Reflector panel assembly
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Solution Overview
Problem
Existing reflector panel constructions for concentrated solar power systems face challenges such as moisture damage, UV degradation, complexity in fabrication, and limited shape accuracy, making them costly and difficult to manufacture while maintaining optical precision under external loads.
Innovation Solution
A reflector panel assembly with a base composed of sheet metal featuring protrusions that provide spaced-apart contact points to support the reflector, allowing for accurate curvature and efficient mass production, using sheet metal forming processes like stamping and incremental sheet forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sandwich panel construction with porous core material is used, then the reflector panel maintains structural integrity, but moisture becomes entrapped in the porous core leading to corrosion and adhesive failure
Solution Approach 1:
The patent removes the porous core material from the sandwich panel construction, retaining only the two stiff face sheets. This extraction eliminates the moisture entrapment issue while preserving the structural integrity provided by the face sheets, directly resolving the contradiction between strength and moisture resistance.
2Weight of moving object
If a stamped metal support with cut-outs is used, then the weight of the support is reduced, but the capability for achieving high shape accuracy is constrained
Solution Approach 1:
The patent employs a curved mold during the forming process to impart the desired curvature to the reflective sheet. This allows the support structure to achieve high shape accuracy without requiring complex cut-outs or raised features, maintaining optical precision while keeping the support structure simple and lightweight.
3Shape
If external support frames with connecting elements are used, then the reflector panel achieves desired shape, but the location of connections is constrained by frame geometry limiting mirror shape accuracy
Solution Approach 1:
The patent removes the external support frame structure and connecting elements, allowing the reflective sheet to be formed directly into the desired shape using a curved mold. This extraction of the frame system eliminates geometric constraints on connection locations, enabling superior mirror shape accuracy to be achieved.
4Manufacturing precision
If conventional sandwich panel construction is used, then accuracy is provided, but fabrication complexity and costs increase due to light blocking edges
Solution Approach 1:
The patent merges the support function and the shaping function into a single integrated process. The support structure serves both as the backing for the reflective sheet and as the means to impart the desired curvature during forming, eliminating the need for separate shaping operations and light-blocking edges, thereby reducing fabrication complexity while maintaining optical accuracy.
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 ensures high stiffness and shape accuracy of the reflector panels, reducing costs and enabling large-scale manufacturing while maintaining optical performance under external forces.
Implementation Method 1
a reflector comprising a sheet element configured to receive and reflect electromagnetic radiation
Data Source
AI summary
Disclosed is a reflector panel assembly for use in a concentrated solar power system, the assembly comprising a reflector comprising a sheet element having a front surface and a rear surface, the reflector configured to receive and reflect electromagnetic radiation incident on the sheet element, a base configured to support the reflector such that a contact surface between the rear surface and the base is configured to maintain a predetermined shape of the reflector. Disclosed also is a base configured to support a reflector for use in a concentrated solar power system, the base composed of sheet material and comprising a plurality of protrusions spaced apart across a surface of the base, the plurality of protrusions extending to contact portions at peaks of the protrusions, the contact portions configured to form a contact surface which supports the reflector.