The invention relates generally to the collection of solar energy to provide electric power, heat, or electric power and heat.
Alternate sources of energy are needed to satisfy ever increasing world-wide energy demands. Solar energy resources are sufficient in many geographical regions to satisfy such demands, in part, by provision of electric power and useful heat.
Systems, methods, and apparatus by which solar energy may be collected to provide electricity, heat, or a combination of electricity and heat are disclosed herein.
In one aspect, a solar energy collector comprises a first row of one or more trough reflectors extending along and attached to a first rotation shaft and a second row of one or more trough reflectors extending along and attached to a second rotation shaft that is arranged side-by-side with the first rotation shaft and oriented parallel to the first rotation shaft. The solar energy collector also comprises a first transverse support beam underlying both the first and the second rotation shafts, and a second transverse support beam underlying both the first and the second rotation shafts and spaced apart from the first transverse support beam along the rotation shafts. The first rotation shaft is pivotably supported by a first bearing on a post extending upward from the first transverse support beam and pivotably supported and driven by a first slew drive on a post extending upward from the second transverse support beam. The first rotation shaft passes through the center of the first bearing and through the center of the first slew drive. The second rotation shaft is pivotably supported by a second bearing on a post extending upward from the first transverse support beam and pivotably supported and driven by a second slew drive on a post extending upward from the second transverse support beam. The second rotation shaft passes through the center of the second bearing and through the center of the second slew drive. The positions of the first bearing and the first slew drive along the first rotation shaft and of the second bearing and the second slew drive along the second rotation shaft are adjustable to match the positions of the first and second transverse support beams to the positions of load bearing elements of a surface underlying the solar energy collector. The underlying surface may be a roof of a building, for example.
The positions of the first bearing and the first slew drive along the first rotation shaft and of the second bearing and the second slew drive along the second rotation shaft may be slidably adjustable along their rotation shafts. The first and second transverse support beams may be oriented parallel to each other, and may be oriented perpendicular to the rotation shafts.
The solar energy collector may comprise transverse reflector supports attached to and extending transversely to the rotation shafts to support the trough reflectors. The solar energy collector may comprise a plurality of receivers. The receivers may comprise solar cells, coolant channels accommodating flow of liquid coolant through the receiver, or solar cells and coolant channels accommodating flow of liquid coolant through the receivers. Each receiver may be supported above a corresponding trough reflector by, for example, one or more receiver supports extending upward from transverse reflector supports that support the corresponding trough reflector, with each receiver fixed in position with respect to its corresponding trough reflector.
Each trough reflector may comprise a plurality of linearly extending reflective elements oriented with their long axes parallel to the trough reflector's rotation shaft, arranged side-by-side in a direction transverse to that rotation shaft, and fixed in position with respect to each other.
Along each rotation shaft, the trough reflectors may be arranged end-to-end with ends of adjacent trough reflectors vertically offset with respect to each other. The trough reflectors may be arranged to form a repeating pattern of tilted trough reflectors, for example. The vertically offset ends of adjacent trough reflectors may overlap. The reflectors may be arranged so that for each pair of vertically offset adjacent trough reflector ends, the upper trough reflector is located further from the earth's equator than is the lower trough reflector.
Each trough reflector may comprise a plurality of linearly extending reflective elements arranged side-by-side on an upper surface of a flexible panel and oriented parallel to the trough reflector's rotation shaft. In such variations that also comprise transverse reflector supports attached to and extending transversely to the rotation shafts to support the trough reflectors, attachment of the trough reflectors to the transverse reflector supports may force ends of the flexible panels against curved edges of the transverse reflector supports to thereby impose a desired concentrating curvature on the trough reflectors.
The solar energy collector may comprise a plurality of longitudinal reflector supports extending parallel to each rotation shaft to support the trough reflectors and a plurality of transverse reflector supports extending transversely from each rotation shaft to support the longitudinal reflector supports, with each transverse reflector support located at or near an end of a trough reflector. In such variations, when the longitudinal reflector supports are in a free state unattached to the solar energy collector they may have a curvature that, in the assembled solar energy collector, is flattened or substantially flattened by the force of gravity. The free-state curvature of the longitudinal reflector supports may thereby compensate for the force of gravity on the trough reflectors to prevent sagging of each trough reflector between its supporting transverse reflector supports.
