TPS-Sealed Solar Thermal Absorber for Automated Assembly
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Solution Overview
Problem
The high manufacturing costs of solar thermal collectors with thermoplastic spacer (TPS) sealed absorber modules are due to the extensive manual work required in series production, particularly when adding insulation and mounting modules into collector frames, which hinders mass production efficiency.
Innovation Solution
A solar thermal absorber element with a TPS sealed back insulation that allows for automatic production line manufacturing, featuring a cover glass, direct-flow absorber, fore and back thermoplastic sealings, and low thermal conductive gases in sealed spaces to reduce thermal losses and protect against mechanical damage, insects, and dust.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual work is used for adding insulation and mounting modules into collector frames, then the quality and reliability of assembly can be maintained, but manufacturing costs increase and productivity decreases
Solution Approach 1:
The absorber module is divided into separate functional components (absorber plate, insulation layer, sealing elements, mounting features) that can be manufactured independently and then assembled automatically. The insulation is provided as a separate component with integration features rather than being manually attached
Solution Approach 2:
The insulation component is designed with self-integration features such as recesses, protrusions, or adhesive layers that enable automatic attachment to the absorber plate without manual intervention. The module structure itself provides the means for its own assembly through features like integrated mounting brackets or snap-fit connections
2Reliability
If thermoplastic spacer (TPS) sealing is used to protect the absorber from sand, salt, and insects, then the reliability and lifespan of the collector improve, but manufacturing costs increase due to manual work requirements
Solution Approach 1:
The TPS sealing function is merged with the module's structural components. The sealing elements are integrated into the absorber plate edges or insulation components rather than being separate parts requiring manual installation. This combines the protective sealing function with the structural framework in a single manufacturable unit
Solution Approach 2:
The TPS sealing components serve multiple functions: they provide the hermetic seal against sand, salt, and insects, while also serving as structural attachment points for the insulation and as mounting features for assembling the complete collector. This multi-functionality eliminates the need for separate manual sealing steps
3Productivity
If mass production using automatic production lines is implemented, then productivity and cost-effectiveness improve, but the complexity of achieving precise assembly of insulated modules decreases
Solution Approach 1:
The insulation components and absorber plates are manufactured with precisely controlled geometric parameters including standardized recess dimensions, protrusion sizes, and tolerance ranges. These parameter specifications enable automatic assembly machines to reliably join components without complex programming or adjustment, transforming a complex assembly task into a simple parameter-matching operation
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
Enables cost-effective mass production of solar thermal absorber elements with reduced thermal losses and extended lifespan by using automatic production lines and low thermal conductive gases, maintaining efficiency and preventing damage from environmental factors.
Implementation Method 1
The fore space is filled up with a first low thermal conductive gas. The back space is filled up with a second low thermal conductive gas.
Data Source
Figure 1a~1b
AI summary
The application relates to a solar thermal absorber element (100) comprising a cover glass (110), a direct-flow absorber (120), a fore thermoplastic spacer (130), a fore sealed space (134), and a first low thermal conductive gas (136) filling up the fore sealed space. The fore thermoplastic spacer attaches the cover glass and the absorber to each other so that there is a first distance (hi) between the cover glass and the absorber, and so that the fore sealed space is surrounded by the cover glass, the absorber, and the fore thermoplastic spacer. The element further comprises a back thermoplastic spacer (170) that attaches a back insulation part (160) and the absorber to each other so that the back thermoplastic spacer causes a second distance (h2) between the insulation part and the absorber, and so that the insulation part, the absorber, and the back thermoplastic spacer surround a back sealed space (174) filled up with a second low thermal conductive gas (176).