BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description of the drawings particularly refers to the accompanying figures in which:
FIG. 1: Cross-section drawings of each layer of the solar cell and water heater plate assembly according to this invention.
FIG. 2: The copper pipe fasteners according to this invention.
FIG. 3: Frame for fixing solar cell and water heater plate assembly in FIG. 1 together to build the PVT collector according to this invention.
FIG. 4: Framing process of all components according to this invention.
FIG. 5: All components of the PVT collector according to this invention.
FIG. 6: PVT collector according to this invention.
Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplifications set out herein illustrate embodiments of the invention in several forms and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE DRAWINGS
Description of this invention is conducted by pointing out an example of the invention to be referred to by using the figures for illustration. The same parts or components in these figures shall be represented by the same reference numbers, without implication of limitation. The scope of the invention shall be in accordance with the claims attached. The embodiments discussed below are not intended to be exhaustive or limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings.
FIG. 1 illustrates a cross-section of each layer of a solar cell and water heater pipe assembly according to an embodiment of this invention, which is part of the PVT collector.
According to FIG. 1, the solar cell and water heater plate assembly 10 includes clear glass 12 which is used as base plate for securing a solar cell 14 which should be of amorphous silicon type due to its stable functionality at high temperature. However, other types of solar cell may also be used. A first layer of polymer glue 15 is made of EVA (Ethylene Vinyl Acetate), for example, for fixing the clear glass plate 12 to a heat collecting metal plate 17 which is made of heat-conductive metal such as zinc, iron, copper, aluminum, etc. The metal plate 17 should be best coated with an electrical insulator 16 to prevent short circuit and corrosion caused by condensation of moisture in the atmosphere. Exemplary electrical insulator 16 include Unitane, a polyurethane. The insulator-coated metal 16,17 shall be fastened to the pipe fasteners 20 with a second layer of polymer glue 18. The pipe fasteners 20 for fastening the heat transfer pipe (see pipe 43 in FIG. 4) to the insulator-coated heat collecting metal plate 16,17 transfers heat from the sun light to the water in the heat transfer pipe 43. Details of the illustrated pipe fasteners 20 are shown in FIG. 2 to be further described.
FIG. 2 illustrates layout of one embodiment of water heater pipe fasteners.
The illustrated pipe fastener 20 is a metal plate of good heat conduction such as copper, aluminum, zinc-coated iron, etc. In one embodiment, it is of rectangular shape with a length of approximately 180 mm. and a width of approximately 125 mm. Size of the pipe fastener 20 may be changed as appropriate. In one embodiment, each pipe fastener 20 consists of means for securing 21,22 such as the edge end 22 and notched niche 21 which, in one embodiment, will generally be as long as the plate. The edge end 22 shall be perfectly fit within the notched niche 21 for proper engagement between the adjacent pipe fasteners 20. In one embodiment, the fastener plate 20 shall consist of means for clamping or parts for fixing with the pipe 23 or the securing rail at least one piece installed at approximately the middle of the plate. For better solution, such parts for fixing to the pipe shall have maximum contact with the fastener plate for maximum transfer of heat from the fastener plate to the pipe and the heat-carrying fluid within the pipe. It may be made in “S” shape for example. But, however, this could cause a more complicated installation as it may require bending of the heat-conducting pipe to the same shape of the parts fixing to the pipe 23. In one embodiment, the pipe fixing parts 23 may be of straight rail shape with the “U” or semicircle shape cross-section, and perpendicular to the plane of the plate. In one embodiment, width of the pipe fixing part 23 is generally around 0.5 inches so that it can be fixed with the heat-conductive copper pipe with 0.5 inches in diameter. In one embodiment, the pipe-fixing part 23 shall be as long as the fastener plate 20 for installation of the heat-conductive pipe by clamping into such “U” shape rail. In one embodiment, the pipe-fixing part 23 should be made of metal which might be welded to the plate 20. In other embodiments, the pipe-fixing part 23 is fastened with screw, or is an aluminum plate cast to be together with the metal plate in one piece.
In one embodiment, two fastener plates 20 are installed by putting them next to each other with the long sides of the plates in parallel. Then the edge end 22 of the first fastener plate 20 is inserted into the notched niche 21 of the second fastener plate 20 and engaged together. This is repeated with further plates 20 until the required size is reached.
Assembling of the Solar Cell and Water Heater Plate Assembly
Solar cell and water heater plate assembly 10 is a part of this PVT collector. In one embodiment, the solar cell and water heater plate assembly 10 is assembled by connecting all light receptors into one piece consisting of PV module 14 which is installed on the glass plate 12, adding a first layer of polymer glue EVA 15 and an electrical insulator to form an insulator-coated metal plate 16,17 (Unitane in one embodiment), adding a second layer of polymer glue EVA 18, and adding pipe fastener 20 with assembling of each component shown in FIG. 1. In one embodiment, the layers of EVA 15,18 shall bond the various components of each layer together by heat pressurized process or lamination because of melting EVA at 250° C. will act like glue pressed with pressure caused by the vacuum inside.
PV module 14, in one embodiment, is PV module of amorphous silicon type (in one embodiment, general size of around 635×1.245 mm.) assembled to a glass structure 12. In one embodiment, the back side is in a box shape with a terminal box at the middle and a bit to the top (not illustrated)
The metal plate 17 is coated with an electrical insulator 16, in one embodiment Unitane, to prevent short circuit and corrosion.