In another aspect, a concentrating solar energy collector comprises a linearly extending receiver and a reflector comprising a plurality of linearly extending reflective elements oriented with their long axes parallel to a long axis of the receiver. The reflective elements are arranged side-by-side in a direction transverse to the long axis of the receiver and fixed in position with respect to each other. The solar energy collector also comprises a linearly extending support structure that accommodates rotation of the receiver, rotation of the reflector, or rotation of the receiver and the reflector about a rotation axis parallel to the long axis of the receiver. Linearly extending gaps between adjacent linearly extending reflective elements reduce wind load on the reflector compared to the same reflector without the gaps.
The gaps may be provided by spacing the linearly extending reflective elements apart horizontally, by spacing the linearly extending reflective elements apart vertically, or by spacing the linearly extending reflective elements apart horizontally and vertically. The reflector formed by the linearly extending reflective elements may have, for example, a parabolic or substantially parabolic shape.
The receiver may comprise solar cells, coolant channels accommodating flow of liquid coolant through the receiver, or solar cells and coolant channels accommodating flow of liquid coolant through the receiver.
These and other embodiments, features and advantages of the present invention will become more apparent to those skilled in the art when taken with reference to the following more detailed description of the invention in conjunction with the accompanying drawings that are first briefly described.
The following detailed description should be read with reference to the drawings, in which identical reference numbers refer to like elements throughout the different figures. The drawings, which are not necessarily to scale, depict selective embodiments and are not intended to limit the scope of the invention. The detailed description illustrates by way of example, not by way of limitation, the principles of the invention. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.
As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly indicates otherwise. Also, the term “parallel” is intended to mean “parallel or substantially parallel” and to encompass minor deviations from parallel geometries rather than to require that any parallel arrangements described herein be exactly parallel. Similarly, the term “perpendicular” is intended to mean “perpendicular or substantially perpendicular” and to encompass minor deviations from perpendicular geometries rather than to require that any perpendicular arrangements described herein be exactly perpendicular.
This specification discloses apparatus, systems, and methods by which solar energy may be collected to provide electricity, heat, or a combination of electricity and heat.
Referring now to
In other variations, a solar energy collector otherwise substantially identical to that of
As is apparent from
In the example of
Referring again to
Although each reflector 120 is parabolic or approximately parabolic in the illustrated example, reflectors 120 need not have a parabolic or approximately parabolic reflective surface. In other variations of solar energy collectors disclosed herein, reflectors 120 may have any curvature suitable for concentrating solar radiation onto a receiver.
In the example of
In the illustrated example, linearly extending reflective elements 150 each have a width of about 123 millimeters (mm) and a length of about 2751 mm. In other variations, linear reflective elements 150 may have, for example, widths of about 100 mm to about 200 mm and lengths of about 1000 mm to about 4000 mm. Linearly extending reflective elements 150 may be flat or substantially flat, as illustrated, or alternatively may be curved along a direction transverse to their long axes to individually focus incident solar radiation on the corresponding receiver.
Although in the illustrated example each reflector 120 comprises linearly reflective elements 150, in other variations a reflector 120 may be formed from a single continuous reflective element, from two reflective elements, or in any other suitable manner.
Linearly extending reflective elements 150, or other reflective elements used to form a reflector 120, may be or comprise, for example, any suitable front surface mirror or rear surface mirror. The reflective properties of the mirror may result, for example, from any suitable metallic or dielectric coating or polished metal surface.
In variations in which reflectors 120 comprise linearly extending reflective elements 150 (as illustrated), solar energy collector 100 may be scaled in size and concentrating power by adding or removing rows of linearly extending reflective elements 150 to or from reflectors 120 to make reflectors 120 wider or narrower. The width of support structure 130 transverse to the optical axis of reflectors 120, and the width of transverse reflector supports 155 (discussed below), may be adjusted accordingly.
