Solar reflector in composite material based on resin reinforced with cut fibres, and uses in solar plants
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional glass reflectors in concentrated solar power plants are fragile, heavy, and inefficient, with high production and maintenance costs due to their thickness, fragility, and light absorption, which reduces energy yield and increases installation complexity.
Innovation Solution
A solar reflector composed of a thermosetting or thermoplastic resin reinforced with cut fibers, featuring a silver-based metallic coating with a thickness of 60 to 200 nm and integrated attachment elements, molded to reduce weight and improve reflectance, allowing for efficient energy reflection and reduced manufacturing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass reflectors with thickness of 4-5 mm are used to ensure mechanical strength, then the reflector gains sufficient structural integrity, but the weight increases significantly and light absorption reaches 3%-6%
Solution Approach 1:
The patent changes the material parameters by substituting glass with a composite material consisting of thermoplastic resin and reinforcing fibers. This material substitution fundamentally alters the density and mechanical properties, achieving sufficient strength with dramatically reduced weight (from several kilograms per square meter to fractions of a kilogram per square meter).
Solution Approach 2:
The patent employs composite materials by combining thermoplastic resin matrix with reinforcing fibers (glass fibers, carbon fibers, or aramid fibers). This composite structure provides the necessary mechanical strength and rigidity while maintaining low weight, directly resolving the contradiction between strength and weight.
2Strength
If glass reflectors with thickness of 4-5 mm are used to ensure mechanical strength, then the reflector gains sufficient structural integrity, but the light absorption increases by 3%-6% thereby decreasing energy yield
Solution Approach 1:
The patent changes the optical parameters by substituting glass with a composite material that has superior optical transparency. The composite material absorbs significantly less light energy (less than 1%), thereby improving energy yield while maintaining adequate mechanical strength through fiber reinforcement.
Solution Approach 2:
The use of fiber-reinforced thermoplastic composite materials provides both mechanical strength and optical clarity. The fibers provide structural integrity while the resin matrix maintains optical transparency, achieving low light absorption (less than 1%) compared to glass (3%-6%).
3Illumination intensity
If glass reflectors are used, then the reflector provides good optical properties, but the reflector becomes fragile and thousands of reflectors may be broken during production, installation and operation
Solution Approach 1:
The patent changes the mechanical parameters by substituting brittle glass with a composite material that exhibits high toughness and impact resistance. The thermoplastic resin matrix and fiber reinforcement provide ductility and fracture resistance, eliminating the fragility issue while maintaining optical transparency and reflector performance.
Solution Approach 2:
The fiber-reinforced thermoplastic composite material combines the optical clarity needed for good optical properties with the mechanical toughness provided by the resin-fiber composite structure. This composite construction eliminates the brittleness of glass, preventing breakage during production, installation, and operation.
4Stability of the object's composition
If glass reflectors are used, then the reflector provides structural stability, but the manufacturing process requires heating to 550°C-1200°C which consumes large amounts of energy and creates residual stresses
Solution Approach 1:
The patent changes the thermal processing parameters by replacing the high-temperature glass manufacturing process (550°C-1200°C) with a low-temperature composite material manufacturing process. The thermoplastic resin can be processed at temperatures below 200°C, dramatically reducing energy consumption and eliminating residual thermal stresses.
Solution Approach 2:
The composite material system allows for low-temperature processing compared to glass. The thermoplastic resin matrix can be molded and cured at relatively low temperatures, eliminating the need for high-temperature heating and subsequent cooling that causes residual stresses in glass reflectors.
5Shape
If glass reflectors are curved on the installation site, then the reflector achieves proper curvature for light focusing, but the process causes damage and requires substantial means to guarantee curvature
Solution Approach 1:
The patent applies preliminary action by pre-curving the reflector during the molding process itself. The composite material is shaped into the required curvature while in its molded state, before installation. This eliminates the need for post-installation curving operations that damage glass and require complex equipment.
Solution Approach 2:
The composite material's properties allow it to be molded into curved shapes during manufacturing and maintain those shapes without requiring subsequent mechanical curving. The material can be formed into the desired geometry in the mold, providing the correct curvature for light focusing without damage or complex curving equipment.
6Ease of operation
If adhesive attachment is used to attach glass reflectors to the structure, then the reflector can be mounted, but the adhesive degrades under climatic stresses such as UV, wind, heat, cold, humidity and corrosive atmosphere
Solution Approach 1:
The patent merges the attachment function with the reflector structure itself. The composite material is molded with integrated attachment elements (such as ribs, flanges, or molded-in mounting features) that are structurally integral to the reflector. This eliminates the need for separate adhesives that would degrade under environmental stresses.
Solution Approach 2:
The reflector provides self-attachment capability through its integrated molded features. The attachment elements are built into the reflector structure, allowing it to be mechanically secured to the support structure without relying on external adhesives that would be subject to degradation from UV, moisture, and temperature cycling.
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 composite reflector achieves a reflectance of over 94%, reduces production and installation costs, and enhances durability, making it suitable for large-scale solar energy collection with improved mechanical properties and reduced environmental impact.
Implementation Method 1
a reflective layer of silver-based metallic coating with a thickness of from 60 to 200 nm, having a reflectance of more than 94%
Implementation Method 2
focusing these rays onto the surface of a receiver composed of material which absorbs this radiation and which converts this concentrated light energy (radiation) into heat
Implementation Method 3
a curved or planar substrate which is a part moulded in composite material based on resin reinforced with cut fibres
Data Source
Figure 1~2
AI summary
The invention relates to a solar reflector for concentrated solar power plants, comprising a substrate a) in composite material based on resin reinforced with cut fibres, said substrate having means b) for attachment without either perforation or gluing, and a metallic reflective coating layer c). The reflector of the invention is used in solar collectors and in solar plants operating on concentrated solar power, more particularly for producing electricity, steam and/or heat.