Solar Refraction Lens Array for Industrial Material Heating

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Solution Overview

Problem

Conventional heating systems for industrial materials, such as furnaces, are inefficient in energy transfer, relying on fossil fuels and resulting in significant energy losses, making them environmentally costly and inefficient, while existing solar technologies are limited in capacity and efficiency for industrial-scale energy capture and transfer.

Innovation Solution

A solar refraction device (SRD) that uses a lens array assembly to refract diffuse solar energy into focused beams, concentrating it onto a heating area within a container to efficiently heat industrial materials, potentially replacing traditional energy sources with renewable energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional furnaces are used to heat industrial materials, then the materials can be heated and melted, but significant energy losses occur during thermal energy transfer resulting in only 30-40% efficiency

Engineering Contradiction:

Improveenergy loss during thermal energy transferVSAvoidenergy efficiency of heating process

Core Design Contradiction:

Loss of energyVSUse of energy by moving object

Solution Approach 1:

The patent replaces conventional thermal heating systems (furnaces, burners) with a solar-optical system that uses lenses to concentrate solar energy directly onto the material. This substitution eliminates the intermediate thermal energy transfer step through air, achieving direct solar-to-material energy transfer and dramatically reducing energy losses.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces optical lenses as an intermediary to focus and concentrate solar energy onto the heating area. The lenses act as mediators that transform diffuse solar radiation into concentrated beams, enabling efficient direct heating without requiring thermal conversion through furnace air, thereby eliminating the 30-40% energy loss inherent in conventional thermal systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If solar energy systems are used to heat industrial materials, then renewable energy can be utilized, but known solar technologies are limited in capacity and efficiency for industrial-scale applications

Engineering Contradiction:

Improveindustrial-scale energy capture capacityVSAvoidenergy conversion efficiency

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent merges multiple optical lenses into an array configuration to combine their individual focusing capabilities. This merging of multiple lens elements creates a system with sufficient total capacity to handle industrial-scale heating requirements while maintaining the high efficiency of direct solar concentration, overcoming the capacity limitations of single-lens or small-scale solar systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the optical parameters of the solar system by using lenses with specific focal lengths and arrangements to concentrate solar energy to the required intensity levels for industrial heating. By adjusting lens parameters (focal length, aperture, arrangement), the system achieves both industrial-scale capacity and high conversion efficiency simultaneously.

Inventive Principle:

Principle #35Parameter changes

3Illumination intensity

If solar energy is not concentrated enough in any given area, then it cannot be used on an industrial scale, but concentrating solar energy requires additional system components that reduce overall efficiency

Engineering Contradiction:

Improvesolar energy concentrationVSAvoidsystem complexity for energy concentration

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent employs curved lens surfaces (spherical or aspherical) to naturally focus parallel solar rays to a concentrated point or line. The curvature of the lenses provides the focusing function through geometric optics alone, eliminating the need for additional mechanical concentration devices, mirrors, or complex tracking mechanisms, thus achieving high illumination intensity with minimal added complexity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 SRD achieves higher energy conversion efficiency compared to traditional solar systems, allowing for the efficient heating and melting of industrial materials with reduced energy losses and environmental impact, making solar energy a viable alternative for industrial processes.

Implementation Method 1

diffuse solar energy that impinges on an outside surface of the SRD and is refracted through the SRD

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

The lens array assembly is configured to refract impinging solar energy to focus the refracted solar energy onto a heating area

Methodology Applied

Scientific EffectFocusing: Focusing

Data Source

PatentUS10422553B2Solar refraction device for heating industrial materials

Publication Date: 2019.09.24 THE BOEING CO

AI summary

Disclosed is a solar refraction device (“SRD”) for heating industrial materials in a heating container, having a bottom, with diffuse solar energy that impinges on an outside surface of the SRD and is refracted through the SRD. The SRD may include a lens array assembly and a plurality of lens panes attached to the lens array assembly. The lens array assembly may include an outside surface corresponding to the outside surface of the SRD, an inside surface, and a plurality of lens array sub-assemblies.