Heliostat Mold Heating for Lower-Cost Solar Thermal Manufacturing
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Solution Overview
Problem
The energy costs for heat in rotational molding and vacuum molding systems are high, contributing significantly to the end product cost, necessitating a more cost-effective energy source.
Innovation Solution
A thermal manufacturing system utilizing a heliostat with reflecting surfaces, a steering mechanism, and a controller to concentrate and direct radiant energy onto a mold, allowing for precise heating and energy management, including a two-axis rotation mechanism and a heat shield structure to optimize energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If traditional oven heating systems are used in rotational molding and vacuum molding, then the heating process can be performed, but the energy costs become excessively high and contribute significantly to end product cost
Solution Approach 1:
The patent replaces the traditional mechanical oven heating system with a solar thermal heating system that uses reflective surfaces (heliostats) to concentrate solar energy onto the mold. This substitution eliminates the need for fossil fuel-based or electric heating, dramatically reducing energy costs while maintaining effective heating capability for plastic molding processes
Solution Approach 2:
The invention changes the heating parameter from conventional thermal conduction/convection in an oven environment to direct solar radiant heating. By adjusting the concentration and direction of solar energy through reflective surfaces, the system achieves the required heating parameters for plastic melting and molding without the overhead costs of traditional heating systems
2Use of energy by stationary object
If solar energy is used to heat the mold, then energy costs are reduced, but the system complexity increases with heliostats, steering mechanisms, and focal point control
Solution Approach 1:
The heliostat system serves multiple functions: it concentrates solar energy onto the mold, tracks the sun's movement throughout the day, and can be adjusted to focus energy on specific areas of the mold as needed. This multi-functionality justifies the added complexity by providing both energy generation and precise thermal control in a single integrated system
Solution Approach 2:
The system employs dynamic steering mechanisms that allow the reflective surfaces to continuously adjust their angle and position, tracking the sun's movement and redirecting solar energy to the mold's focal point. This dynamic adjustment capability maintains optimal heating efficiency throughout the operating day while allowing the system to adapt to changing solar conditions
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
This approach reduces energy costs and enhances manufacturing efficiency by allowing dynamic control of heating, simplifying mold design, and improving product quality, making the process more flexible and accessible to locales without traditional energy infrastructure.
Implementation Method 1
The heliostat includes at least one reflecting surface, a steering mechanism and a controller
Implementation Method 2
capable of directing at least a first portion of the at least one reflecting surface toward a first one of multiple, selectable focal points
Implementation Method 3
The heated hollow mold heats the plastic powder on the bottom inner layer of the hollow mold. The melted plastic powder bonds together
Implementation Method 4
The melted plastic powder bonds together (e.g., sinters) to form a complete plastic layer
Data Source
AI summary
A system for a thermal manufacturing system including a heliostat and a mold. The heliostat includes at least one reflecting surface, a steering mechanism and a controller. The steering mechanism is coupled to the at least one reflecting surface and capable of directing at least a first portion of the at least one reflecting surface toward a first one of multiple, selectable focal points. The mold is located in a second one of the selectable focal points. A manufacturing method is also disclosed.