DIRECT FLOW SOLAR COLLECTOR

A direct flow solar collector and solar hot water system are presented wherein high pressure connections are eliminated to lower installation costs while freeze and stagnation protection is provided by a cooling loop and a continuous circulation protocol. A novel fin design and a modular concept deliver manufacturing, shipping and assembly efficiencies while providing flexibility for customizing the collector configuration.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuing application of co-pending International Application PCT/US2013/065807, filed 20 Oct. 2013, and a continuation-in-part application of co-pending International Application PCT/US2013/027339, filed 22 Feb. 2013, with combined priority claims to U.S. Provisional Application 61/603,541, filed 27 Feb. 2012, U.S. Provisional Application 61/660,446, filed 15 Jun. 2012 and U.S. Provisional Application 61/716,727, filed 22 Oct. 2012, the aforementioned PCT/US2013/065807 additionally with a priority claim to the aforementioned PCT/US2013/027339, all the foregoing of which are incorporated herein by reference in entireties.

FIELD OF THE INVENTION

This invention relates to the harnessing of solar energy, and more particularly to solar hot water heating.

BACKGROUND OF THE INVENTION

Concerns with the aging infrastructure of the electricity grid in the United States, the environmental impact of carbon-based fuels, the geo-political ramifications of crude oil supply, the depletion of natural resources, the safety concerns related to nuclear power, and the distribution and extraction challenges surrounding natural gas have all brought increasing attention to safe alternative energy sources such as Solar. Solar energy can be captured as heat as well as converted to electricity. Next to space heating, water heating is the most significant use of this virtually inexhaustible and universally available resource.

Radiation from the sun is captured by a hot water solar collector, which is generally a part of a system comprising a water supply and/or storage means, a circulation pump, and a heat-exchanger means. Flat-plate solar collectors are popular in the sunny, year-around warm, climates in the United States. They are comprised of a heat-absorption panel in contact with circulating water and are typically housed under a transparent covering and over an insulating bed. The flat panels absorb solar energy in much the way photo-voltaic (PV) electric panels do. Heat transfer efficiency is a function of reflective, conductive, and convective heat losses, as well as the temperature differential between the absorption panel and the incident water. While highly efficient where optimally located, flat-plate collectors give poor performance, nevertheless, in high temperature applications and in cold conditions where high heat losses, due to the large surface exposure of the panels, are experienced. Furthermore, maintenance is cumbersome and often involves shutting the system down or replacing the entire collector.

Evacuated tube (EVT) collectors are common in China, where 60% of global solar collector capacity is installed and where over 70% of the EVT's are manufactured. The most popular EVT type is a double-walled glass tube having an evacuated air space between the walls. The inside tube is coated to enhance absorption and back-reflection of spectral infra-red (IR). Heat absorbed by the tubes is transferred to a manifold, into which they are inserted, by circulation of a liquid through an internal viaduct (U-tube) or by phase change of a captive liquid in a capillary (heat pipe). The tubular design accommodates different solar angles. The use of a complete vacuum as an insulator makes them appropriate for cold climates and where extremely high temperatures are required or maintained. Maintenance is also simpler, in that individual tubes can be replaced, often while the system is in use.

The major disadvantage of the EVT collector is the cost in dollars per BTU. Considering the disadvantages of both the flat-plate and EVT types of collectors, the northern climates of the United States, where freezing temperatures are an issue for much of the year, and low solar angles and short days are prevalent for a portion of the year, are left under-served by solar hot water. The same holds true for other colder locations throughout the world where the economics of cheaper energy sources prevail.

The object of the present invention is to enable solar hot water heating in both cold and warm climates by making the installation of a solar hot water system less expensive and the operation thereof more efficient. These objects are achieved by comprehensively addressing cost elements in the construction, configuration and operation of the EVT collector.

SUMMARY OF THE INVENTION

The heat pipe EVT design requires a heat exchange in the manifold, whereas the U-tube design avoids this exchange and the energy losses attendant thereto by directly heating the solar liquid. The disadvantages of the currently-practiced U-tube technology, however, present opportunities for improvement. Both freezing and overheating, also called “stagnation”, become issues with the solar liquid present in the EVT. Typically, to protect from freezing, glycol antifreeze is used for the solar liquid in a closed-loop circulation system. High pressure is required to prevent the glycol from boiling during periods of stagnation. To heat water in a storage tank, or a swimming pool, the glycol must communicate through a heat exchanger, presenting another opportunity for thermal loss.

The high pressure requirement drives high installation costs. The U-tubes are typically arranged in an array and integrated into a manifold configuration at a factory location. Typically, 30-40 U-tubes are joined by brazing, soldering or welding and then shipped to the installation site in an out-sized shipping configuration. Shipping costs associated with such a configuration can be expensive.

