US20170176052A1

US20170176052A1 - Solar thermal collector

Info

Publication number: US20170176052A1
Application number: US15/381,643
Authority: US
Inventors: Michael Scott CAMPBELL
Original assignee: Big Blue Ball LLC
Current assignee: Big Blue Ball LLC
Priority date: 2015-12-18
Filing date: 2016-12-16
Publication date: 2017-06-22
Also published as: PH12015000444A1

Abstract

A solar thermal collector using one-piece parabolic frame having a one-piece reflector or thin mirror film provided on the top portion of the one-piece parabolic frame, a heat collection element tube where heat transfer fluid is to be provided and a solar tracking system that provides precise focus of the parabola to the sun optimizing the heat transfer from the heat collection element tube (HCE) to the heat transfer fluid (HTF).

Description

CLAIM TO PRIORITY

This application claims priority to Philippine Application No. 12015000444 filed on Dec. 18, 2015, the entire disclosure and content of which is hereby incorporated by reference.

TECHNICAL FIELD OF THE INVENTION

The present invention is directed to a solar thermal collector but more specifically to a parabolic heat collector using one-piece parabola having a thin mirror film provided on its top portion, a heat collection element tube where heat transfer fluid is to be provided and a solar tracking system that provides precise focus of the parabola to the sun optimizing the heat transfer from the heat collection element tube (HCE) to the heat transfer fluid (HTF), so as to provide hot fluids to any system used for process heat application requiring hot fluids as an input medium, including but not limited to absorption chillers.

BACKGROUND OF THE INVENTION

The sun which is probably the most efficient source of energy emits light and heat in the form of electromagnetic radiation which is called solar energy. Capturing this radiation and turning it into usable forms is what most companies nowadays are doing. Solar energy is the sun's nuclear fusion reactions within the continuous energy generated. Variety of applications for solar energy are as follows:
Residential application of solar energy. Solar panels or photovoltaic cells are installed on the roof of the house to collect the solar energy for power consumption and other applications such as heating water, space heating and pool heating. Photovoltaic technology employs solar cells to convert energy from the sun into electricity. Photovoltaic cells produce direct current electricity from the sun's rays, which can be used to power equipment, or to recharge batteries.
The sun's thermal energy is also used in industrial application such as offices and warehouses. Solar energy is used to power radio and television stations. It can also be used to supply power to lighthouses and warning lights for aircraft.
Another application of solar energy is electric Cars. Electric vehicles powered by energy obtained from solar panels on the surface of the car converts the sun's energy directly into electrical energy. Electric car technology is a fast growing endeavor of most car manufacturing companies. However, the solar cells provided on electric cars are very fragile and can only operate for limited distances without sun. Development teams have focused their efforts on optimizing the efficiency of the vehicle, but many have only enough room for one or two people.
Yet, another application of solar energy is for power generation in remotely situated places like schools, clinics, and buildings. In some remote areas, water pumps are run on solar energy. Large scale desalination plants also use power generated from solar energy instead of electricity.
The present invention is another form of application for solar energy utilizing, a solar thermal collector to heat fluids used within heat applications. More specifically. the present application utilizes parabolic minors to reflect the sun's solar energy onto a small, thin-wall tube filled with water, oil, or other heat transfer fluid (HTF) medium providing hot fluids to a system used for any process heat application requiring hot fluids as an input medium; such as absorption chillers as an example but not limited to this one application.
The sun's energy reflected onto the tube is maintained through a drive system and automated controls tracking the sun's travel across the sky throughout the day. The drive system rotates rows of parabolas, connected end to end on the short side, having the thin-walled tube as one continuous tube filled with an HTF centered as the focal point of the parabolas.
End row parabolas either feed a next row or accept from a prior row of fluid to continue heating the fluid row to row. The fluid is either directly used in the process application or stored in external storage to maintain a larger volume of hot fluid used in non-real-time heating such as after the sun has set and heating is no longer capable.
An array is created from the rows of parabolas interconnected end to end and at HTF header connections that return the fluid post process to the array and exit the array to process or storage system.
U.S. Pat. No. 7,950,387 B2 issued to Darren Kimura, et. al. also pertains to solar energy collectors. Kimura's patent teaches a concentrating solar energy collector having a frame or housing, a heat collector provided at the bottom portion of the frame or housing, plurality of mirrors disposed on the frame or housing, plurality of brackets to hold the plurality of mirrors and frame or housing, a transparent cover provided on top of the frame or housing and a storm cover disposed on top of the transparent cover. The plurality of mirrors is positioned in the frame or housing to receive solar radiation and concentrate at least a portion of the radiation on the heat collector. A storage reservoir is also attached to the frame or housing and in fluid communication with the heat collector. The solar energy collectors maybe joined together to form sections of two or three, or more collectors. The sections may be then coupled together to form one or more rows. Kimura's patent also teaches the use of a tracking device to determine the orientation of the sun and pivot the solar energy collector to optimize collection of solar radiation.
Another prior art is disclosed in Published United States Patent Application No. 2013/0228165 A1 also issued to Darren Kimura, et. al. Kimura's published patent application teaches a concentrating solar energy collector having a frame or housing, a heat collector provided at the bottom portion of the frame or housing, plurality of mirrors disposed on the frame or housing, plurality of brackets to hold the plurality of mirrors and frame or housing, a transparent cover provided on top of the frame or housing and a storm cover disposed on top of the transparent cover. The plurality of mirrors is positioned in the frame or housing to receive solar radiation and concentrate at least a portion of the radiation on the heat collector. The solar energy collectors maybe joined together to form sections of two or three, or more collectors. The sections may be then coupled together to form one or more rows. Kimura's patent also teaches the use of plurality of stanchions to support the heat collector.
Yet, another prior art is disclosed in Published United States Patent Application No. US2012/0186579 A1 issued to Kip Dopp, et. al. Dopp's published patent application teaches a solar energy collector having a support structure, a plurality of arc-shaped reflectors connected by at least one fastener at a midpoint of the larger arc formed by joining the arc-shaped reflectors and a collector tube wherein the plurality of arc-shaped reflectors are positioned to illuminate the collector tube.
The problem with the above-mentioned prior art is the utilization of plurality of mirrors or reflectors in concentrating solar energy to the heat collector. Using plurality of mirrors or reflectors in the solar energy collector means more brackets to hold or connect the mirrors or reflectors to the frame or housing of the solar energy collector. With brackets covering most of the parts of the mirrors or reflectors, less solar energy can be concentrated to the heat collector. The above-mentioned prior art failed to maximize concentration of solar energy to the heat collectors due to plurality of brackets holding the plurality of mirrors or reflectors.
The present invention has come about from years of work in the solar thermal industry and the deficiencies of design of the prior inventions of parabola and drivetrain methods. These deficiencies in design relating to failures from materials, structural integrity and environmental factors have initiated the present invention proposed in this summary. Additional design failure of prior inventions in drivetrain methods have proven ineffective, increased costs of parts not needed, and corrosion of metal surfaces resulting in failure of system components and system operation.
Prior multi-piece, metallic, parabola designs have historically proven:

