Method for producing a solar collector and solar collector made by this method from at least one sheet material
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Solution Overview
Problem
Existing solar collectors are unsuitable for efficiently heating air for agricultural crop drying due to high production costs and inefficiencies in heat transfer, particularly when using liquid heat transfer media.
Innovation Solution
A method involving a layered structure of film materials welded to form a hollow chamber strand with insulating profiles, using heat input or diffusion adhesives, which eliminates the need for connecting means and allows for cost-effective production and efficient air heating by forming an endless product that can be cut to desired lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic films are used for structural design of solar collectors, then production costs are reduced, but heat transfer efficiency for air heating is insufficient
Solution Approach 1:
The solar collector is divided into multiple functional layers (transparent cover layer, absorber layer, insulation layers) with distinct roles. The hollow chamber strand is segmented into repeating units with insulating profiles, allowing optimized heat transfer paths while maintaining low-cost film material construction throughout.
Solution Approach 2:
The invention uses composite film structures combining transparent films for light transmission, black absorber films for heat absorption, and insulation films for thermal retention. This multi-material film composite approach achieves efficient air heating while maintaining the cost advantage of all-film construction.
2Loss of energy
If liquid heat transfer media are used in heat transfer lines, then heat transfer is effective, but production costs and system complexity increase
Solution Approach 1:
The invention extracts the heat transfer function from liquid media and transfers it directly to air through the hollow chamber structure. The air itself becomes the heat transfer medium, eliminating the need for separate liquid heat transfer fluids and their associated pumps, seals, and maintenance requirements.
Solution Approach 2:
The hollow chamber strand creates pneumatic pathways for air flow through the collector. The insulating profiles within the hollow chambers guide and contain the air flow, creating an efficient pneumatic heat transfer system that replaces liquid hydraulic systems.
3Strength
If connecting means and auxiliary materials are used in production, then structural integrity is ensured, but production costs increase
Solution Approach 1:
The welding seams serve dual functions: they join the film layers together to create the structural laminate and simultaneously form the insulating profiles that define the hollow chambers. This merging of joining and shaping functions eliminates the need for separate connecting means.
Solution Approach 2:
The film material itself is used to create both the structural components and the insulating elements. The welding process transforms the flat film laminate into three-dimensional hollow chamber structures with integrated insulation, allowing the material to serve multiple structural purposes without additional components.
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 significantly reduces production costs and enhances the efficiency of air heating in solar collectors, making them more viable for agricultural applications by minimizing heat loss and allowing for flexible design.
Implementation Method 1
The film layers of the laminate are welded to one another by means of parallel weld seams to form a film composite
Implementation Method 2
In principle, however, it is also conceivable to weld the film layers of the layered structure together using a diffusion adhesive
Implementation Method 3
Known solar collectors are used to convert the radiant energy emitted by the sun into heat
Implementation Method 4
a layered structure comprising at least one absorber film is built up with the film material
Implementation Method 5
The hollow chamber strand is composed of the heat transfer line and the insulating chamber profile that protects the heat transfer line against heat loss into the ground or another subsoil
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
In the case of a solar collector made of a film material and a heat transfer line formed therewith, the film material has a transparent film forming the heat transfer line on the upper side and an absorber film forming the heat transfer line on the underside. This film material is used to form a hollow chamber strand (8) that has the heat transfer line and an insulating chamber arrangement. To produce the solar collector, the foil material is welded to form a heat transfer line. For this purpose, a layered structure comprising an absorber film is built up with the film material from three film layers (3, 4) and the film layers (3, 4) are welded together by means of parallel weld seams (6) to form a film composite. An outer film layer of the film composite is then cut into film strips (7) along the weld seams (6) and the film strips (7) are welded along their cut edges (9) to a transparent film material to form the hollow chamber strand (8).