Referring again to
In variations in which coolant is flowed through receivers 110, the receivers may comprise top covers that are substantially transparent to solar radiation. This may create a green-house effect in which direct solar illumination of the top cover of a receiver further heats the receiver and thus further heats the coolant. Such substantially transparent receiver top covers may be formed from a polycarbonate plastic, for example.
In some variations, the receivers comprise solar cells but lack channels through which a liquid coolant may be flowed. In other variations, the receivers may comprise channels accommodating flow of a liquid to be heated by solar energy concentrated on the receiver, but lack solar cells. Solar energy collector 100 may comprise any suitable receiver. In addition to the examples illustrated herein, suitable receivers may include, for example, those disclosed in U.S. patent application Ser. No. 12/622,416, filed Nov. 19, 2009, titled “Receiver For Concentrating Photovoltaic-Thermal System;” and U.S. patent application Ser. No. 12/774,436, filed May 5, 2010, also titled “Receiver For Concentrating Photovoltaic-Thermal System;” both of which are incorporated herein by reference in their entirety.
Referring again to
Support structure 130 also comprises a plurality of receiver supports 165 each connected to and extending from an end, or approximately an end, of a transverse reflector support to support a receiver 110 over its corresponding reflector 120. As illustrated, each reflector 120 is supported by two transverse reflector supports 155, with one transverse reflector support at each end of the reflector. Similarly, each receiver 110 is supported by two receiver supports 165, with one receiver support at each end of the receiver. Other configurations using different numbers of transverse reflector supports per reflector and different numbers of receiver supports per receiver may be used, as suitable.
In the illustrated example, each of the transverse reflector supports 155 for a row of reflectors 120 is attached to a rotation shaft 170 which provides for rotation of the reflectors and receivers in that row about their rotation axis 140, which is coincident with rotation shaft 170. Rotation shafts 170 are pivotably supported by master posts 175a and slave posts 175b, as described in more detail below. In other variations, any other suitable rotation mechanism may be used.
In the example of
In the illustrated example transverse reflector supports 155 each comprise two parallel and identical or substantially identical rows of upward pointing projections (e.g., tabs) 180 arranged side-by-side along the length of the transverse reflector support transverse to rotation shaft 170. The two rows of projections 180 are spaced apart from each other in a direction parallel to rotation shaft 170. In the illustrated example, the spacing between the two rows of projections on a transverse reflector support is about 50 mm. In other variations, the two rows of projections may be spaced apart from each other by, for example, about 30 mm to about 100 mm.
Away from either end of a row of reflectors 120, typically each of the projections 180 in one row of projections supports an end of a corresponding one of the longitudinal reflector supports 160 for a first reflector 120, and each of the projections 180 in the other row of projections supports an end of a corresponding one of the longitudinal reflector supports 160 for another reflector 120 located on the opposite side of the transverse reflector support from the first reflector 120. A single transverse reflector support 155 may thus support an end of one reflector 120 and the adjacent end of another reflector 120. Two adjacent transverse reflector supports 155 (
At an end of a row of reflectors 120, typically both rows of projections 180 on the outermost transverse reflector support 155 support the outermost ends of the longitudinal reflector supports 160 in the outermost reflector 120. This arrangement is shown in
To enable both rows of projections 180 on an outermost transverse reflector support 155 to support the same longitudinal reflector supports, the transverse reflector support 155 may be positioned closer to its neighboring transverse reflector support than the typical spacing between transverse reflector supports in the interior of the solar energy collector.
This arrangement with both rows of projections 180 of the outermost reflector support 155 supporting the same longitudinal reflector supports allows the outer ends of the outer reflectors 120 to be better secured to support structure 130. This may be advantageous because the outermost reflectors 120 may experience wind loads greater than those experienced by the interior reflectors 120.