- High manufacturing costs
- Increased weight resulting in higher shipping costs and system inefficiency.
- Structurally inept wind load bearing ability creating structural failures and safety concerns.
- High assembly time increasing end customer costs in labor.
- Requires skilled labor for assembly and installation increasing costs to the end customer.
- High number of parts increases probability of lost parts in shipment and shipment preparation.

Metals are highly corrosive causing structural failure in extreme environments: Humidity, salt, dirt, rain, pollutants in the air, all contribute to structural failures caused by these corrosive properties to metals such as steel, stainless steel and aluminum.
Rust, stainless steel to aluminum corrosion and stainless steel to stainless steel thread of fasteners; nuts, bolts, screws PEM nuts.
Consistent recurring system failures cause loss of process heat output of the system causing operating cost increase having to resort back to traditional heating methods such as fossil fuels and boilers.

OBJECT OF THE INVENTION

It is therefore the primary object of the present invention to provide for a solar thermal collector that would solve the problems of the prior art
Yet another object of the present invention is to provide for a solar thermal collector comprising a one-piece parabolic frame, a one piece reflector provided on top of the one-piece parabolic frame, frame support assembly disposed on the one-piece parabolic frame and one-piece reflector, arm assembly disposed on both ends of the one-piece parabolic frame and one-piece reflector, stanchion assembly provided on the frame support assembly, a stand assembly to support the solar energy collector and a motor disposed on the stand assembly and glove assembly.
Yet another object of the present invention is to provide for a solar thermal collector wherein the frame support assembly comprises at least a long inner frame, a short inner frame, an inner center support frame, a long outer frame, a short outer frame and an outer center support, frame.
Yet another object of the present invention is to provide for a solar thermal collector wherein the arm assembly comprises a right glove member, a left glove member, a shoe member, a hub member and plurality of arm rod members.
Yet another object of the present invention is to provide for a solar thermal collector wherein the right and left glove members are being defined by an arrow tip like body having a flange extending from its back portion and an L-shaped flange perpendicularly extending from the arrow tip like body.
Yet another object of the present invention is to provide for a solar thermal collector wherein the flange is provided with a clamp.
Yet another object of the present invention is to provide for a solar thermal collector wherein the hub member is being defined by a T-shaped body having an opening in the middle and depressions disposed on ends of the T-shaped body.
Yet another object of the present invention is to provide for a solar thermal collector wherein the ends of the T-shaped body is provided with clamps.
Yet another object of the present invention is to provide for a solar thermal collector wherein the hub member is provided with a heat collecting element bearing.
Yet another object of the present invention is to provide for a solar thermal collector wherein the hub member is provided with an end hub.
Yet another object of the present invention is to provide for a solar thermal collector wherein the shoe member is being defined by an L-shaped body having a vertical flange extending from its top portion and a depression disposed on the vertical flange.
Yet another object of the present invention is to provide for a solar thermal collector wherein the vertical flange is provided with a clamp.
Yet another object of the present invention is to provide for a solar thermal collector wherein the stanchion assembly comprises a stand, holding supports disposed at one end of the stand, bearing housing provided at the other end of the stand and a bearing clamp provided on top of the bearing housing.
Yet another object of the present invention is to provide for a solar thermal collector wherein the stanchion assembly is provided with insulator gasket.
Yet another object of the present invention is to provide for a solar thermal collector wherein a glass insulator is disposed within the insulator gasket.
Yet another object of the present invention is to provide for a solar thermal collector wherein a heat collecting element tube is provided within the glass insulator.
Yet another object of the present invention is to provide for a solar thermal collector wherein heat transfer fluid is disposed within the heat collecting element tube.
Yet another object of the present invention is to provide for a solar thermal collector wherein the stand assembly comprises a motor stand, a base support provided at one end of the motor stand, a motor support plate disposed at another end of the motor stand, motor brackets provided at both ends of the motor support plate and a motor disposed on the motor support plate.
Yet another object of the present invention is to provide fore a solar thermal collector wherein the motor is provided with a shaft.
Yet another object of the present invention is to provide for a solar thermal collector wherein the shaft is provided with a motor gear.
Yet another object of the present invention is to provide for a solar thermal collector wherein the motor gear meshes with a hub gear.
Yet another object of the present invention is to provide for a solar thermal collector wherein the hub gear is connected to the end hub.
Yet another object of the present invention is to provide for a solar thermal collector wherein the solar energy collector is made of polycarbonate honeycomb material.
Still, another object of the present invention is to provide for a solar thermal collector constructed of a polycarbonate honeycomb material provides;