The substitution of water for glycol as the solar liquid eliminates the high pressure requirement. Elimination of the high pressure requirement means less expense in materials, shipping, and assembly. In an alternative low pressure system, seals and flexible tubing can be used to join components. Eliminating the factory configuration means that modular design can be implemented and customization facilitated. Assembly work can be done on-location with unskilled labor. Pressure and relief tanks can be eliminated as necessary system components, and the higher cost of pressure-rated pumps can be avoided. System maintenance can be achieved without bleeding and recharging lines and without incurring the loss of a relatively expensive solar liquid, such as glycol.

Freezing and stagnation remain as issues, however, with water-based solar liquid. This is partially addressed in the present art by gravity drain-back systems, which prevent freezing by evacuating the solar liquid channels. Typically, however, some liquid is always left fugitive in the channels, regardless of the orientation or tilt of the collector array. These “gravity blind-spots”, or pathway low spots, can cause flash vaporization during stagnation periods, thereby causing damage to the EVT's. Even when drain-back systems are purged by air flushes, or other means, the high temperatures of stagnation can cause damage to system components. This damage can be particularly devastating to plastic, rubber and aluminum parts used in low-pressure systems.

The present invention presents the novel concept of “dumping heat” by continuous circulation of the solar liquid during non-heating periods and by the use of supplemental cooling during over-heating periods. With a sufficiently large storage tank as a heat repository, it has been shown that water in the tank can be maintained in a range of 40-65° C., even in a high solar fraction climate, such as Mexico. Since the heat gained is essentially free, the wasting of it is not an economic matter, regardless of efficiency loss, particularly if the waste heat is simply vented to the environment. In colder climates, the maintenance of constant circulation between the solar collector and an appropriately-sized storage tank can prevent freezing, particularly where exposed plumbing is insulated.

An additional novel concept facilitates lowering pressure and enhancing the thermal efficiency of the U-tube. The concept addresses the fin, which is commonly attached to standard tubing and projects arcuate “wings” there from which serve to absorb radiant heat passing through the EVT walls. In the concept, the fin and the water channel are combined in a single extrusion, which is then bent into a “U” shape. The space between the upright arms of the “U” is filled with resilient insulating material, which has the effect of spreading the arms outwardly and urging them against the EVT wall. The construction eliminates the insulating air gap that results from separate components, and the curvature of the extrusion, by closely following the wall contour, adds additional thermal efficiency by permitting large area surface contact with the wall.

Further, the cross-sectional area of the water channel is enlarged by changing by changing from a circular to an ellipsoidal shape. The enlargement, measuring almost twice that of the standard tube, permits a larger volume of throughput resulting in lower pressure. With system pressure reduced, not only by eliminating glycol but also by making the channel enlargement, inexpensive and easy-to-install flexible tubing may be used in the interconnecting links of the U-tubes.

Still another novel concept derives from manipulation of series and parallel connections channeling the water through the U-tubes. U-tubes connected in series provide higher output temperatures, but too many tubes connected in this manner produce lower heat-transfer efficiency because successive heating causes reduction of the temperature differential, the thermal driving force. On the other hand, U-tubes connected in parallel have a constant temperature differential but require a longer circulation and pump operation time to achieve the same heating result. An unexpected result of the parallel configuration, however, is that the necessarily larger supply channels tend to cause a cavitation effect in the relatively smaller tube channels; that is, air pockets get trapped that produce an insulating layer and result ultimately in lowered thermal efficiency. The inventive concept is to use an optimal combination of both configurations to give an improved result in terms of operating cost per BTU.

It is accordingly an object of the present invention to lower the system pressure requirements by using a U-tube design in an atmospheric system with water as the solar liquid. It is a further object to eliminate drain-back systems by continuously circulating the solar liquid and providing supplemental cooling. It is a further object to prevent freezing of the solar liquid by trickle circulation and the selective insulation of water channel lines. It is a further object to lower assembly and material costs by using flexible tubing connections. It is a further object to improve thermal efficiency by integrating the water channel and the fin in the same structure to eliminate any air gap in otherwise separate structures. It is a further object to improve thermal efficiency by making surface-to-surface contact between the fin and EVT inner wall. It is a further object to enlarge the U-tube water channel to lower the tube-to-tube pressure drop. It is a further object to use a combination of series and parallel connections in the water channels to optimize thermal efficiency. It is a further object to make more efficient use of roof-top space by reducing tube-to-tube spacing in the manifold. It is a further object to manage roof-top space by configuring the EVT array with tubes on either or both sides of the manifold as dictated by site layout. It is a further object to manage roof-top space and improve appearance by permitting low angle or horizontal installation profiles essentially hidden from view. It is a further object to facilitate snow removal from the collector. It is a further object to provide a solar hot water system incorporating a hot water storage vessel. It is a further object to provide a method of configuring a solar collector to achieve operating efficiency.