In the illustrated example, upper surfaces or edges 183 of projections 180 (
Referring now to
The position and shape of protrusions 205 are selected to substantially match or complement the position and shape of corresponding protrusions 210 on the sides of projections 180. In addition, the thickness and material from which longitudinal reflector support 160 is formed are chosen such that sidewalls 200 are sufficiently elastic that they may flex outwardly sufficiently to pass side wall protrusions 205 over protrusions 210 but will afterwards experience a restoring force clamping side wall protrusions 205 into engagement with the undersides of protrusions 210. Longitudinal reflector support 160 may in this way be secured or locked to projection 180 by forces pulling flat tray bottom 190 against projection reference surface 183. A longitudinal reflector support exhibiting this self-locking feature may be provided, for example, by rolling, folding, or otherwise forming a sheet of pre-galvanized steel having a thickness of about 0.6 mm into the illustrated shape.
More generally, longitudinal reflector supports 160 may snap-on to transverse reflector supports 155 through the engagement of any suitable complementary interlocking features on longitudinal reflector support 160 and transverse reflector support 155. Slots and locking tabs, or protrusions and recesses, for example, may be used in other variations.
In the illustrated example, longitudinal reflector supports 160 are about 2753 mm long and have upper tray portions about 125 mm wide (sized to accommodate a reflective element). In other variations, longitudinal reflector supports 160 are about 1000 mm to about 4000 mm long and have upper tray portions about 100 mm to about 200 mm wide.
Linearly extending reflective elements 150 may be attached to longitudinal reflector supports 160 with, for example, glue or other adhesive. Any other suitable method of attaching the reflective elements to the longitudinal reflector support may be used, including screws, bolts, rivets and other similar mechanical fasteners, and clamps or spring clips.
In addition to attaching linear reflective element 150 to longitudinal reflector support 160, in the illustrated example glue or adhesive 215 positioned between the outer edges of linearly extending reflective elements 150 and tray side walls 195 may also seal edges of the reflective elements and thereby prevent corrosion of the reflective elements. This may reduce any need for a sealant separately applied to the edges of the reflective elements. Glue or adhesive 215 positioned between the bottom of the linearly extending reflective element and flat tray bottom 190 of the longitudinal support may mechanically strengthen the reflective element. Further, flat tray bottom 190 may provide sufficient protection to the rear surface of the reflective element to reduce any need for a separate protective coating on that surface. A coating of paint on the rear surfaces of the reflective elements may be sufficient additional protection, for example.
Transverse reflector supports 150 comprising projections and complementary snap-on longitudinal reflector supports 160 as disclosed herein may be used to support linearly extending reflective elements in a solar energy collector having any suitable configuration. The particular configurations of support structure and rotation mechanism shown in the illustrated examples are not intended to imply any limit on the use of such transverse reflector supports and snap-on longitudinal reflector supports. Any other suitable support structures and rotation mechanisms may be used in combination with such transverse reflector supports and snap-on longitudinal reflector supports.
Referring now to
Rotation shafts 170 and transverse frame rails 225 are typically oriented perpendicularly to each other, as illustrated. In the illustrated example, rotation shafts 170 have two functions: they enable rotation of a row of reflectors and receivers to track the position of the sun, and they are longitudinal frame rails of support structure 130 providing strength and rigidity along their axes.
As explained in more detail below with reference to
Rotation shafts 170 may be formed, for example from steel tubing have a square cross-section with a side length of, for example, about 100 mm to about 150 mm, and wall thicknesses of, for example, about 3 mm to about 10 mm. A rotation shaft 170 may be formed from a single continuous tube. Alternatively, a rotation shaft may be formed from two or more lengths of tube joined together. Such joining may be accomplished mechanically, or by welding, or by any other suitable method. In the illustrated example, rotation shafts 170 are formed by joining shorter lengths of tube using mechanical splices 232, which have the form of clamps that conform to the cross-sectional shape of the tube and overlap the joint between two shorter lengths of tube. The splice 232 clamps to both pieces of tube, joining them together in a collinear orientation.
Referring now to
Referring now to
Typically, a rotation shaft for a row of reflectors and receivers is supported by one master post 275a and about three to about five slave posts 275b, but any suitable number and combination of master posts 275a and slave posts 275b may be used.
Although the example support structure 130 just described is shown in the figures supporting reflectors and receivers using particular example reflector supports and receiver supports, any suitable configuration of reflector and receiver supports may be used with the adjustable support structure disclosed herein.