- Increased structural integrity and safety.
- Increased strength and safety.
- Increased wind load bearing capability and safety.
- Elimination of multi-part construction reduces costs.
- Elimination of multi-part construction increases efficiency and thermal output.
- Reduced weight lowering shipping costs and increasing system efficiency.
- Reduced assembly time reducing installation costs.
- Assembly by unskilled individuals reducing installation costs.
- Eliminates lost parts in transit increasing profitability.
- Increased environmental protection from corrosion increasing profitability.
- Elimination of downtime of failed structure increasing profitability.
- Reduced cost of repair and replacement parts increasing profitability.

Another object of the present invention is to provide a drivetrain that eliminates the chain, sprocket, and multiple drive shaft prior problems. Past inventions utilized an inefficient and short-lived drive system of multiple steel chains and steel sprockets that rust and corrode in extreme environments causing the solar array to stop functioning in a short amount of time and repeated costly replacement of parts. Past inventions utilize multiple drive shafts connected to the motor to drive the sprocket and chain system reducing efficiency, increasing weight, increasing costs of shipping, increasing costs of repairs from failure, and increasing costs of installation time.
The present invention eliminates the use of a multiple piece hub assembly creating failure to system functionality due to excessive wear from rotation and heat exchange during HTF heating and cooling. This drivetrain of the present invention eliminates the chain, and sprocket, and multiple drive shaft prior problems. The present invention virtually eliminates the corrosion of parts, increases efficiency and significantly reduces manufacturing costs, shipping, maintenance and repairs which, are all transferred to the end customer. The present invention incorporates and produces increased quality and longer life of the overall solar thermal collector product having an increase in value to the customer while increasing the overall performance of the array.
Another embodiment of the present invention is the structural strength and integrity of the arm assembly on each end of the one-piece parabola frame. Past invention has allowed flexing of the arm structure creating stress in the glass envelope resulting on broken glass and lost insulating capability of the glass around the HCE tube. Past invention resulting of broken glass has resulted in increased cost of replacement glass, shipping, and labor in addition to lost thermal process heat from downtime of the system for repairs. The present invention virtually eliminates the problems of past invention as the arm assembly if formed of the one-piece hub and end hub, one-piece gloves and shoe, and arm rod connection of the hubs to shoes and gloves. The present invention of the arm assembly increased structural strength adds to the one-piece parabola structural integrity also increasing longevity of shape and focal capability on the HCE tube over time. The present invention of the arm structure provides increased efficiency of the system, increased thermal output of process HTF heat, reduced downtime from damaged and broken parts, and overall increased value to the customer.
Another embodiment of the present invention is the use of a slotted glass tube. A slot is cut in a tube of borosilicate glass down its length, slightly larger in width of the HCE tube, allowing easy installation, less breakage during installation, and easy removal for periodic cleaning as needed. Past inventions utilize glass tube creating extreme breakage, inability to remove and clean, and increased difficulty and breakage while installing the HCE tube during assembly of the system. The present invention virtually eliminates the installation issues of the past, affords the customer easy cleaning of the glass as necessary, and allows installation of the HCE tube without issues of the glass tube in the way. Past invention forces the glass tube installed during the installation of the HCE tube creating hazards to safety of the installer and the system. The past invention also forces the HCE tube removed and replaced in order to replace broken glass. The present invention increases safety of the installer, reduced installation time, reduced costs of replacement glass, reduced downtime of the system, and increased value to the customer.
Many of the attendant features will be more readily appreciated as the same becomes better understood by reference to the following detailed description considered in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the present invention for a solar thermal collector;

FIG. 2 is an exploded view showing the arm assembly and the parabolic frame;