These objects, and others to become hereinafter apparent, are embodied in a solar collector comprising a manifold having an input port, an output port and a plurality of orifices. The solar collector further comprises a corresponding plurality of solar tubes connected to the manifold through the orifices, the plurality of solar tubes assembled in a planar array and positioned for exposure to solar radiation. The solar collector further comprises at least one liquid channel from the input port to the output port. The liquid channel has at least one continuous flow path there through. The solar collector further comprises a means for transferring heat absorbed from solar radiation in each solar tube to a solar liquid flowing through the at least one continuous flow path. The solar collector further comprises a means for circulating the solar liquid through the means for transferring heat. Finally, the solar collector comprises a means for cooling the solar liquid to maintain its temperature at or below a preferred temperature. So configured, heat from solar radiation is transported for work purposes through the solar liquid by the means for transferring heat and by the means for circulating and the solar liquid is prevented from overheating by the means for cooling.

In one embodiment, the means for transferring heat comprises a fin inserted into each solar tube and extending the length of the tube. The fin has an integrated U-shaped channel extending from an input end to an output end. The input end of a first U-shaped channel in a first solar tube of the planar array forms a fluid connection to the input port while the output end of the first U-shaped channel of the first solar tube forms a fluid connection in preferred configuration to the input end of a last U-shaped channel in a last solar tube. The output end of the last U-shaped channel in the last solar tube then forms a fluid connection to the output port. So configured, at least one liquid channel is formed for a continuous flow path through each solar tube, the flow of solar liquid therein receiving heat by conduction from the fin. In a particular instance of the embodiment, the preferred configuration is a serial linkage joining ten solar tubes and a parallel linkage joining four serial linkages.

Also in the embodiment, the means for cooling comprises a cooling loop and a controller. The controller is programmed to redirect circulation of the solar liquid through the cooling loop when the solar liquid is above a first preferred temperature. In a particular instance of the embodiment, the first preferred temperature is in the range of 55-60° C.

In the preferred embodiment, a solar hot water system comprises a solar collector having a manifold, a plurality of solar tubes, at least one liquid channel, and a means for transferring heat, as discussed above. The solar hot water system further comprises a storage vessel for hot water in fluid communication with the input port and the output port of the manifold. The solar hot water system further comprises a means for circulating the solar liquid through the means for transferring heat to the storage vessel. Lastly, the solar hot water system comprises a means for cooling the solar liquid to maintain its temperature at or below a preferred temperature. So configured, the heat from solar radiation if used to heat the water in the storage vessel by the means for transferring heat and by the means for circulating and the solar liquid is prevented from overheating by the means for cooling. In a particular instance of the preferred embodiment, the solar hot water system further comprises a means for preventing freezing of the solar liquid.

As this is not intended to be an exhaustive recitation, other embodiments are described in the detailed description below; or may be learned from practicing the invention; or may otherwise become apparent to those skilled in the art.

DESCRIPTION OF THE DRAWINGS

Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood through the accompanying drawings and the following detailed description, in which like reference characters designate the same or similar parts throughout the several views, and wherein:

FIG. 1 is a perspective view of a mounted solar collector of the present invention shown in a bi-lateral configuration;

FIG. 2 is a truncated elevation view of an EVT;

FIG. 3 is a section view of the EVT taken along the lines 3-3 of FIG. 2;

FIG. 4 is a partial perspective view of two serially connected U-tubes;

FIG. 5 is a detail view of detail 5 in FIG. 4;

FIG. 6 is a detail view of detail 6 in FIG. 4;

FIG. 7 is a partial perspective view of a 20-tube array showing series and parallel path connections;

FIG. 8 is a partial plan view of a 20-tube array showing a modular connection to tubes 21 and 22 in phantom line;

FIG. 9 is a side view of a 10-tube module with an eleventh tube in phantom line;

FIG. 10 is a truncated section view taken along lines 10-10 of FIG. 9 showing solar liquid paths;

FIG. 11 is a partial exploded perspective view of three serially-linked tubes;

FIG. 12 is a truncated perspective view of an extruded fin;

FIG. 13 is a truncated elevation view of a U-tube

FIG. 14 is a section view taken along the lines 14-14 of FIG. 13 showing a cross-section of the water channel;

FIG. 15 is a perspective view of the manifold;

FIG. 16 is an exploded perspective view of the manifold and insulation;

FIG. 17 is a diagram of a solar collector system of the present invention; and

FIG. 18 is a perspective view of the mounted solar collector of FIG. 1 shown in a unilateral configuration.

 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Flow paths referenced in the specification are illustrated throughout the drawings by bolded arrows (other than those indicating sectional cuts).

