Solar Collector Panel Structure for High-Pressure Freeze Tolerance
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Solution Overview
Problem
Traditional solar water heating systems face inefficiencies due to poor heat transfer, structural weaknesses from manifolds, and the need for additional equipment to handle pressure and extreme temperatures, leading to increased costs and complexity.
Innovation Solution
A closed direct-connected solar water heating system with a solar collection panel featuring interconnected pockets formed by securing sheets of material with spot welds, allowing for elevated pressure handling and operation in extreme temperatures without heat exchangers or drain back systems, and utilizing fittings instead of manifolds for fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional tubes are used in solar collection panels, then fluid flow is enabled, but heat transfer surface area is minimal leading to poor heat transfer efficiency
Solution Approach 1:
The solar collection panel is segmented into multiple serpentine flow paths within a single continuous tube, creating multiple heat transfer zones along the tube length. This segmentation allows the tube to contact the plate surface at multiple points, significantly increasing the effective heat transfer surface area compared to a single straight tube configuration.
Solution Approach 2:
The invention transitions from a simple linear tube configuration to a three-dimensional serpentine path that winds through the plate. By adding spatial complexity in multiple dimensions, the tube maintains contact with the plate surface across a larger area without increasing the panel's external footprint.
2Loss of energy
If solar collection panels are made larger to compensate for limited heat transfer surface area, then heat transfer efficiency improves, but cost, weight, and difficulty of blending into surroundings increase
Solution Approach 1:
The serpentine tube configuration segments the heat transfer function across multiple zones within a compact panel, achieving high heat transfer efficiency without increasing panel size or weight. The segmented flow paths maximize surface contact within the available panel footprint.
Solution Approach 2:
By utilizing three-dimensional serpentine routing within the panel plane, the invention achieves extended heat transfer surface area without increasing the panel's external dimensions, thus avoiding increased weight and improved aesthetic blending.
3Ease of operation
If manifolds are used for fluid distribution, then fluid flow management is improved, but structural weakness and susceptibility to freezing damage increase
Solution Approach 1:
The invention extracts and eliminates the manifold component entirely from the system. Fluid distribution is achieved directly through the serpentine tube configuration embedded in the plate, removing the vulnerable manifold structure that is prone to freezing damage and structural failure.
Solution Approach 2:
The functions of heat transfer and fluid distribution are merged into a single integrated serpentine tube structure. The tube simultaneously serves as the heat exchange surface and the fluid distribution network, eliminating separate manifold components and reducing structural vulnerability.
4Strength
If silver brazing is used to secure manifolds to panels, then structural attachment is achieved, but structural weakness is created due to annealing
Solution Approach 1:
The invention removes the manifold component that requires brazing attachment, thereby eliminating the source of structural weakness caused by silver brazing annealing. The serpentine tube is directly integrated into the plate structure without requiring separate attachment processes.
Solution Approach 2:
The tube and plate are merged into an integrated structure where the serpentine tube is formed as part of the plate assembly process, eliminating the need for separate attachment methods like silver brazing that compromise structural integrity.
5Loss of energy
If heat exchangers are used to transfer heat from fluid to water, then heat transfer is enabled, but system complexity and cost increase
Solution Approach 1:
The invention merges the heat transfer function directly into the solar collection panel through the serpentine tube configuration. The same structure that collects solar energy and conducts heat also serves as the heat exchange surface, eliminating the need for separate heat exchanger components and reducing system complexity.
Solution Approach 2:
The serpentine tube structure performs multiple functions simultaneously: it serves as the solar energy collection conduit, the heat transfer surface, and the fluid distribution network. This multi-functionality eliminates the need for dedicated heat exchanger components, simplifying the overall system.
6Ease of operation
If manifolds extend beyond solar collection panels, then fluid connection is enabled, but space occupation increases and blending into surroundings becomes difficult
Solution Approach 1:
The invention removes the protruding manifold structure that extends beyond the panel boundaries. Fluid connections are achieved through ports integrated directly into the panel edges, eliminating the need for external manifold extensions and reducing the overall space occupation.
Solution Approach 2:
The fluid connection function is merged into the panel structure itself through integrated edge ports. The connection points are incorporated directly into the panel boundaries rather than extending beyond them, allowing panels to abut one another and reducing the visual and physical footprint.
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 enhances efficiency, reduces costs and complexity, allows for integration into building structures, and operates effectively at elevated pressures and extreme temperatures, eliminating the need for supplemental equipment and improving installation ease.
Implementation Method 1
solar collection panel featuring a serpentine tube configured to contact a majority of a surface area of the solar collection panel... allowing for elevated pressure handling and operation in extreme temperatures
Implementation Method 2
the serpentine tube... configured to contact a majority of a surface area of the solar collection panel, thereby increasing an amount of heat transfer between the solar collection panel and heat exchange fluid flowing through the serpentine tube
Implementation Method 3
the serpentine tube... allows the solar collection panel to withstand freezing and thawing of the heat exchange fluid flowing through the serpentine tube
Data Source
AI summary
Described herein are embodiments of solar heating systems, including solar collection panels used in the solar heating systems, and methods for manufacturing solar collection panels suitable for use in the solar collection panels. The solar heating system is a closed direct connected solar heating system that need not include heat exchangers or drain back systems. The solar collection panels include a series of interconnected pockets between two sheets of material and inlet and outlet fittings for providing fluid into and out of the solar collection panel. The system described herein is capable of operating under pressures of 160 psi or higher and can also tolerate extreme temperature conditions, such as freezing temperature conditions.