FIG. 3 is another exploded view showing the frame support assembly, parabolic frame and parabolic reflector;

FIG. 4 is a side view of FIG. 1;

FIG. 5 is a cut-away view showing the connection of the parabolic frame and parabolic reflector to the long inner frame and long, outer frame of the frame support assembly;

FIG. 6 is another cut-away view showing the connection of the parabolic frame and parabolic reflector to the to the inner center support frame, short inner frame, short outer frame and outer center support frame of the frame support assembly;

FIG. 7 is also a cut-away view showing the connection between the parabolic frame and parabolic reflector to the long inner frame, short inner frame and short outer frame of the frame support assembly;

FIG. 8 is a perspective view of the shoe member;

FIG. 9 is a perspective view of the left glove member;

FIG. 10 is a perspective view of the right glove member;

FIGS. 11a and 11b show a side view and a perspective view of the stand assembly;

FIG. 12 is a perspective view of the motor showing the connection to the hub member;

FIG. 13 is a perspective view of the top portion of the stand assembly;

FIG. 14 is a perspective view of the hub member;

FIG. 15 is a perspective view of the stanchion assembly;

FIG. 16 is a perspective view of the insulator gasket, glass insulator and the heat collecting element tube;

FIG. 17 is a perspective view of the solar parabola of an embodiment of the present invention;

FIG. 18 illustrates the mold shape dimensions and angular reflective paths of the sunlight on the parabola;

FIG. 19 illustrates an embodiment of the drive system of an embodiment of the present invention;

