Method for manufacturing a ceramic roof tile, as well as roof tile provided with a solar heat receiving panel and hot water system provided with such roof tiles
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Solution Overview
Problem
Existing ceramic roof tiles with integrated solar panels face challenges such as potential damage during hole creation for conductor routing and inefficiency in energy conversion for heating purposes, requiring specialized and more expensive solar panels.
Innovation Solution
A method of manufacturing ceramic roof tiles with a hole by using a mold with a bulge to create a thinned part that is broken away post-curing, allowing for easy conductor routing and integration with standard solar panels, and incorporating a metal coating for direct heat absorption with minimal loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a hole is introduced in the roof tile for leading away electrical conductors, then electrical connectivity is achieved, but the roof tile may be damaged or distorted
Solution Approach 1:
The mold includes a bulge that creates a thinned part in the roof tile at the desired hole location before curing. This preliminary shaping allows the hole to be easily created after curing without compromising the tile's structural integrity during the manufacturing process
Solution Approach 2:
The manufacturing process separates the tile formation and hole creation into distinct stages: first forming the tile with a thinned region, then removing material from this pre-defined location to create the hole, avoiding attempts to create holes in fully cured rigid tiles
2Ease of manufacture
If standard solar panels with electronic units on the underside are used, then cost is reduced, but the electronic units require access from below the roof tile
Solution Approach 1:
The mold bulge creates a thinned part that extends through the tile thickness, enabling the electronic unit to pass through the roof tile from the front side. This preliminary structural preparation allows standard solar panels to be used without requiring complex rear-access installations
Solution Approach 2:
The invention changes the spatial arrangement by creating a through-hole in the roof tile, allowing the electronic unit to access the solar panel from the front side rather than requiring access from behind the tile, thus enabling use of standard solar panel configurations
3Use of energy by moving object
If solar panels are used to generate electricity, then electrical energy is produced, but efficiency is lost when converting this energy back to heat for heating purposes
Solution Approach 1:
Instead of converting electrical energy back to heat (losing efficiency), the invention uses the roof tile itself as a solar thermal collector with metal coating to directly absorb solar radiation and convert it to heat, turning the heating application into a direct benefit rather than a conversion cycle
Solution Approach 2:
The roof tile is designed to serve multiple functions: it provides structural roofing coverage, incorporates electrical connectivity through the thinned part hole, and includes metal coating for direct solar thermal energy absorption, eliminating the need for separate heating systems
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 method prevents tile distortion and enables efficient energy conversion with reduced heat loss by allowing standard solar panels to be used and direct heat transfer to a medium, enhancing the robustness and efficiency of the solar heat absorbing system.
Implementation Method 1
The sun light then directly heats up the metal coating which transfers its heat via the conducting element and the heat conductor directly to the medium to be heated
Implementation Method 2
the metal coating which transfers its heat via the conducting element and the heat conductor directly to the medium to be heated
Data Source
AI summary
When a roof tile provided with a hole is manufactured, first a non-cured composition 11 is fed between two facing mold surfaces 13b and 15b of two mold halves 13 and 15 after which the two mold halves are brought together.The mold surface 13b of one of the two mold halves 13 is provided with a bulge 17 which has a thickness 19 that is smaller than the distance 21 between the two mold surfaces 13b and 15b at the location of this bulge in the state of the mold halves brought together. As a result, the roof tile obtains a thin part 23 at the location of this bulge 17. After the pressing operation the two mold halves 13 and 15 are taken apart and the composition 11 is cured. Once the roof tile 1 has cured, the thin part 23 is broken away from the roof tile and in this manner the hole 5 in the roof tile is formed.