FIGS. 1 and 18 show the major components of a solar collector 1. A solar tube planar array 12 is connected to a manifold 20 through orifices 29. The manifold 20 has an input port 22 and an output port 23 defining there through and there between at least one liquid channel 4 receiving circulation of a solar liquid 3 (see FIG. 17) through at least one continuous flow path 9 (see also FIG. 10). When the planar array 12 is mounted to receive solar radiation, such as on the roof top of a building, the solar collector 1 may be supported by frame members 2 received in frame slots 100 located in the middle and both ends of the solar collector 1 (see also FIGS. 6 and 15).

As shown in FIGS. 7 and 8, the solar tube planar array 12 is comprised of a plurality of solar tubes 7. The planar array 12 may be arrayed from opposing sides of the manifold 20, or bi-laterally, as shown in FIG. 1. Alternatively, the planar array 12 may be configured only on one side, or unilaterally, as shown in FIG. 18. The latter configuration facilitates snow removal, in addition to accommodating site-particular space constraints. When arrayed bi-laterally, the tubes are typically oriented east-west; when arrayed unilaterally, the orientation is north-south. The array should be inclined to present roughly perpendicular to the sun's rays at the installation latitude. In most cases, the inclination angle 106 is in the range 0-18° plus the solar angle (FIG. 1). At a high solar angle, the profile elevation can be as little as 25 cm. The frame members 2 may be directly anchored to a supporting surface by any fastening means, or may be moveably held in-place by a weighted base (not shown). An approximate weight for a sufficiently-weighted base is 25 kg.

The number of solar tubes 7 in the planar array may be limited by roof-top layout or, otherwise, by the design pressure drop across the circulatory pathway. In the preferred embodiment, it is desirable to maintain a low operating pressure for cost advantage reasons. In a particular preferred embodiment, it is the objective to maintain the operating pressure at 0.14-0.70 kgf/cm2 (2-10 psi) and a flow rate of 5.68 1 pm (1.5 gpm). Accordingly, an optimal array would be comprised of not more than 40 tubes. Such an array has a footprint approximately 47% smaller than a thermally-equivalent flat plate collector.

The solar tube 7 is designed to receive solar radiation through a glass envelope and retain the energy as heat in the interior. In the preferred embodiment, the solar tube 7 is a double-walled EVT 8, as shown in FIGS. 2-6. There is a vacuum space 101 in EVT 8 between an inner tube 102 and an outer tube 103, the vacuum serving as an insulator for entrapped heat. The inner tube 102 has several coating layers to enhance performance, namely an anti-reflection layer, an absorbance-enhancing layer and an IR reflection layer. The EVT 8 has an open end 104 and a closed end 109. When the solar tube 7 is connected to the manifold 20 through one of the orifices 29, the open end 104 shoulders against a ledge 105 in the interior (FIG. 15). The closed end 109 is cradled in an end cup 17, which is supported in the mounted configuration of solar collector 1 by an end cup support 18. The end cup support 18 has an adjustment screw 107, which serves to bias the open end 104 against the ledge 105. The solar tubes 7 may be individually removed and replaced in the array by disconnecting the end cup 17 from the end cup support 18.

The at least one liquid channel 4 is comprised of a means for transferring heat 30, as shown in FIGS. 11-14. In the preferred embodiment, said means comprises a fin 31. Fin 31 has an integrated U-shaped channel 32, which forms a part of the at least one continuous flow path 9. The integration of the U-shaped channel 32 into the fin 31 eliminates thermal losses resulting from air gaps between otherwise separate structures. Fin 31 is inserted into the EVT 8 to the extent of the draw therein. Fin 31 has arcuate wing members 108 flanking the U-shaped channel 32 to form a contact surface with the inner tube 102 through which heat is conducted to the solar liquid 3 flowing through the U-shaped channel 32. The arms of the “U” of the U-shaped channel 32 may be biased outwardly by a resilient insulation plug 44 (see also FIG. 5) to make contact with the wall of the tube and thereby eliminate another potential air gap. Fin 31 is fabricated as an extrusion 36 and is comprised of aluminum. Arcuate wing members 108 may be trimmed away (FIG. 12) to form nipples 39 of U-shaped channel 32 at either end thereof. Two such nipples 39 may be joined in a U-configuration by a U-shaped connector 109 (not shown). The U-shaped connector 109 may be, for example, a compression-molded piece of silicone. In the preferred embodiment, the U-configuration is achieved by bending a single extrusion with slotted wings into the U-shaped channel 32. The U-shaped channel 32 maintains its throat by means of gussets 35 therein.