FIG. 20 illustrates the main drivetrain components of the present invention; and

FIG. 21 illustrates a collector row in a solar array of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present description will be better understood from the following detailed description read in light of the accompanying drawings, wherein like reference numerals are used to designate like parts in the accompanying drawings. The descriptions of the various embodiments of the invention as discussed hereinbelow are for example only and not intended to limit the scope of the invention, its uses and variations of size, shape, material structure or assembly methods.
According to at least one embodiment of the present invention shown in FIGS. 1-3, a solar thermal collector 10 is provided where inside the inner parabolic frame 200 lays a single sheet of parabolic reflector 201 (thin mirrored aluminum) to reflect the sun onto a heat collector (thin wall tube) with Heat Transfer Fluid (HTF). The design of the present invention surpasses the prior art, removing the multiple metal parts and fasteners eliminating corrosion and breakdown in extreme environments such a tropical jungles and intense deserts. The present invention uses a non-metallic, one-piece material of various types and can be manufactured of recyclable materials as well.
In operation, the sun's energy being reflected onto the small, thin tube filled with HTF is maintained through a drive system and automated controls tracking the sun's travel across the sky throughout the day. The drive system rotates rows of parabolas 10 (see FIG. 21), connected end to end on the long side, having the thin walled tube welded as one continuous tube filled with HTF centered as the focal point of the parabolas. End row of parabolas either feed a next row or accept from a prior row the HTF to continue heating the HTF row to row. The HTF is either directly used in the process application or stored in external storage to maintain a larger volume of hot fluids used in non-real time heating such as after the sun has set and heating is no longer possible. An array is created from rows of parabolas interconnected end to end and at HTF header connections that return the HTF post process to the array and exit the array to the process or storage system.
One embodiment of the present invention is the drivetrain which utilizes a hub gear and a motor gear. The present invention virtually eliminates the corrosion of parts, increases efficiency and significantly reduces costs manufacture, shipping, maintenance and repairs which, are all transferred to the end customer. The present invention incorporates and produces increased quality and longer life of the overall solar thermal collector product having an increase in value to the customer while increasing the overall performance of the array.
Another embodiment of the present invention provides a one-piece hub and end hub eliminating connection of multiple hub pieces with screws and nuts that weaken and loosen causing lost focus of the mirror reflection on the HCE tube and failure of the system from broken hub parts. The present invention incorporates and produces increased quality and longer life of the overall solar thermal collector product having an increase in value to the customer while increasing the overall performance of the array.
Another embodiment of the present invention is the structural strength and integrity of the arm assembly on each end of the one-piece parabola frame. The present invention of the arm assembly's increased structural strength adds to the one-piece parabola structural integrity also increasing longevity of shape and focal capability on the HCE tube over time. The present invention of the arm structure provides increased efficiency of the system, increased thermal output of process HTF heat, reduced downtime from damaged and broken parts, and overall increased value to the customer.
Another embodiment of the present invention is the use of a slotted glass tube. A slot is cut in a tube of borosilicate glass down its length, slightly larger in width of the HCE tube, allowing easy installation, less breakage during installation, and easy removal for periodic cleaning as needed.
Another embodiment of the present invention is a solar parabolic heat collector using a one-piece parabola and drivetrain of a DC motor connected to an elliptical gear driving an arm connected to a joining tube between parabolas turning the row of parabolas as they track the sun.
The present invention provides a one-piece hub and end hub eliminating connection of multiple hub pieces with screws and nuts that weaken and loosen causing lost focus of the mirror reflection on the HCE tube and failure of the system from broken hub parts. The present invention incorporates and produces increased quality and longer life of the overall solar thermal collector product having an increase in value to the customer while increasing the overall performance of the array.
Referring now to FIGS. 1-4, there is shown the present invention for a solar thermal collector being designated by reference numeral 10 comprising a one-piece parabolic frame 200, a one piece reflector 201 provided on top of the one-piece parabolic frame 200, arm assembly (see inset) disposed on the one-piece parabolic frame 200 and one-piece reflector 201, arm assembly 223 disposed on both ends of the one-piece parabolic frame 200 and one-piece reflector 201, hub assembly 230 forming arm center support and rotational axis for the collector 10 assembly, shoe assembly 224 forming lower collector support and bottom arm structure, stanchion assembly 229 supporting the heat collector tube provided on the frame support assembly, a stand assembly 232 to support the solar energy collector 10 and a motor disposed on the stand assembly 232 driving the gears of rotation to track the sun. The reflector frame support assembly comprises at least a long inner frame 221, a short inner frame 222, an inner center support frame 220.
FIGS. 5-7 of the appended drawings shows the details of the long inner frame 221, short inner frame 222, inner center support frame 220, and their connection to the one-piece parabolic frame 200 and one piece reflector 201. In FIG. 5, the long inner frame 221 is being defined by a generally L-shaped frame body and provided on the top portion of the one-piece reflector 201. A plurality of holes 270 are provided on the area spacedly disposed on the long support frame 221, one-piece reflector 201 and one-piece parabolic frame 200. Connecting means (not shown) are then provided in the holes 270 to connect the long support frame 221, long center frame 220, one piece reflector 201, and one-piece parabolic frame 200.
FIGS. 6 and 7 shows the connection between the inner center support frame 220, short support frame 222, long support frame 221, one piece reflector 201 and one-piece parabolic frame 200. The short inner frame 222 is provided on top of the one-piece reflector 201. The inner center support frame 220 is then provided to the inside edge of the short inner frame 222. The long support frame 221 is then provided to the end edge of the short support frame 222. The plurality of holes 270 are also spacedly provided on the inner center support frame 220, short support frame 222, long support frame 221, one piece reflector 201 and one-piece parabolic frame 200. Connecting means (not shown) are then provided in the holes 270 to connect the center support frame 220, short support frame 222, long support frame 221, one piece reflector 201 and one-piece parabolic frame 200.
