Vacuum-Tight Soldering Frame for Evacuated Flat Solar Collectors
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Solution Overview
Problem
The existing methods for vacuum tight soldering of the perimeter metal coating of a transparent wall to the perimeter metal frame of an evacuated flat panel solar collector are time-consuming and require manual intervention, limiting production efficiency and reliability.
Innovation Solution
A device with a movable heating and pressing frame that automatically positions and applies heat and pressure to the soft metal ribbon, allowing for rapid and efficient soldering without manual intervention, using separate heating elements for the glass wall and metal frame and incorporating thermal insulation and cooling mechanisms to optimize the soldering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering is used, then vacuum tightness reliability is achieved, but production speed is slow and labor intensive
Solution Approach 1:
The soldering device performs the soldering operation automatically without manual intervention. The heating frame moves autonomously along the collector, applies heat and pressure through the pressing frame, and completes the soldering of the soft metal ribbon to seal the gap between the transparent wall and metal frame, achieving both automation and vacuum tightness
Solution Approach 2:
The patent replaces the manual mechanical soldering process with an automated system that uses a movable heating frame with integrated heating elements and pressing mechanisms. This automated mechanical system maintains consistent heat and pressure application, ensuring reliable vacuum tightness while dramatically increasing production speed
2Productivity
If automated soldering device is used, then production speed increases, but device complexity increases
Solution Approach 1:
The movable heating frame serves multiple functions: it provides structural support, houses heating elements for thermal application, incorporates a pressing frame for mechanical pressure, and moves autonomously along the collector. This multi-functionality reduces the need for separate devices and simplifies the overall system while maintaining high productivity
Solution Approach 2:
The heating frame is divided into separate heating elements positioned at different locations (front, rear, and side elements) that can independently heat different sections of the soft metal ribbon. This segmentation allows for targeted heating while keeping each individual heating element relatively simple in design
3Reliability
If heating frame covers entire collector, then complete sealing is achieved, but heating time increases
Solution Approach 1:
The movable heating frame progresses along the collector in a continuous periodic motion, heating the soft metal ribbon section by section rather than heating the entire collector at once. This allows complete sealing to be achieved through sequential heating while maintaining short heating time at each location
Solution Approach 2:
The heating elements are positioned to concentrate thermal energy precisely where needed - at the gap between the transparent wall and metal frame where the soft metal ribbon requires heating. This localized heating approach ensures complete sealing at critical points while minimizing overall heating time and energy consumption
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 rapid and accurate soldering of a large area without skilled labor, significantly increasing production capacity and ensuring reliable vacuum tightness of the solar collectors.
Implementation Method 1
a first upper heating frame (24) and a second lower pressing frame (25)... heating the soft metal ribbon (6) provided on said perimeter metal coated part (5) of the transparent wall (4) and on said perimeter metal frame part (3)
Implementation Method 2
heating the soft metal ribbon (6)... soldering the soft metal ribbon 6 to said perimeter metal frame 3 and said perimeter metal coating 5
Implementation Method 3
a second lower pressing frame (25)... for pressing the soft metal ribbon (6) provided on said perimeter metal coated part (5) of the transparent wall (4) and on said perimeter metal frame part (3)
Implementation Method 4
a thermal insulating element (28)... separating the heating frame (24) into two elements
Data Source
Figure 1
Figure 2~4
AI summary
Device for vacuum tight soldering together a perimeter metal coating (5) of a transparent wall (4) to a perimeter metal frame (3) of a holding structure (2) of an evacuated solar collector (1), in particular a flat solar collector, said collector comprising a joining ribbon (6), preferably a soft metal strip or ribbon, in particular a lead and/or copper strip or ribbon, which is adapted to vacuum tight seal the gap (7) between said transparent wall (4) and said metal frame (3) and which is adapted to be soldered, in particular soft soldered, to said perimeter metal frame (3) and said perimeter metal coating (5) of the transparent wall (4), said joining ribbon comprising a soldering alloy, said device comprising heating means (24) for heating: a first part (5A) of said transparent wall (4) comprising at least a portion of said perimeter metal coating (5), a second part (3A) of said holding structure (2) comprising at least a portion of said perimeter metal frame (3), and said joining ribbon (6) to at least the melting temperature of said soldering alloy, when said transparent wall (4) is positioned in said holding structure (2) with said joining ribbon (6) overlapping at least partially said perimeter metal frame (3) and said metal coating (5), and pressure means (25) for applying at least on said first (5A) and second (3A) parts and said joining ribbon (6) a force which guarantees a mechanical contact of the melted soldering alloy to said metal frame (3) and said metal coating(5) throughout the solidification process of said soldering alloy.