When fin 31 is inserted into EVT 8 (FIG. 11), two nipples 39 protrude from the open end 104 of the solar tube 7 to form an input end 33 and an output end 34 of U-shaped channel 32, as shown in FIG. 10. The output end 34 in one solar tube 7 may be connected to the input end 33 in another solar tube to form a serial linkage 41. The input end 33 in one solar tube may also be connected to the input end in another solar tube to form a parallel linkage 42. The input end 33 of a first U-shaped channel 37 in a first solar tube 5 of the planar array 12 is connected to the input port 22 of the manifold 20 and the output end 34 of a last U-shaped channel 38 in a last solar tube 6 is connected to the output port 23. The input port 22 is connected to the output 23 in a preferred configuration 40 comprised of a preferred number of solar tubes 7 in the serial linkage 41 and a preferred number of serial linkages 41 in a parallel linkages 42 to form the at least one liquid channel 4 through which the solar liquid 3 may flow through each solar tube 7 in the at least one continuous flow path 9. Because the at least one liquid channel 4 is contained within the fins 31, the solar tubes 7 may be changed out for repair or replacement, in the manner discussed above, without affecting the operation of the solar collector.

One objective in the optimization of thermal efficiency is to avoid non-turbulent flow in the at least one continuous flow path 9. This is achieved by using serial linkage 41, wherein the cross-sectional area of the at least one liquid channel 4 can more closely approximate that of the cross-sectional area of the U-shaped channel 32. Another objective in the optimization of thermal efficiency is to maintain at least some temperature differential across the path through serial linkage 41. This requires limiting the number of solar tubes 7 in any one serial linkage 41 and connecting multiple serial linkages 41 in the parallel linkage 42. The span of the parallel linkage 42, in terms of the number of tubes, is determined by the optimal pressure drop across the at least one continuous flow path 9, which in turn defines the operating pressure of the system. In the preferred embodiment, the cross-sectional area of the U-shaped channel 32 is approximately 72 mm2. This area compares favorably with the approximately 36 mm2 opening of the standard tube of current art. The preferred embodiment comprises ten solar tubes 7 to a serial linkage 41 and four serial linkages 41 to a parallel linkage 42, optimally defining the planar array 12 as an array of 40 tubes (the first 10 tubes only are shown in FIG. 10). It has been discovered that optimal thermal efficiency, as measured by cost per BTU, occurs by balancing the non-turbulent flow consideration, having the consequence of avoiding insulating air pockets in the channel, with the pressure consideration, having the consequence of protecting temperature differential. The thermal performance of the 40-tube array herein described is roughly equivalent to two 1.22 m×3.05 m (4′×10′) flat plate collectors. The pressure consideration also affects other efficiencies of construction.

One of these other efficiencies afforded by low operating pressure is the use of flexible tubing 10. Flexible tubing 10 is inexpensive and simplifies installation. FIGS. 7 and 8 show a network of the flexible tubing 10 in both serial and parallel configurations. In the preferred embodiment, the flexible tubing 10 is comprised of high temperature (rated at 250° C.) silicone rubber. The flexible tubing 10 forms a seal with the nipples 39 when compressed thereon by a band, clip, or other form of compression known in the art. As shown in solid line in FIG. 8, a modular unit of planar array 12 is comprised of 20 solar tubes 7. As shown in dashed line, two or more modular units may be combined by extending parallel linkage 42 through linkage sections 13 of flexible tubing 10. The modularity of the design facilitates customized installation and delivers cost benefits associated with on-site assembly.

The manifold 20 is comprised of manifold housing assembly 21 and insulation core 25, as shown in FIGS. 15 and 16. The manifold housing assembly 21 is comprised of a housing base 26 and a housing top 27. The housing top 27 is connected to the housing base 26 by a manifold seal 24 at each side to form an enclosure. Each manifold seal 24 comprises a plurality of orifices 29 to receive the solar tubes 7 of the planar array 12. The insulation core 25 has a center bore 28 in which the at least one liquid channel 4 is situated, wherein the function of said insulation core is to insulate the liquid channel 4 from heat loss. The housing base 26 and the housing top 27 are fabricated from aluminum by extrusion means. The manifold seal 24 is fabricated in a molding of ethylene propylene diene monomer (EPDM) material. The insulation core 25 is fabricated from sponge rubber material.

The solar collector 1 further comprises a means for circulating 60 the solar liquid 3 through the means for transferring heat 30. In the preferred embodiment, the means for circulating 60 comprises a first low-pressure pump 61, a solar liquid loop 74 and a holding tank 65, as shown in FIG. 17. The holding tank 65 serves as a reservoir for the solar liquid 3, which may be supplied to the reservoir from another source or may circulate in a closed loop therein. The solar liquid loop 74 communicates with the holding tank 65 and includes the supply path 59 and the return path 58. The first low-pressure pump 61 is controlled by controller 55.