FIG. 8-12 shows the details of the arm assembly from FIG. 4. The arm assembly comprises a shoe member 224, a right glove member 25, and a left glove member 26, a hub member 230, and end-hub member 231, a plurality of rod clamps 233, and a plurality of arm rods 227. The right and left glove members 25 and 26, are being defined by an arrow tip like body 274 having a flange 31 extending from its back portion and an L-shaped flange 276 perpendicularly extending from the arrow tip like body 274. Depressions 33 are provided on the flange 31 while a clamp 34 is disposed opposite the flange 31. The clamp 34 is also provided with a secondary depression 35 equivalent to the depression 33 provided on the flange 31. The arm rod member 29 will then be disposed on the depression 33 of the flange 31 while the clamp 34 will then be provided on the flange 31 thereby enclosing the arm rod member 29 to the flange 31 and the clamp 34. Both flange 31 and clamp 34 are provided with holes 36 that will be provided with connecting means (not shown) in order to connect the arm rod member 29 to the right and left glove members 25, 26. The shoe member 27 is being defined by an L-shaped body 37 having a vertical flange 38 extending from its top portion and a depression 39 disposed on the vertical flange 38. A clamp 40 is provided opposite the vertical flange 38. Depression 41 is disposed on the clamp 40 opposite the depression 39 of the vertical flange 38. Both vertical flange 38 and clamp 40 are provided with holes 42 where connecting means will be disposed in order to connect the arm rod member 29 to the shoe member 27. To complete the arm assembly, a hub member 28 as shown in FIG. 11a is provided being defined by a T-shaped body 43 having an opening 44 in the middle and depressions 45 disposed on ends of the T-shaped body 43 provide a location for the glass receiver tube gasket to 263 to seat. Clamps 46 are disposed opposite the ends of the T-shaped body 43. Depression 47 opposite the depressions 249 on the ends of the T-shaped body 43 is provided on the clamps 46. Holes 48 are provided on the of the T-shaped body 43 and clamp 46. Connecting means in the form of bolt and nut 273 (FIG. 11a not shown) are provided on the holes 48 in order to connect the arm rod member 29, (as shown in FIG. 10 connecting the arm rod to the left glove), to the hub member 28. It is to be understood that the connecting means may be in a form of a bolt and nut, screw, rivet, etc. A heat collecting element bearing 51 is provided as shown at location 252 through the opening 251 within the hub member 43. Location 252 is tapered to provide a press-fit within the hub 43 to secure, the heat collecting element bearing 51 within the hub 43. Disposed perpendicularly from the T-shaped body 43 of the hub member 43 is an end hub 52 shown in FIG. 11b . The end hub 52 is provided with an end-hub gear flange 254 with a plurality of holes 53 as shown in FIG. 11b securing the hub gear 239 as shown in FIG. 13 through a connecting means of a plurality bolt and nut (not shown) and the holes 250 in the hub gear 239. A locator spring pin hole 272 is provided in the end-hub gear flange 254 to align the hub gear 239 in the corresponding hole 247 in the hub gear 239 with a spring pin 253.
As shown in FIG. 15, the stanchion assembly 229 comprises a stand 258, holding supports 262 disposed at one end of the stand wherein the holding supports 262 are connected to the inner center support frame 220 of the reflector frame support assembly 232, a bearing housing 256 provided at the other end of the stand and a bearing clamp 254 provided on top of the bearing housing 256. A groove 260 is provided in the bearing housing 256 and the opposing bearing clamp 254 for a plural of slotted glass tube insulator gasket 263 (see FIG. 16) is provided in the stanchion assembly 229. The slotted glass tube insulator gasket 263 is sandwiched between the bearing housing 256 and bearing clamp 254. An adjusting slot 257 is provided for vertical adjustment of the bearing housing 256 where the bearing housing 256 is connected using a bolt and nut (not shown). A plurality of spring pin 255 is seated into the bearing housing on one side and the bearing clamp 254 on the other aligned with opposing holes 281 in the bearing clamp 254 and, bearing housing 256. A heat collector tube bearing 259 is provided with a slotted groove recess 280 surrounding the center of the heat collector bearing 259. The heat collector bearing 259 sandwiched between the bearing housing 256 and the bearing clamp 254 by a raised edge 261 provided in the bearing housing 265 and bearing clamp 254 to eliminate movement of the collector tube bearing 259 and separation of the slotted glass tube insulator gasket 263 on each side of the stanchion 229.
As shown in FIG. 16, the insulator gasket 263 is provided with a glass insulator 264. A heat collecting element tube 282 is provided within the glass insulator 268 wherein the heat collecting element tube 282 is provided with a heat transfer fluid (HTF).
As shown in FIG. 14, the motor stand assembly comprises a stand assembly 232 fitted with a motor stand base support 238 provided at the bottom of the stand assembly 232, a connecting plate 237, and a motor support plate 235 disposed at the top end of the stand assembly 232, motor brackets 234 and 236 provided at both ends of the motor support plate 235 connecting a motor (not shown) disposed on the motor brackets 234 and 236 using a plurality of holes 283 with a plurality of bolts and nuts (not shown). A shaft hole 275 is disposed on the motor brackets 234, 236 for the motor output shaft (not shown). The connecting plate 237 and motor stand base support 283 attaches to a stand assembly 232 at the opening 277 connecting with a nut and bolt (not shown) at holes 276. Holes 278 in the motor stand base support 283 are provided for attachment to mounting anchors (not shown).
As shown in FIG. 13, top portion of the stand assembly 232 is defined by a pair of holding supports 244,245 and hub clamps 243,246 connect the hub 28 or end-hub 25 to the stand assembly 232. It is to be understood that the pair of holding supports 244,245 are to be welded to the stand assembly 232 (not shown). A pair of clamps 243,246 will hold a flange split bearing (not shown) surrounding the center outside of the hub 28 or end-hub 52. Holes 285 disposed on the clamps 243,246 and holding supports 244,245 enable the clamps 243,246 and holding supports 244,245 to be connected to each other with the aid of any type of connecting nuts and bolts (not shown). Clamp 246 is understood to be welded to the holding supports 244,245 and stand assembly 232.
Going back to FIG. 12, the shaft of the motor (not shown) is provided with a motor gear 240 wherein the motor gear 240 meshes with a hub gear 239. The hub gear 239 is provided with plurality of holes 250 that matches the plurality of holes 53 (FIG. 11b ), of the end-hub 52 in gear flange 254. It is to be understood that holes 250 of the hub gear 239 and holes 53 of the end-hub gear flange 254 will be connected using a plurality of bolts and nuts (not shown). When the hub member 52 is already connected to the hub gear 239 which is connected to the motor (not shown) through motor gear 240, the arm assembly will now be able to rotate the parabolic frame 200 to about the hub 28 and end-hub 52 and concentrate solar energy to the heat collecting element tube 282. The glass insulator 268 will pass through the opening 45 of the hub member 28,52 positioned at one end of the parabolic frame 200, where the heat collecting element bearing 51 disposed inside the opening 252 will help stabilize the glass insulator 268 and the heat collecting element tube 282. After passing the hub member 28,52 the glass insulator 268 will also pass the insulator gasket 263 of the stanchion assembly 229. After passing the stanchion assembly 229, the glass insulator 268 will again pass through another hub member 28,52 positioned at the other end of the parabolic frame 200.
The example described is a solar thermal collector having fluid heating system. Although the present examples are described and illustrated herein as being implemented in a parabolic parabola solar thermal fluid heating system, the system described is provided as an example and not a limitation. As those skilled in the art will appreciate, the present examples are suitable for application in a variety of different types of parabolic parabola solar thermal fluid heating systems.
A. Stand Assemblies
Stand assemblies 232 are the supporting mechanisms and provide the axel point of rotational support of the row of solar thermal collectors 10. Stand assemblies 232 are mounted at the base to various applications; poured concrete pillars or a poured concrete slab on the ground as an example, frameworks of steel pipe welded together attached to the rooftop of a building may be another example of a mounting application though these are not the only mounting application for the stand bases. Stand assemblies 232 are mounted specific distances apart in line and parallel to the one before; (3) stand assemblies 232 are mounted specific distances apart in line and parallel to the one before; (3) stand assembly 232 in a two-solar thermal collector system 10.
B. Solar Thermal Collector Assembly
