All-Polymer Solar Heating Panel With Expansion Venting
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Solution Overview
Problem
Existing flat plate solar collectors for heating fluids face challenges with material durability and thermal stress due to temperature variations, as conventional materials like metals and low-temperature polymers are not suitable for high-temperature applications, and there is a need for efficient thermal management to prevent structural failure and maintain efficiency.
Innovation Solution
An all-polymer flat plate solar panel with an integrated controller, utilizing high-temperature polymers like HTN, PPS, and PPSU for the absorber and frame, along with expansion slots and venting to accommodate thermal expansion, and an integrated controller for efficient heat transfer and pump operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional materials like metals and low-temperature polymers are used in flat plate solar collectors, then the panel can be manufactured with standard materials, but the panel cannot withstand high temperatures and suffers from thermal stress and structural failure
Solution Approach 1:
The patent changes the material parameter from conventional metals and low-temperature polymers to high-temperature polymers (HTN, PPSU, PPA) that can withstand temperatures up to 140-150°C. This material parameter change enables the panel to maintain structural stability at high temperatures while avoiding thermal stress and structural failure associated with conventional materials
Solution Approach 2:
The patent uses composite construction combining multiple high-temperature polymer materials with different properties: HTN for the absorber, PPSU and PPA for the frame and manifolds. This composite approach allows optimization of each component for its specific thermal and mechanical requirements while maintaining overall system reliability at high temperatures
2Temperature
If high-temperature polymers are used for the absorber and frame, then the panel can withstand high temperatures, but thermal expansion causes internal stress and potential structural failure
Solution Approach 1:
The patent explicitly designs expansion slots into the frame structure to accommodate thermal expansion of the high-temperature polymer components. These slots allow the frame to expand and contract freely with temperature changes, preventing buildup of internal thermal stress that would otherwise lead to structural failure
Solution Approach 2:
The patent segments the frame structure with expansion slots that create movable joints between different sections. This segmentation allows each section to expand independently, managing thermal stress through controlled movement rather than rigid continuous structure
3Loss of energy
If the panel is sealed to prevent heat loss, then thermal efficiency is improved, but internal pressure buildup causes structural failure
Solution Approach 1:
The patent extracts the pressure relief function from the sealed enclosure by incorporating venting mechanisms that selectively remove excess pressure while maintaining thermal efficiency. The vents are designed to open only when pressure exceeds safe levels, separating the heat retention function from pressure containment
4Productivity
If an integrated controller is added to manage pump operation and fluid circulation, then thermal management and heat transfer efficiency are improved, but device complexity increases
Solution Approach 1:
The patent merges the controller, pump, and temperature sensors into an integrated thermal management system. This combination optimizes heat transfer by coordinating pump operation with real-time temperature data, improving productivity while managing complexity through integrated design rather than separate 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 solution provides a durable, efficient, and cost-effective solar panel capable of withstanding high temperatures, minimizing thermal stresses, and ensuring reliable operation by using polymers that remain stable up to 140-150°C, while the integrated controller optimizes heat transfer and fluid circulation.
Implementation Method 1
an absorber for absorbing solar radiation and for heating a heat transfer fluid
Implementation Method 2
heat transfer fluid flowing through parallel flow passages of the absorber to transfer heat
Implementation Method 3
utilizing high-temperature polymers like HTN, PPSU, and PPA for the absorber and frame, along with expansion slots and venting to accommodate thermal expansion
Implementation Method 4
an integrated wireless controller to manage pump operation and fluid circulation for efficient heat transfer
Data Source
AI summary
A flat plate heating solar panel comprised of polymer materials that can withstand relatively high temperatures. The polymer materials utilized in the panel have similar thermal expansion characteristics so that different components can by connected to each other without excessive stresses and damage during temperature changes, and with major components capable of being fabricated by molding processes, including extrusion and injection molding. An expansion joint or slot is provided in the enclosure frame to allow relative movement between the header connector and the frame in order to minimize stresses when large temperature differences exist between the absorber/header and the frame, and the slot design also provides a vent to relieve excessive air pressures inside the panel at high temperatures. An electronic controller with wireless capability, powered by a small photovoltaic solar cell with energy storage by a supercapacitor or an ultracapacitor, is integrated with the panel to operate a pump to circulate a heat transfer fluid through the panel when heating capability exists and when heat is needed to increase the temperature of the substance to be heated by the panel.