The solar collector 1 further comprises a means for cooling 50 the solar liquid 3 to prevent over-heating. The means for cooling 50 is initiated when the solar liquid 3 reaches a preferred temperature 51. The means for cooling 50 may include refrigeration of, or immersion of, the solar liquid loop 74 in an air stream or a body of water, such as a pool or lake. The means for cooling 50 may also include cycling the first low-pressure pump 61 during nighttime or overcast days. In the preferred embodiment, the means for cooling 50 comprises the controller 55 and a cooling loop 52, as shown in FIG. 17. When the solar liquid 3 reaches a first preferred temperature 53, the controller 55 initiates circulation of the solar liquid in the holding tank 65 through the cooling loop 52 by activating a second low-pressure pump 62. In an instance of the preferred embodiment, the first preferred temperature 53 is in the range of 55-60° C. The cooling loop 52 essentially vents heat by convection to a relatively cooler environment, such as may be found in an underground vault. In the preferred embodiment, the cooling loop 52 is comprised of a serpentine configuration of stainless steel tubes linked with silicone tubing. The controller 55 is in signal communication with one or more sensors 64 positioned at selected locations throughout the solar liquid loop 74. The sensors 64 may be transducers or thermocouples and may measure temperature or pressure or both. In the preferred embodiment, at least one of the sensors 64 is located in the holding tank 65 and measures the temperature of the solar liquid 3.

The solar collector 1 further comprises a means for preventing freezing 80 of the solar liquid 3 in the exposed portion of the solar collector. The means for preventing freezing 80 comprises the continuous circulation of the solar liquid during low temperatures. In the preferred embodiment, the controller 55 activates the first low-pressure pump 61 when the solar liquid 3 drops below a second preferred temperature 81. In an instance of the preferred embodiment, the second preferred temperature 81 is in the range of 2-5° C. The means for preventing freezing 80 further comprises insulation of the exposed portions of the solar liquid loop 74. In the preferred embodiment, an insulation wrap 82, packed within a flexible polypropylene (PP) hose, surrounds the flexible tubing 10 leading to and from the input and output ports (FIG. 1). The insulation wrap 82 may be comprised of sponge rubber, or any other known insulating material. The means for preventing freezing 80 additionally includes the resilient insulation plugs 44 positioned inside the solar tubes 7.

In the preferred embodiment, the holding tank 65 is a hot water storage vessel 71, as shown in FIG. 17. Hot water storage vessel 71 is a member of a solar hot water system 70, which is also includes solar collector 1. In an instance of the preferred embodiment, hot water storage vessel 71 is a roto-cast tank comprised of crossed-lined high-density polyethylene (HDPE). In another instance, the solar liquid 3 of the solar hot water system 70 is water 73 stored in water storage vessel 71. Preferably, the water 73 is of neutral pH and may contain stabilizing or anti-corrosion additives. The means for circulating 60 further comprises a circulation of water 73 from a hot zone 76 of the water storage vessel 71 to a cold zone 77. The water storage vessel 71 is preferably large enough in volume for a stratification to occur by the colder, denser water gravitating downward. The water storage vessel 71 is also preferably large enough to retain heat during extended non-solar periods. In the preferred embodiment, the water storage vessel 71 is jacketed with insulation. The insulation may be comprised of polyurethane foam, or other known insulating material. The solar liquid loop 74 fluidly connects the cold zone 77 to the input port 22 and the hot zone 76 to the output port 23. The cooling loop 52 circulates in and out of the hot zone 62.

Hot water storage vessel 71 may further comprise submerged heat exchanger 72. The heat exchanger 72 effectively removes heat from the storage part of the system. In the case of swimming pool heating, chlorinated pool water may be heated in the heat exchanger 72 without contaminating the solar liquid 3. For domestic hot water use, the heat exchanger 72 outputs hot water on demand from a pressurized cold water intake-line. In the preferred embodiment, heat exchanger 72 is comprises of stainless steel tubing configured into a spiral and is submerged in the solar liquid 3.

In an alternative embodiment, a method of configuring a solar collector to achieve operating efficiency, as measured by cost per BTU, comprises the steps as follows:

    • a) providing the solar collector 1, wherein the means for transferring heat 30 is a fin 31 inserted into each solar tube 7 and extending the length thereof, said fin having an integrated U-shaped channel 32 extending from an input end 33 to an output end 34; the input end 33 of a first integrated U-shaped channel 37 in a first solar tube 5 of the planar array 12 forming a fluid connection to the input port 22; the output end 23 of the first U-shaped channel 37 in the first solar tube 5 forming a fluid connection in a preferred configuration 40 to the input end 33 of a last U-shaped channel 38 in a last solar tube 6; and the output end 34 of the last U-shaped channel 38 in the last solar tube 6 forming a fluid connection to the output port 23;
    • b) implementing the preferred configuration 40 by joining a preferred number of solar tubes 7 in a serial linkage 41, said serial linkage 41 balancing heat transfer efficiency with non-turbulent hydraulic flow;
    • c) implementing the preferred configuration 40 by joining a preferred number of serial linkages 41 in a parallel linkage 42, said parallel linkage 42 balancing heat transfer efficiency with hydraulic pressure.