The solar thermal collector assembly 10 is mounted onto the stand assembly 232 starting with the first solar thermal collector 10 at one end of the row of stands. Additional solar thermal collectors 10 are connected to the last installed until the ending row solar thermal collector 10 has been attached to the last in the row.
C. Drivetrain
The system is driven by DC motor 65 connected to the motor gear 240 meshed with the drive gear 241 connected to the end-hub gear flange 254 of the end-hub 52 connecting a plurality of arm rods 29 to the left glove member 26, right glove member 25, and shoe member 24, of the solar thermal collector 10 or between solar collector assemblies 10 via right glove member 25, left glove member 26, shoe member 27, hub member 28 and plurality of arm rod members 29 of the arm assembly 14 (FIG. 1).
The motor power is initiated through a simple system of automation controls delivering a set voltage, based on time to rotate per degree of angle, sent from a controller.
The solar thermal collector 10 row consists of a minimum of two solar thermal collectors 10 with a maximum number of solar thermal collectors 10 per row dependent on the motor output torque value and thermal output temperature need. The motor output torque value is based on the torque requirements as solar thermal collector 10 are added to a given row and weight increases as solar thermal collector 10 are connected.
The initial two solar thermal collector 10 connect at the stand assembly 232 using an arm assembly 14 structure. The arm assembly 14 is attached to the parabolic frame 200 and reflector 201 at the outer edge on each side and at the apex of the solar thermal collector 10. These are connected to the center point, hub member. The hub member of each connected solar thermal collector 10 is connected to an axel deliver rotational location at the stand assembly 232 and clamp.
Focal integrity from solar thermal collector 10 to another solar thermal collector 10 is increased using an outer center support frame 23 attached at the back-side of each solar thermal collector 10, between solar thermal collectors 10 at the outer edge on the side not rotating on each side of the stand. Only one side of the row between solar thermal collectors 10 will move past the stand assembly 232 during rotation as the row is stationed at the 20-degree position and rotates a maximum of 250 degrees at the end of the day.
A solar tracking system provides precise focus of the parabola to the sun optimizing the heat transfer from the Heat Collection Element tube (HCE) to the Heat Transfer Fluid (HTF). Tracking of the sun initiates rotation of a row of parabolas connected end-to-end at each (8) Hub/Axel Assembly contiguously rotating around the HCE tube maintaining the focus on the HCE tube continuously during all times of solar heat generation during the optimal heat collection time of day.
The tracking uses a safety system via a weather station and Programmable Logic Controller (PLC). The weather station continuously monitors data such as but not limited to; wind speed, wind direction, rain accumulation, ambient temperature and Dynamic Normal Irradiation (DNI). A PLC continuously monitors the safety system and all components of the solar system delivering monitoring data such as but not limited to; input temperature, output temperature and flow rate. When all each row motor to move to the targeted location provided by an algorithm generating a target angle system. The tracking system continues updating the target angle in precise angles at a programmed time interval throughout a programmed time space o daily tracking. Example, automatic initiation ½ hour after sunrise start ½ hour before sunset close daily.
The safety system delivers data measured through programmed set points in a PLC logic program to either keep the system in a non-tracking state, “no startup”, when environmental conditions such as no sun, high wind or high rains may cause to the parabolas or no solar heating is available. When during tracking, weather conditions such as; high winds, excessive rain or loss of sun are determined by the tracking system dangerous or not solar heat collection capable or internal temperatures of the system HTF exceed normal to a programmed set point in the PLC, the system automatically closes the system until the set point alarm changes to non-alarm state and the “start-up” condition is valid.
According to a further embodiment of the present invention, FIG. 17 illustrates the shape and general size of the parabolic solar parabola. The parabola composition is comprised of a single or sandwiched polycarbonate or polypropylene structure variations not limited to: solid and variations of honeycomb sandwich substrate materials. Reference Numeral 200 represents the top or reflector side. Numeral 201 represents the bock or bottom side.
FIG. 18 illustrates the molded shape and angular reflective paths that sunlight would take when reflecting from the surface of the parabola 203 to the focal point 202 of the parabola.
FIG. 19 illustrates one embodiment of the drive system utilizing the aim method of rotation. An elliptical mechanism is connected to the output shaft of the motor. The sleeved coupling 205 of the drive arm is connected to the elliptical plate. The coupling sleeve 206 connects the elliptical plate to the drive arm. The drive arm adjustment clamp 207 serves as an adjuster lock mechanism for the drive arm during installation. A first half 208 of the drive arm is connected to the drive arm hinge link 209 which connects to the second half 210 of the drive arm. The second half 210 of the drive arm is connected to the drive arm end coupling 211 which serves the purpose of the arm endpoint of rotation and the drive arm hub connected to the drive arm axle and parabola interconnecting rod 212.
FIG. 20 illustrates represents a zoom callout of the main drivetrain components in FIG. 19. A driveshaft component 213 connects the motor gearbox output shaft 214 on one end and the coupling to the elliptical mechanism 217 on the opposing end at the next drive arm assembly. The motor gearbox providing the drive power for row rotation. Numeral 216 represents the opposing motor gearbox output shaft 215 is connected to the elliptical mechanism 217. The elliptical connecting pin 218 for attachment of the drive arm motor coupling 205 connects the first half 208 of the drive arm connected to the drive arm link 209 which connects the second half 209 of the drive arm connected to the drive arm end coupling 211 attached to the drive arm axel and parabola interconnecting rod 212. The elliptical mechanism drive pin 220 connects the drive shaft 213 on the opposing side of the motor gearbox.
FIG. 21 illustrates a collector row as part of a solar array made up of eight (8) parabolas 200.
The preferred embodiments of the present invention for a solar thermal collector are described in the above-mentioned detailed description of the preferred embodiment. While these descriptions directly describe the embodiments, it is understood that those skilled in the art may conceive modifications and/or variations to the specific embodiment shown and described therein. Any such modifications or variations that fall within the purview of this description are intended to be included therein as well. Unless specifically noted, it is the intention of the inventor that the words and phrases in the specification and claims be given the ordinary and accustomed meanings to those of ordinary skill in the applicable art. For example, terms such as connection means and bolt and nut are directed to encompass any similar or equivalent conventional fastening devices or implements that those of skill in the art would understand as being applicable to the structures or elements in which they are used. The foregoing description of a preferred embodiment and best mode of the invention known to the applicant at the time of filing the application has been presented and is intended for the purposes of illustration and description. It is not intended to be exhausted or to limit the present invention to the precise form disclosed, and many modifications and variations are possible in the light of the above teachings.
The embodiment was chosen and described in order to best explain the principles of the present invention and its practical application and to enable others skilled in the applicable art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.

