Abstract: A solar thermal assisted water heating system includes a thermal collector comprising a plurality of fluid channels configured to collect heat from a surface of a photovoltaic module, a drain-back tank coupled to the thermal collector, a first pump coupled to the drain-back tank and configured to pump fluid from the drain-back tank to the thermal collector, a first heat exchanger configured to receive fluid from the thermal collector, a heat pump coupled to the first heat exchanger and configured to remove heat from the fluid and heat water with the removed heat, and a controller configured to control the first pump and heat pump. The system may include a photovoltaic module and a hot water tank. These systems improve the efficiency of water heating, and the drain-back tank may serve as a thermal battery that stores heat and provides the stored heat when environmental temperatures decrease.

Abstract: A fluid cooled photovoltaic module in which a polymer heat exchanger transfers heat from the photovoltaic module to a circulated fluid. The photovoltaic module is maintained at a cool temperature enabling increased power output while the heat transferred to the circulated fluid can be useful for applications that require heat. A polymer heat exchanger is specifically utilized to achieve a robust design that is cost effective; high performance; easily adaptable to various photovoltaic module types and sizes; compatible with conventional photovoltaic module balance of systems; light weight; resistant to water sanitizers and other chemicals; resistant to lime-scale buildup and heat exchanger fouling; corrosion resistant; easily transported, assembled, installed, and maintained; and leverages high production manufacturing methods.

Abstract: A fluid cooled photovoltaic module in which a polymer heat exchanger transfers heat from the photovoltaic module to a circulated fluid. The photovoltaic module is maintained at a cool temperature enabling increased power output while the heat transferred to the circulated fluid can be useful for applications that require heat. A polymer heat exchanger is specifically utilized to achieve a robust design that is cost effective; high performance; easily adaptable to various photovoltaic module types and sizes; compatible with conventional photovoltaic module balance of systems; light weight; resistant to water sanitizers and other chemicals; resistant to lime-scale buildup and heat exchanger fouling; corrosion resistant; easily transported, assembled, installed, and maintained; and leverages high production manufacturing methods.

Abstract: An integrated solar thermal and photovoltaic apparatus. The apparatus includes a solar thermal module, and a photovoltaic module comprising a plurality of solar cells configured in a polymeric material. The apparatus has an amorphous material configured between the thermal solar module and the photovoltaic module. The amorphous material has a semi-viscous, thermally conductive, and mastic characteristic to allow for thermal expansion and contraction of either or both the photovoltaic module or the solar thermal module during an operating time. The apparatus has an aperture region provided on a first side of the photovoltaic module and the solar thermal module is overlying a second side of the photovoltaic module. The thermal solar module, the photovoltaic module, and the amorphous material form an integrated thermal solar module.

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: 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: 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: 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: 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 plastic ring is spun onto the end of a plastic pipe, the heat of friction fusing the contacting surfaces between the ring and the pipe, forming a weld therebetween upon cooling. The ring provides greater radial rigidity at the end of the pipe, and carries a flange extending beyond the outside diameter of the pipe. A flexible sleeve is slipped over the ends of two adjacent sections of such pipe with the flanges in abutting position. Band-type clamps surround the sleeve overlying the rings and are tightened to effect a seal between the sleeve and the periphery of the flanges. The end rings are spun onto the pipe ends with either the inside or the outside diameter of the pipe engaging the interfering surface on the ring in two different embodiments.

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 valve body is formed of a section of flow pipe for connection to an open end on a flow pipe by means of a surrounding sealing sleeve and outer clamp. A valve body end cap is formed of a standard pipe cap with inlet ports drilled through the end thereof. A valve seat member is centrally mounted on the inside of the valve body end cap having a valve seat on the end opposite the mounting end. The valve seat member has a first predetermined height for positioning the valve seat a predetermined distance above the inside surface of the end cap. An internal step is formed on the inside diameter of the end cap at a second predetermined height above the inside of the end cap. A spacing ring is placed on the internal step having a thickness to provide for a desired difference between the first predetermined height and the sum of the second predetermined height and the spacing ring thickness. A diaphragm formed to fit the inside diameter of the valve body end cap is positioned with one face in contact with the ring.

Abstract: A valve body having a circular cylindrical shape may be made of plastic or any other suitable material. A radial hole through the wall of the body has a pressure inlet fitting positioned therein. A flexible tubing is passed through the body co-axial therewith. The tubing is folded back to overlie the ends of the valve body and a valve end tube is positioned to overlie the folded back ends of the flexible tubing. Clamps are utilized to impart inward radial pressure about the circumference of the valve end tube overlying the folded back tubing. The valve end tube is adapted to receive the ends of an inlet and an outlet flow conduit. Pressure of varying magnitude introduced through the pressure inlet fitting serves to meter the fluid flow through the conduit from a full flow to substantially zero flow as the flexible tube distends into the passage through the valve body.

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.