It is to be understood that the invention is not limited in its application to the details of construction, to the arrangements of the components and to the method of using set forth in the preceding description or illustrated in the drawings. For example, the serial linkage count may be greater than ten to provide higher temperatures; or the parallel linkage count may be greater than 4 to provide an increased solar fraction in colder climates. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.

Claims

1. A solar collector, comprising:

a manifold having an input port, an output port and a plurality of orifices;
a corresponding plurality of solar tubes connected to the manifold through the orifices, the plurality of solar tubes assembled in a planar array and positioned for exposure to solar radiation;
at least one liquid channel from the input port to the output port, said liquid channel having at least one continuous flow path there through;
a means for transferring heat absorbed from solar radiation in each solar tube to a solar liquid flowing through the at least one continuous flow path;
a means for circulating the solar liquid through the means for transferring heat; and
is a means for cooling the solar liquid to maintain its temperature at or below a preferred temperature;
whereby heat from solar radiation is transported for work purposes through the solar liquid by the means for transferring heat and by the means for circulating and the solar liquid is prevented from overheating by the means for cooling.

2. The solar collector of claim 1, wherein the means for transferring heat comprises a fin inserted into each solar tube and extending the length of the tube, said fin having an integrated U-shaped channel extending from an input end to an output end, the input end of a first U-shaped channel in a first solar tube of the planar array forming a fluid connection to the input port, the output end of the first U-shaped channel of the first solar tube forming a fluid connection in preferred configuration to the input end of a last U-shaped channel in a last solar tube, the output end of the last U-shaped channel in the last solar tube forming a fluid connection to the output port, whereby at least one liquid channel is formed for a continuous flow path through each solar tube, the flow of solar liquid therein receiving heat by conduction from the fin.

3. The solar collector of claim 2, wherein the preferred configuration is a serial linkage joining a preferred number of solar tubes and a parallel linkage joining a preferred number of serial linkages.

4. The solar collector of claim 3, wherein the preferred number of solar tubes in a serial linkage is ten and the preferred number of serial linkages in a parallel linkage is four.

5. The solar collector of claim 2, wherein the integrated U-shaped channel is formed as a part of an extrusion of the fin in a construction eliminating air gaps in a heat conduction path while simplifying assembly steps.

6. The solar collector of claim 5, wherein the fin extrusion is comprised of aluminum or an alloy thereof.

7. The solar collector of claim 6, wherein the fin is formed into a U-shape by bending a single extrusion length.

8. The solar collector of claim 7, wherein the fin is resiliently biased to make contact with the wall of the solar tube and essentially eliminate thereby any insulating air space there between.

9. The solar collector of claim 1, wherein the means for cooling comprises a cooling loop and a controller, the controller programmed to redirect circulation of the solar liquid through the cooling loop when the solar liquid is above a first preferred temperature.

10. The solar collector of claim 9, wherein the first preferred temperature is in the range of 55-60° C.

11. The solar collector of claim 1, wherein the means for circulating the solar liquid comprises a low-pressure pump in a low-pressure loop.

12. The solar collector of claim 11, wherein the low-pressure loop comprises flexible tubing for at least a part of the continuous flow path.

13. The solar collector of claim 12, further comprising a means for preventing freezing of the solar liquid.

14. The solar collector of claim 13, wherein the means for preventing freezing comprises maintenance of low pressure circulation below a second preferred temperature and an insulation wrap of the flexible tubing combined with a resilient insulation plug situated in the interstitial space of each solar tube.

15. The solar collector of claim 1, further comprising a means for preventing freezing of the solar liquid.

16. The solar collector of claim 15, wherein the means for preventing freezing comprises a low pressure circulation of the solar liquid below a second preferred temperature.

17. The solar collector of claim 14, wherein the second preferred temperature is in the range of 2-5° C.

18. The solar collector of claim 16, wherein the second preferred temperature is in the range of 2-5° C.

19. The solar collector of claim 1, wherein the plurality of solar tubes is arrayed bi-laterally from opposing sides of the manifold.

20. The solar collector of claim 1, wherein the plurality of solar tubes is arrayed unilaterally from one side of the manifold.

21. A solar hot water system, comprising:

a solar collector having a manifold with an input port, an output port and a plurality of orifices; a corresponding plurality of solar tubes connected to the manifold through the orifices, the plurality of solar tubes assembled in a planar array and positioned for exposure to solar radiation; at least one liquid channel from the input port to the output port, said liquid channel having at least one continuous flow path there through; and a means for transferring heat absorbed from solar radiation in each solar tube to a solar liquid flowing through the at least one continuous flow path;
a storage vessel for hot water in fluid communication with the input port and the output port of the manifold;
a means for circulating the solar liquid through the means for transferring heat to the storage vessel; and
a means for cooling the solar liquid to maintain its temperature at or below a preferred temperature;
whereby heat from solar radiation is used to heat the water in the storage vessel by the means for transferring heat and by the means for circulating, and the solar liquid is prevented from overheating by the means for cooling.