The pipe fastener plate 20 as shown in FIG. 2 is for fastening a pipe. In one embodiment, the pipe fastener 20 has a length of approximately 180 mm., a width of approximately 125 mm. In one embodiment, pipe fastener 20 is comprised of multiple sections or pieces that are attached together. In one embodiment, wherein the pipe fastener 20 has a length of approximately 180 mm and a width of approximately 125 mm a total of 30 pieces are used. It should be understood, that for pipe fastener 20 the size and number of pieces may be changed as appropriate to allow sufficient span for size of the main heat conductive pipe and the frame. There is also a hole for installing a terminal box which is used to help prevent moisture or humidity. The edge of the copper splice lock shall be filed to avoid damage to the seal (in one embodiment, a rubber plate such as a fluoroelastomer, such as VITRON a registered trademark of Dupont Dow Elasomers which is heat resistance up to 400° F./200° C. and resistance to fuel and chemical is used) in the process of creating vacuum as described below and to prevent damaging of various components, such as fasteners, in the laminator ovens.
In one embodiment, the splice plate for fixing pipe 20 is a flat metal plate with “U” or semicircle shape piece in the middle, perpendicular to the plate, for holding the pipe by clamping. In one embodiment, one end of the splice edge 20 is the niche 21 and the other end is the prominent part 22 perfectly fit with the niche of the other splice plate for fixing pipe.
FIG. 3 illustrates an embodiment of a frame for holding solar cell and water heater plate assembly 10 together to build the PVT collector.
FIG. 4 illustrates a framing process of all components.
FIG. 6 illustrates an embodiment of the PVT collector.
In FIG. 3, frame 30 consists of a first space 32, a second space 34, a third space 36, and a fourth space 38, respectively. In one embodiment, the first space 32 has the size adjusted for installation of clear glass to create the green house effect inside.
The second space 34 is the space for installation of PV module and water heater plate 10. The third space 36 is for installation of splice for fixing pipe 20 and the heat conductive pipe. Before installation, the rubber seal such as Buthyl Rubber should be attached to the edge of the solar cell and water heater plate assembly 10 which is to be placed in the second space 34 and the glass which is to be placed in the first space 32 on all 4 sides before the framing process to avoid moisture (see FIG. 4). The third space includes the rough skin polymer sheet. The fourth space 38 is the space for heat insulation for improving heating efficiency.
Preparation of the Solar Cell and Water Heater Plate Assembly 10
In one embodiment, after preparation of the work piece, lamination treatment process shall be started as follows:
- 1. Arrange the layout structure before laminating process by arranging as per FIG. 1.
- 2. Put on rough skin polymer sheet and then put Viton rubber plate on top of the rough skin polymer sheet.
- 3. Put the solar cell and water heater plate assembly in 4 trays, 2 trays at the top and 2 trays at the bottom. The trays support the solar cell and water heater plate assembly.
- 4. Create vacuum in the tray ready with the work by switching on the vacuum connected to the tray. The tray includes a small hole adapted to bring the contents of the tray in communication with the vacuum being applied.
- 5. Check whether there is air leakage at the solar cell and water heater plate assembly.
- If there is, check the rough skin polymer sheet to see whether it gets in the way of the vacuum system and check the Viton rubber to see whether it perfectly adhere to the o-ring.
- If there is no leakage, proceed on to the next step.
- 6. Check to ensure that the vacuum is at approx 2-4 Torr.
- 7. Once the required vacuum is achieved, push the tray shelf trolley into a laminator oven.
- 8. Before the heat treatment process, set timer of the oven heater at 22 minutes and set timer for the circulating fan of the oven at 27 minutes.
- 9. Switch on all 3 heaters and set temperature at 250 C and switch on the circulating fan and exhaust fan.
- 10. Start the heat treatment until the heater timer has expired and switch off all 3 heaters.
- 11. Wait until the timer for the circulating fan has expired and then switch off the circulating fan.
- 12. After that open the oven, wait for 5 minutes while keeping the exhaust fan operating until temperature in the oven is close to the room temperature.
- 13. Pull the tray shelf trolley out of the oven. Let the work cool down naturally.
- 14. Switch off the vacuum pump and take out the work tray.
- 15. Inspect the work piece for defects.
After the lamination process, put the solar cell and water heater plate assembly 10 in the frame 30 (as shown in FIG. 4 and 5) and install the glass as follows:
- 1. On the side of the frame 30 (in one embodiment with 1.245 meter length), measure and drill holes for main copper pipe on all 4 sides and stick the copper pipe into the frame 30. Then connect the header copper pipe 42 with the copper tubes 43 by welding. In one embodiment, the connection is done by welding before installing the copper pipe to the locking splice 20 to avoid damage to the glass due to heat.
- 2. Attach Buthyl Rubber at the edge of PV module and edge of the glass on all 4 sides before the framing process.
- 3. Install PV module and glass into the frame 30 on the length side first. Then put the copper pipe to the locking splice of the copper pipe, and then start framing process on the width side, arrange the layout position of the frame and fasten with screws on all 4 corners to add strength to the structure.
- 4. Put silicone to seal the drilled holes for main pipes to avoid moisture.
- 5. Inspect the work for defect. The final work shall look like FIG. 4.
After that, put fiber glass heat insulator or glass wool insulator 44 with 2 inches thickness, insulator density 24 kg/m3 with aluminum foil on 1 side, and line the fiber glass insulator on each side that may not be possible until it is completely covered. The side with aluminum foil shall be on the lower side of the PV module. Finally, install an aluminum cover door 48 at the lowest section. Before fastening with screw, seal all 4 sides with silicone to prevent moisture. The components are shown in FIG. 5 and the completely assembled version is shown in FIG. 6.
While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.
Patent Application
20080011289
