Abstract: An improved thermosiphon solar heater is disclosed. The thermosiphon solar heater includes a substantially planar collector including a plurality of heat exchanger channels that are positioned next to one another in a parallel relationship. The thermosiphoning solar heater also includes a pair of headers fluidly coupled to the collector. A first header is disposed at a top end of the collector. A second header is disposed at a bottom end of the collector. The thermosiphoning solar heater further includes one or more exposed storage tanks fluidly coupled to the header and positioned in a side by side relationship next to the collector.

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: Improved plastic heat exchanger production systems are described. The production systems are arranged to extrude plastic tubing, cut the tubing into segments of desired length and convey the tubing to a plurality of aligned tube inserters. Clip strips are feed through the tube inserters which sequentially automatically insert tube segments into the clip strips. The clip strips are then cut at desired lengths to provide tubing panels of a desired size or sizes. In a preferred system, header pipes are attached to the respective ends of the cut tubing panels to provide completed heat exchanger panels. When desired, heat exchangers having laterally offset tubes may be created by cutting one or more middle clip strips into spacer segments and rotating the spacer segments to laterally offset at least some of the tubes. In another aspect of the invention, improved tube inserters suitable for inserting plastic tubing into a plastic clip strip are described.

Abstract: Methods and apparatus for coupling heat exchange tubing to header pipes which include flanges are disclosed. Heat exchange tubing may generally be coupled, or bonded, to header pipe arrangements in order to produce heat exchanging devices which may be used in solar heating systems and thermal energy storage (TES) devices. According to one aspect of the present invention, a method for forming a heat exchanging device includes pretreating the ends of the heat exchange tubes used in the device. The pretreated ends are then heated to at least partially melt the pretreated ends. At the same time, heat is also applied to the header pipe arrangement included in the device to at least partially melt a flange arrangement which is a part of the overall header pipe arrangement. The pretreated ends of the heat exchange tubes are then sealed against the header pipe arrangement.

Abstract: A panel having multiple tubular passages extending therethrough and fitted on each end with a fluid tight hollow header. Apertures through one side of the headers place the tubular passages in communication with the interior of the headers. Fluid pumped into one header flows through the tubular passages to the other header, exchanging heat with the environment surrounding the panel as it passes therethrough. The panels are formed to provide a flow restrictive feature at the ends of the through fluid passages so that substantial flow will exist in all passages in all panels in an array of panels. One method for obtaining a fluid tight bond between the headers and the panel involves a forming process utilizing a heated die applied to the panel ends, and a subsequent panel and header material melting process followed by imposing pressure contact between the formed panel ends and the headers to thereby effect a permanent bond or weld.

Abstract: A panel having multiple tubular passages extending therethrough and fitted on each end with a fluid tight hollow header. Apertures through one side of the headers place the tubular passages in communication with the interior of the headers. Fluid pumped into one header flows through the tubular passages to the other header, exchanging heat with the environment surrounding the panel as it passes therethrough. The panels are formed to provide a flow restrictive feature at the ends of the through fluid passages so that substantial flow will exist in all passages in all panels in an array of panels. One method for obtaining a fluid tight bond between the headers and the panel involves a forming process utilizing a heated die applied to the panel ends, and a subsequent panel and header material melting process followed by imposing pressure contact between the formed panel ends and the headers to thereby effect a permanent bond or weld.