22. The solar hot water system of claim 21, wherein the solar liquid is the water in the storage vessel and the means for circulating comprises circulation through the storage vessel, the water of the storage vessel having a stratification of heat therein defining a hot section and a cold section, the input port of the manifold in fluid connection to the cold section of the storage vessel and the output port of the manifold in fluid connection to the hot section.

23. The solar hot water system of claim 21, wherein the means for transferring heat comprises a fin inserted into each solar tube and extending the length of the tube, said fin having an integrated U-shaped channel extending from an input end to an output end, the input end of a first U-shaped channel in a first solar tube of the planar array forming a fluid connection to the input port, the output end of the first U-shaped channel of the first solar tube forming a fluid connection in preferred configuration to the input end of a last U-shaped channel in a last solar tube, the output end of the last U-shaped channel in the last solar tube forming a fluid connection to the output port, whereby at least one liquid channel is formed for a continuous flow path through each solar tube, the flow of solar liquid therein receiving heat by conduction from the fin.

24. The solar hot water system of claim 23, wherein the preferred configuration is a serial linkage joining a preferred number of solar tubes and a parallel linkage joining a preferred number of serial linkages.

25. The solar hot water system of claim 24, wherein the preferred number of solar tubes in a serial linkage is ten and the preferred number of serial linkages in a parallel linkage is four.

26. The solar hot water system of claim 23, wherein the integrated U-shaped channel is formed as a part of an extrusion of the fin in a construction eliminating air gaps in a heat conduction path while simplifying assembly steps.

27. The solar hot water system of claim 22, wherein the means for cooling comprises a cooling loop and a controller, the cooling loop in fluid communication with the hot section, the controller programmed to switch on circulation through the cooling loop when the water of the storage vessel is above a first preferred temperature.

28. The solar hot water system of claim 27, wherein the first preferred temperature is in the range of 55-60° C.

29. The solar hot water system of claim 21, wherein the means for circulating the solar liquid comprises a low-pressure pump in a low-pressure loop.

30. The solar hot water system of claim 29, further comprising a means for preventing freezing of the solar liquid.

31. The solar hot water system of claim 30, wherein the means for preventing freezing comprises a low pressure circulation of the solar liquid below a second preferred temperature.

32. The solar hot water system of claim 31, wherein the second preferred temperature is in the range of 2-5° C.

33. The solar hot water system of claim 21, wherein heated water for application purposes is provided by circulation through a heat exchanger immersed in the storage vessel.

34. A method of configuring a solar collector to achieve operating efficiency, comprising:

providing a solar collector having a manifold with an input port, an output port and a plurality of orifices; a corresponding plurality of solar tubes connected to the manifold through the orifices, the plurality of solar tubes assembled in a planar array and positioned for exposure to solar radiation; at least one liquid channel from the input port to the output port, said liquid channel having at least one continuous flow path there through; and a fin inserted into each solar tube and extending the length of the tube, said fin having an integrated U-shaped channel extending from an input end to an output end, the input end of a first U-shaped channel in a first solar tube of the planar array forming a fluid connection to the input port, the output end of the first U-shaped channel in the first solar tube forming a fluid connection in a preferred configuration to the input end of a last U-shaped channel in a last solar tube, the output end of the last U-shaped channel in the last solar tube forming a fluid connection to the output port, whereby at least one liquid channel is formed for a continuous flow path through each solar tube, the flow of solar liquid therein receiving heat by conduction from the fin;
implementing the preferred configuration by joining a preferred number of solar tubes in a serial linkage, said serial linkage balancing heat transfer efficiency with non-turbulent hydraulic flow; and
implementing the preferred configuration by joining a preferred number of serial linkages in a parallel linkage, said parallel linkage balancing heat transfer efficiency with hydraulic pressure;
whereby the cost per BTU is optimized by balancing pressure and flow characteristics.

35. The method of claim 34, wherein the preferred number of solar tubes in a serial linkage is ten and the preferred number of serial linkages in a parallel linkage is four.

Patent History
Publication number: 20140360492
Type: Application
Filed: Aug 25, 2014
Publication Date: Dec 11, 2014
Inventor: Yan Kunczynski (Carson City, NV)
Application Number: 14/467,179
Classifications
Current U.S. Class: Process Of Heating By Using Solar Heat (126/714); Having Heat Exchanger Within Storage Tank (126/641); Pump (126/646); Plural Conduits (126/663)
International Classification: F24J 2/24 (20060101); F24J 2/46 (20060101); F24J 2/34 (20060101);