As shown in
Referring now to
Other variations may combine horizontal gaps of length L with vertical gaps of height H. In such variations, W, L, and H may be selected to reduce wind load by a desirable amount while maintaining solar radiation collection efficiency at or above a desired level. The width W of the linearly extending reflective elements 150 may be, for example, about 100 mm to about 200 mm, the horizontal spacing L between adjacent reflective elements may be, for example, about 0 mm to about 20 mm, and the vertical spacing H of adjacent reflective elements may be, for example, about 10 mm to about 100 mm.
In the variations described above, reflectors 120 comprise parallel rows of linearly extending reflective elements 150 which are, for example, each individually supported by a longitudinal reflector support 160. Alternatively, and as described below, reflective elements 150 may be arranged side-by-side on flexible panels. The flexible panels may then be supported by longitudinal reflector supports and transverse reflector supports similar to those described above. Such arrangements of reflective elements on flexible panels are referred to below as reflector-panel assemblies. A reflector 120 may comprise one or more such reflector-panel assemblies. For example, a reflector 120 may comprise two or more such reflector-panel assemblies arranged side-by-side transversely to the rotation axis of the solar energy collector.
In variations of solar energy collector 100 comprising reflector-panel assemblies, the transverse reflector supports may impose a parabolic curve, an approximately parabolic curve, or any other suitable curve on the reflector-panel assemblies in a plane perpendicular to the rotation axis. The linearly extending reflective elements 150 may thereby be oriented to form a linear Fresnel (e.g., parabolic) trough reflector with its linear focus located at or approximate at the surface of receiver 110. Referring to
Referring now to
Linearly extending reflective elements 150 may be attached to flexible panel 350 with, for example, an adhesive that coats the entire back surface of each reflective element 150. The adhesive coating may be applied, for example, directly to a reflective (e.g., silver and/or copper) layer located on the back surface of reflective element 150 or to a protective layer on the reflective layer. In such variations, the adhesive layer may protect the reflective layers from corrosion in addition to attaching the reflective elements to the panel. The use of such a protective adhesive layer may advantageously reduce any need to apply other protective coatings, such as paint layers, to the back surfaces of the reflective layers. The adhesive may be, for example, a spray-on adhesive such as, for example, 3MTM 94 CA spray adhesive available from 3M, Inc. The adhesive layer may have a thickness of, for example, about 0.05 mm to about 0.5 mm, typically about 0.2 mm. The spray-on adhesive may preferably be applied to only the back surfaces of the reflective elements, or to only the top surface of the flexible panel 350 to which the reflective elements are attached, rather than to both the back surfaces of the reflective elements and the top surface of the flexible panel. Alternatively, the spray-on adhesive may be applied to both the top surface of the flexible panel and the back surfaces of the reflective elements, but this may add process steps, complexity, and expense. Any other suitable adhesive, any suitable fastener, or any other suitable fastening method may also be used to attach reflective elements 150 to panel 350.
Referring again to
Referring now particularly to
Referring again to
To facilitate bending of flexible panel 350 at gaps 355 between reflective elements 150, each longitudinal reflector support 360 may be arranged to underlie a single reflective element 150 as shown in
Longitudinal reflector supports 360 may have a length of, for example, about 600 mm to about 3700 mm, typically about 2375 mm, a depth (panel 350 to bottom wall 360C) of, for example, about 25 mm to about 150 mm, typically about 50 mm, and a width (wall 360A to wall 360B) of, for example, about 25 mm to about 150 mm, typically about 75 mm. Any other suitable materials, dimensions, and configurations for longitudinal reflector supports 360 may also be used.
In the illustrated example each reflector-panel assembly 280 is attached to and supported at its ends by a pair of adjacent transverse reflector supports 155. Suitable methods and arrangements for accomplishing this may include those disclosed, for example, in U.S. patent application Ser. No. 13/619,881, filed Sep. 14, 2012, titled “Solar Energy Collector”; U.S. patent application Ser. No. 13/619,952, filed Sep. 14, 2012, also titled “Solar Energy Collector”; U.S. patent application Ser. No. 13/633,307, filed Oct. 2, 2012, also titled “Solar Energy Collector”; and U.S. patent application Ser. No. 13/651,246, filed Oct. 12, 2012, also titled “Solar Energy Collector”; all of which are incorporated herein by reference in their entirety. Any other suitable method or arrangement may also be used.