Claims

1. A solar thermal collector comprising a one-piece parabolic frame, a one piece reflector provided on top of the one-piece, parabolic frame, frame support assembly disposed on the one-piece parabolic frame and one-piece reflector, arm assembly disposed on both ends of the one-piece parabolic frame and one-piece reflector, stanchion assembly provided on the frame support assembly, a stand assembly to support the solar energy collector and a motor disposed on the stand assembly and glove assembly.

2. A solar thermal collector according to claim 1 wherein the frame support assembly comprises at least a long inner frame, a short inner frame, an inner center support frame, a long outer frame, a short outer frame and an outer center support frame.

3. A solar thermal collector according to claim 1 wherein the arm assembly comprises a right glove member, a left glove member, a shoe member, a hub member and plurality of arm rod members.

4. A solar thermal collector according to claim 3 wherein the right and left glove members are being defined by an arrow tip like body having a flange extending from its back portion and an L-shaped flange perpendicularly extending from the arrow tip like body.

5. A solar thermal collector according to claim 4 wherein the flange is provided with a clamp.

6. A solar thermal collector according to claim 3 wherein the hub member is being defined by a T-shaped body having an opening in the middle and depressions disposed on ends of the T-shaped body.

7. A solar thermal collector according to claim 6 wherein the ends of the T-shaped body is provided with clamps.

8. A solar thermal collector according to claim 3 wherein the hub member is provided with a heat collecting element bearing.

9. A solar thermal collector according to claim 3 wherein the hub member is provided with an end hub.

10. A solar thermal collector according to claim 3 wherein the shoe member is being defined by an L-shaped body having a vertical flange extending from its top portion and a depression disposed on the vertical flange.

11. A solar thermal collector according to claim 10 wherein the vertical flange is provided with a clamp.

12. A solar thermal collector according to claim 1 wherein the stanchion assembly comprises a stand, holding supports disposed at one end of the stand, bearing housing provided at the other end of the stand and a bearing clamp provided on top of the bearing housing.

13. A solar thermal collector according to claim 12 wherein the stanchion assembly is provided with insulator gasket.

14. A solar thermal collector according to clam 13 wherein a glass insulator is disposed within the insulator gasket.

15. A solar thermal collector according to claim 14 wherein a heat collecting element tube is provided within the glass insulator.

16. A solar thermal collector according to claim 15 wherein heat transfer fluid is disposed within the heat collecting element tube.

17. A solar thermal collector according to claim 1 wherein the stand assembly comprises a motor stand, a base support provided at one end of the motor stand, a motor support plate disposed at another end of the motor stand, motor brackets provided at both ends of the motor support plate and a motor disposed on the motor support plate.

18. A solar thermal collector according to claim 17 wherein the motor is provided with a shaft.

19. A solar thermal collector according to claim 18 wherein the shaft is provided with a motor gear.

20. A solar thermal collector according to claim 19 wherein the motor gear meshes with a hub gear.

21. A solar thermal collector according to claim 20 wherein the hub gear is connected to the end hub.

22. A solar thermal collector according to claim 1 wherein the solar energy collector is made of polycarbonate honeycomb material.