Abstract: A variety of arrangements and methods relating to a solar water heating system are described. Various implementations involve a relatively lightweight, affordable, low-pressure solar water heating system that is easier to ship and assemble and that is resistant to overheating and freezing damage. In one aspect of the invention, a solar water heating system includes a solar collector panel, a piping system and an improved, self-regulating expansion reservoir. Some designs involve automatic filtration, push fittings, a method for regulating power from a photovoltaic panel, UV resistant polymer components and/or other features. In a particular embodiment of the invention, multiple pumps, a heat exchanger and a controller for a solar water heating system are integrated into a single, compact module.

Abstract: Solar water heating systems that are formed as all-in-one kits that include all the components necessary for assembling the solar water heating systems at a chosen site is disclosed. Depending on the desired system, the kit may for example include a solar collector, one or more supplemental storage tanks, pumps, heat exchangers, valves, fittings, piping, timers, insulation, flashings, hose bibs, supports, brackets, fasteners, sealants and/or the like. In fact, the kit may further include all or some of the necessary tools required to assemble the solar water heating system.

Abstract: A weaving apparatus used to separate the tubes of a heat exchanger so that spacers that hold the tubes apart can be inserted between the tubes to increase thermal efficiency. The weaving apparatus includes a frame assembly and a weaving mechanism contained within the frame assembly. The weaving mechanism includes an alignment plate to align the tubes and separation plates to separate the tubes after they have been aligned. The weaving apparatus thus automates the step of separating the tubes of the heat exchanger so that the spacer can ready inserted between the tubes.

Abstract: The present invention relates to an integral solar energy collector storage systems. Generally, an integral collector storage system includes a tank system, a plurality of heat exchange tubes with at least some of the heat exchange tubes arranged within the tank system, a first glazing layer positioned over the tank system and a base plate positioned under the tank system. In one aspect of the invention, the tank system, the first glazing layer an the base plate each include protrusions and a clip is provided to hold the layers together. In another aspect of the invention, the first glazing layer and the base plate are ribbed to provide structural support. This arrangement is particularly useful when these components are formed from plastic. In yet another aspect of the invention, the tank system has a plurality of interconnected tank chambers formed from tubes. In this aspect, a supply header pipe and a fluid return header pipe are provided at a first end of the tank system.

Abstract: Methods and apparatus for forming continuous lengths of material with non-uniform cross-sections are disclosed. In accordance with one aspect of the present invention, a method for forming a continuous length of material that is of a substantially non-constant cross-section includes providing the material to a single shaping wheel. The material is in a first state, and the single shaping wheel includes a template that is arranged to form a three-dimensional shape using the material. The method also includes shaping the material to form an extended strip from the material, as well as at least one three-dimensional shape in the extended strip. The extended strip and the three-dimensional shape being formed using substantially only the single shaping wheel. In one embodiment, the method includes cooling the extended strip by cooling the material from a molten state to a solid state.

Abstract: Methods and apparatus for extracting stored thermal energy using a combined internal and external melt cycle are disclosed. The present invention relates, in one aspect, to a heat exchange system which uses both an internal melt cycle and an external melt cycle to extract stored thermal energy. The heat exchange system includes a thermal energy storage medium and a heat exchanger which is in communication with the thermal energy storage medium. The heat exchanger is arranged to hold a heat exchange liquid and to facilitate the indirect transfer of heat between the heat exchange liquid and the thermal energy storage medium. The heat exchange system further includes a fluid supply which provides a fluid which directly contacts the thermal energy storage medium to transfer heat between the fluid and the thermal energy storage medium.

Abstract: Disclosed is a heat exchange tube having angled heat-exchange performance-improving indentations on the tube. These angled performance-improving indentations increase the amount of heat transferred to a heat exchange liquid flowing through the tubes without substantially increasing the pressure drop or reducing the flow rate of the heat exchange liquid through the tube. An array of tubes can be made using heat exchange tubes of this invention, and a heat exchanger can be formed from an array or from tubes of this invention. In certain preferred embodiments, heat exchangers of this invention are particularly well-suited for use in solar-heating swimming-pool water or for use in thermal energy storage units.

Abstract: A method for fabricating a solar energy collector assembly of the integral storage type is disclosed herein. This assembly utilizes a specifically designed storage arrangement which is expanded into its final shape from an initial collapsed configuration. In the specific embodiment disclosed, the storage arrangement includes many of its own design features apart from the overall collector assembly and serves as the main structural component of the entire assembly.

Abstract: A device for fastening down one section of a strap, cord or the like is disclosed herein. This device which is especially suitable for use in the installation of solar panels includes a base member to be fixedly attached to a given support structure, for example a roof, and a cap disengageably connected with the base member in a predetermined way. The base and cap include confronting surface segments which cooperate with one another for engaging and retaining the strap or cord section in a fixed position along a path having a plurality of bends, preferably four 90.degree. bends.

Abstract: A supply of hollow plastic tubing is obtained from an extrusion and sizing apparatus, or from a supply of hollow tubing on a reel. The hollow tubing is provided at a predetermined speed to a tensioning device which imparts a tension in the hollow tubing and delivers it to a feeding point at one edge of the periphery of a rotating drum. The continuous hollow tubing is wound around the periphery of the drum at the one edge and it is forced axially on the periphery by a helical shoe overlying the periphery at the one edge. A bank of quartz lamps heats one side of the hollow plastic tubing just prior to reaching the feeding point, and another bank of quartz lamps heats the opposite side of the hollow plastic tubing at the one edge of the drum just after the tubing passes the shoe. The two heated surfaces are pressed together by the axial force exerted by the shoe, and are fused in side by side relation to form a cylinder having a wall consisting of spiral turns of the plastic tubing fused together.

Abstract: A solar panel assembly is disclosed herein and includes a solar panel arrangement having a main body which defines internal passageways, between inlet and outlet headers, a corrugated glazing sheet located on the top side of the panel body and at least one but preferably two corrugated support sheets located under the panel body. The assembly also includes a header cover on each end of the panel which, in part, encloses a corresponding one of the headers and which, in part, nests against the corrugated glazing sheet and one of the corrugated support sheets.