As shown in
Longitudinal reflector supports 360 may be attached to brackets 310 with any suitable fastener, adhesive, or other fastening method. As in the illustrated example, further discussed below, longitudinal reflector supports 360 may snap-on to brackets 310 through the engagement of any suitable complementary interlocking features on supports 360 and on brackets 310. One or both of the complementary interlocking features may be configured to have sufficient elasticity to flex to allow a support 360 to be installed in a bracket 310 and then provide restoring forces that retain the complementary features in an interlocked configuration. Suitable complementary interlocking features may include, for example, tabs and slots, hooks and slots, protrusions and recesses, and spring clips and slots.
Referring now to
Referring again to
Brackets 310 may be formed, for example, form molded plastic, sheet steel, or any other suitable material. Although the illustrated snap-on configuration just described may be advantageous, any other suitable configuration for brackets 310 may also be used. Further, the use of brackets 310 is not required. As noted above, any suitable method for attaching reflector-panel assemblies 280 to transverse support 155 may be used.
Two coplanar reflector-panel assemblies arranged in line along the rotation axis and attached end-to-end to a shared transverse reflector support 155 are generally spaced apart by a small gap to accommodate thermally induced expansion and contraction of the collector and to provide mechanical design tolerances. The gap between the reflector-panel assemblies does not reflect light and consequently behaves like a shadow on the reflector, which may be projected by the reflector onto the receiver. The shadow on the receiver resulting from the gap may degrade performance of solar cells on the receiver similarly to as described above with respect to shadows cast by receiver supports.
Referring now to
In the illustrated example, each reflector-panel assembly is supported at one end by a tall side wall 155B of one transverse reflector support 155, and at the other end by a short side wall 155C of another transverse reflector support 155, with adjacent ends of the reflector-panel assemblies vertically offset rather than coplanar. As shown in
If reflective elements 150 are front surface reflectors, then in the offset reflector-panel geometry just described parallel rays 370A and 370B (
Non-uniform illumination of the receiver resulting from gaps between reflector-panel assemblies may also be reduced or eliminated by shaping the ends of reflector-panel assemblies to spread reflected light into what would otherwise by a shadow on the receiver resulting from the gap. For example, ends of otherwise coplanar reflector-panel assemblies may curve or bend downward (away from the incident light), so that light rays are reflected in a crossing manner from the ends of the adjacent reflector-panel assemblies toward the receiver, blurring the shadow from the gap.
The force of gravity may make reflector-panel assemblies 280 sag between their supporting transverse reflector supports 155, and thereby cause each reflector-panel assembly to assume a slightly concave curvature along the rotation axis of the collector, distorting the shapes of reflectors 120. The resulting periodic concave curvature of the reflectors along the long axis of the solar energy collector may make the illumination of the receiver less uniform along its long axis, and consequently reduce the efficiency with which solar cells in the receiver generate electricity. Referring now to
The influence of gravity on the shapes of the reflector-panel assemblies may depend on the orientation of the collector and may, for example, be different for orientations corresponding to operation at solar noon, early morning, or early evening. The “pre-bend” necessary to counter sagging may consequently also depend on the orientation of the collector. In such cases, the “pre-bend” may preferably be selected to eliminate sagging at solar noon.
Where not otherwise specified, structural components of solar energy collectors disclosed herein may be formed, for example, from 16 gauge G-90 sheet steel, or from hot dip galvanized ductile iron castings, or from galvanized weldments and thick sheet steel.
This disclosure is illustrative and not limiting. Further modifications will be apparent to one skilled in the art in light of this disclosure and are intended to fall within the scope of the appended claims. All publications and patent application cited in the specification are incorporated herein by reference in their entirety.
This application claims benefit of priority to U.S. Provisional Application No. 61/621,820 titled “Concentrating Solar Energy Collector” and filed Apr. 9, 2012, which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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61621820 | Apr 2012 | US |