Abstract: A solar collector is provided that is formed from relatively thin polymer sheets. Three or more sheets are welded together to integrally define a storage tank, a plurality of layers of fluid flow channels (e.g. risers), and other desired features within the collector. The storage tank is located at a first end of the collector and a heat exchanger is provided within the storage tank. The heat exchanger is arranged to transfer heat from the storage tank to a target fluid (such as water) that is to be heated or preheated by the collector. The collector is arranged so that when it is installed, the collector may be positioned with the storage tank located generally above the fluid flow channels. The storage tank and the fluid flow channels are arranged such that when the collector is installed and filled with a working fluid, a thermosiphon effect will cause the collection of hot water within the storage tank.

Abstract: A variety of polymer manifolds and associated fabrication methods are described. The described manifolds can be used in heat exchangers and a variety of other applications. In one aspect a polymer manifold is formed by welding distal tips of a multiplicity of polymer tubes to a polymer retainer. The tubes pass through guide passages that extend between opposing faces of the retainer and the distal tip of each tube is welded to a manifold face of the retainer. The welds between the tubes and the manifold face form sealed connections between the tubes and the manifold face. In some embodiments a locking plate is positioned adjacent the retainer. The tubes also pass through the locking plate such that during assembly, the locking plate and/or the retainer can be translated or otherwise moved slightly relative to the other to hold the tubes in place during welding to the retainer.

Abstract: A panel former is provided for producing a panel that is formed from polymer tubing for solar collectors, heat exchangers, and other devices. The panel former can receive the tubing and continuously wrap the tubing around a drum so that support members can be welded to the tubing. After the support members are welded to the tubing, the tubing can be cut along a line substantially parallel to the support members to remove the tubing from the panel former and to form the risers in a panel.

Abstract: A variety of methods of forming polymer manifolds and the resulting manifold structures are described. The described manifolds are well suited for use in heat exchangers and a variety of other applications. In one aspect a polymer manifold includes a multiplicity of tubes having first ends that are received by a manifold housing. A polymer film is secured to the manifold housing and to the ends of each of the tubes. The film is arranged to seal the housing while leaving the openings of the tubes exposed to thereby create a manifold. In some embodiments, a potting material is used to reinforce the film. In a method aspect, a manifold may be formed by positioning first ends of the tubes in a manifold housing and welding a polymer film to the manifold housing and to distal tips of the tubes. Openings for the tubes are then formed in the film by directing heat towards the film which melts or vaporizes the film in the regions of the tube openings.

Abstract: A variety of methods of forming polymer manifolds and the resulting manifold structures are described. The described manifolds are well suited for use in heat exchangers and a variety of other applications. In one aspect a polymer manifold includes a multiplicity of tubes having first ends that are received by a manifold housing. A polymer film is secured to the manifold housing and to the ends of each of the tubes. The film is arranged to seal the housing while leaving the openings of the tubes exposed to thereby create a manifold. In some embodiments, a potting material is used to reinforce the film. In a method aspect, a manifold may be formed by positioning first ends of the tubes in a manifold housing and welding a polymer film to the manifold housing and to distal tips of the tubes. Openings for the tubes are then formed in the film by directing heat towards the film which melts or vaporizes the film in the regions of the tube openings.

Abstract: A solar collector is provided that is formed from relatively thin polymer sheet(s). The sheet(s) are welded together to integrally define a storage tank, a plurality of fluid flow channel (e.g. risers), and other desired features within the collector. The storage tank is located at a first end of the panel and a heat exchanger is provided within the storage tank. The heat exchanger is arranged to transfer heat from the storage tank to a target fluid (such as water) that is to be heated or preheated by the collector. The collector is arranged so that when it is installed, the collector may be positioned with the storage tank located generally above the fluid flow channels. The storage tank and the fluid flow channels are arranged such that when the collector is installed and filled with a working fluid, a thermosiphon effect will cause the collection of hot water within the storage tank.

Abstract: A solar collector is provided that is formed from relatively thin polymer sheet(s). The sheet(s) are welded together to integrally define a storage tank, a plurality of fluid flow channel (e.g. risers), and other desired features within the collector. The storage tank is located at a first end of the panel and a heat exchanger is provided within the storage tank. The heat exchanger is arranged to transfer heat from the storage tank to a target fluid (such as water) that is to be heated or preheated by the collector. The collector is arranged so that when it is installed, the collector may be positioned with the storage tank located generally above the fluid flow channels. The storage tank and the fluid flow channels are arranged such that when the collector is installed and filled with a working fluid, a thermosiphon effect will cause the collection of hot water within the storage tank.

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: 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: 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 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: A portable parts washer flows a washing agent over an object to remove any contaminants. The washing agent and contaminants flow into a basin mounted below the object. The washing agent is drawn from the basin and used to wash the object to provide a closed-loop system. A venturi-type injector mixes ozone from an ozone generator with the washing agent. A pump draws the washing agent from a first inlet to the basin, forces the washing agent through the injector, and returns the washing agent through a first outlet to the basin. Various splash protection mechanisms are used to protect an operator from any substances that may splash off of the object.

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: 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.