastic film (16), - joining the first film material (10) with the second film material (11) to form at least one fluid channel (9) between the first and the second film material (10, 11). The first plastic film (13) and the second plastic film (16) are partially joined to each other by material bonding and/or mechanical means, in particular by sewing, in connection areas (12), such that at least one cavity is formed between the connection areas (12), which forms the at least one fluid channel (9). The invention further relates to a corresponding heat transfer element (2).