Thermal transfer device for covers

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Solution Overview

Problem

Conventional spa covers made of expanded polystyrene (EPS) suffer from moisture absorption, leading to weight gain, reduced insulating value, and structural issues, while existing solar heating solutions are not suitable for spas due to weight, aesthetics, and integration challenges with existing heating systems.

Innovation Solution

A thermally active spa cover using twinwall polycarbonate with integrated solar thermal and photovoltaic technology, featuring a sealed shell for moisture protection, air passages for heat exchange, and a self-contained heating system that can be easily installed and removed, maintaining the spa's appearance and functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If EPS is used for the spa cover, then the cover is lightweight and low-cost, but the material absorbs moisture leading to weight gain and reduced insulating value

Engineering Contradiction:

Improvecover manufacturing costVSAvoidcover durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the material parameter from EPS to twinwall polycarbonate, which has different moisture absorption characteristics. The polycarbonate material maintains structural integrity and insulating value without absorbing moisture, thereby improving reliability while keeping manufacturing costs reasonable through efficient molded construction

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure combining twinwall polycarbonate with foam core insulation and fabric covering. This composite approach creates a moisture-resistant outer shell that protects the insulating core, solving the moisture absorption problem while maintaining lightweight properties and manufacturing efficiency

Inventive Principle:

Principle #40Composite materials

2Strength

If the cover structure is made rigid to prevent deformation, then structural strength is improved, but the cover becomes difficult to remove and handle

Engineering Contradiction:

Improvecover structural strengthVSAvoidcover removability

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent divides the cover into multiple sections or panels that can be detached from one another. This segmentation allows the cover to maintain rigid structural strength when assembled while enabling easy removal and handling by separating the sections, directly resolving the contradiction between strength and operability

Inventive Principle:

Principle #1Segmentation

3Use of energy by moving object

If solar heating components are integrated into the cover, then heat collection efficiency is improved, but the cover weight increases

Engineering Contradiction:

Improvesolar heat collectionVSAvoidcover weight

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The patent employs thin-film solar heating components integrated into the cover structure. These thin films provide solar heat collection functionality while adding minimal weight, allowing the cover to maintain its lightweight characteristics while gaining thermal energy collection capabilities

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent designs the cover to serve multiple functions: thermal insulation, solar heat collection, and weight reduction. By integrating solar heating components that also contribute to the overall structure, the patent achieves multi-functionality where the same components provide both structural support and energy collection, avoiding additional weight

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Loss of energy

If the cover provides high insulation to retain heat, then energy loss is reduced, but the cover prevents useful solar energy transfer to the water

Engineering Contradiction:

Improveheat loss preventionVSAvoidsolar energy transfer

Core Design Contradiction:

Loss of energyVSUse of energy by moving object

Solution Approach 1:

The patent implements a dynamic cover system that can adjust its insulation properties. The cover can transition between high-insulation mode for heat retention and low-insulation mode for solar energy transfer, allowing it to adapt to different environmental conditions and operational requirements, thereby resolving the contradiction between heat retention and solar energy utilization

Inventive Principle:

Principle #15Dynamics

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 efficient solar heat collection and passive heat transfer, maintaining temperature control, reducing energy consumption, and enhancing durability and aesthetics, while avoiding the drawbacks of traditional spa covers.

Implementation Method 1

A thermally active spa cover using twinwall polycarbonate with integrated solar thermal and photovoltaic technology, featuring a sealed shell for moisture protection, air passages for heat exchange

Methodology Applied

Scientific EffectSolar thermal heating: Solar Energy

Implementation Method 2

passive heat transfer, maintaining temperature control

Methodology Applied

Scientific EffectHeat transfer: Convection

Implementation Method 3

integrated solar thermal and photovoltaic technology

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Implementation Method 4

featuring a sealed shell for moisture protection

Methodology Applied

Scientific EffectMoisture protection: Physical Containment

Implementation Method 5

air passages for heat exchange

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11561026B1Thermal transfer device for covers

Publication Date: 2023.01.24 SPA COVER PROD LLC

AI summary

The solar thermal collection and radiant heating system for a spa comprising upper and lower absorber members having fluid passageways and in thermal communication, a skin member encasing said upper and lower absorber members and an insulative member located therebetween the upper and lower members and a solar collection device located on the skin member.