Embossed Modular Solar Panel Channels for Lower-Cost Heat Transfer
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Solution Overview
Problem
Current solar collectors for heating a thermally conductive medium are costly to produce due to complex and expensive methods of connecting copper pipes to the absorber sheet, and the geometry of copper tubes does not optimize heat transfer efficiency.
Innovation Solution
A solar collector design featuring a metal sheet underneath the absorber sheet with embossings that form channels for the heat-conducting medium, allowing for a more flexible geometric shape and eliminating the need for individual copper pipes, combined with a high-temperature-resistant coating applied before assembly, enabling cost-effective production and improved heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper pipes are connected to the absorber sheet using conventional joining methods (welding, soldering, gluing), then the heat transfer function is achieved, but the production cost increases and the manufacturing complexity increases
Solution Approach 1:
The patent merges the channel structure directly into the absorber sheet by forming channels within the sheet material itself, eliminating the need for separate copper pipes. This integration maintains heat transfer functionality while significantly simplifying manufacturing and reducing production costs.
Solution Approach 2:
The patent extracts the channel function from separate copper pipe components and incorporates it directly into the absorber sheet structure. This separation of functions allows the absorber sheet to serve dual purposes: absorbing solar energy and providing fluid flow channels.
2Reliability
If copper pipes are used for heat transfer, then the heat transfer function is achieved, but the device complexity increases due to individual assembly requirements
Solution Approach 1:
The patent combines the absorber sheet and channel structure into a single integrated component. The channels are formed directly within the absorber sheet material, eliminating the need for separate pipe assembly and reducing overall device complexity.
3Reliability
If copper tubes with conventional geometry are used, then the heat transfer function is achieved, but the heat transfer efficiency is not optimized due to suboptimal surface volume ratio
Solution Approach 1:
The patent applies local quality optimization by designing channels with specific geometric characteristics (enhanced surface area relative to volume) directly within the absorber sheet. The channel cross-sections and routing are optimized locally to maximize heat transfer efficiency while maintaining manufacturing simplicity.
4Ease of manufacture
If the absorber sheet is coated with selectively absorbing coating before assembly, then the coating efficiency is improved, but the coating may be damaged during subsequent high-temperature joining processes
Solution Approach 1:
The patent employs a sacrificial protective layer applied to the absorber sheet before coating. This temporary layer protects the selective absorbing coating during high-temperature joining processes, allowing the coating to be applied early in manufacturing when it provides maximum benefit, then removed after serving its protective purpose.
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 design significantly reduces production costs, enhances heat transfer efficiency, and allows for modular assembly of solar collectors with optimized channel geometry, improving overall performance and efficiency.
Implementation Method 1
The absorber sheet has a selectively absorbing coating which is resistant to high temperatures
Implementation Method 2
at least one absorber sheet for absorbing the sunlight
Implementation Method 3
channels for the heat-conducting medium, which are connected to the absorber sheet in such a way that heat can be transferred from the absorber sheet to the heat-conducting medium
Data Source
Figure 1~2
Figure 3~4
AI summary
The panel has an absorber unit (1) with an absorber plate (2) for absorption of sunlight. Channels (5) are connected with the absorber plate such that heat is transferred from the absorber plate to a heat conducing medium. The absorber plate has a selectively absorbent coating, where the coating is high temperature proof. A bottom plate (3) is arranged underneath the absorber plate and is sealingly connected with the absorber plate. The bottom plate and/or the absorber plate have embossings that form the channels for the medium after the connection of the plates. An independent claim is also included for a method of manufacturing a solar panel.