Active thermal insulation system including evacuated structures and a vacuum sustaining unit
A thermal insulation system includes an evacuated structure including an internal space in which a vacuum is sustained by a vacuum pump operating when it is determined that a pressure within the internal space has risen to a predetermined level. In one embodiment, such a system is used within a dome structure extending over and around a heat receiving structure within a solar heating system.
Not Applicable
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTNot Applicable
BACKGROUND OF THE INVENTION1. Field of the Invention
This invention relates to thermal insulation systems, more particularly to such systems including evacuated structures, and yet more particularly to the use of such systems to allow heat retention within solar heat collectors.
double glazed vacuum structures, and, more particularly, to such structures having a means for providing and maintaining a vacuum between spaced-apart glass sheets for thermally insulating solar heat collectors.
2. Summary of the Background Information
A solar heat collector typically includes a heat receiving structure through which a fluid, such as water, is circulated to be heated by solar radiation. The heat receiving structure comprises elements such as piping, tubing, a reservoir tank, and a thermally conductive structure to absorb heat from radiant energy and to transmit the heat to the fluid. Preferably, a transparent cover is placed over the heat receiving structure, allowing the passage of radiant energy, so that the vessel is heated by sunlight, while minimizing the conduction of heat, allowing the heat receiving structure to rise to a relatively high temperature without substantial heat losses to the atmosphere around the solar heat collector. The effectiveness of the thermal insulation in preventing heat loss to the atmosphere has a significant effect on the overall efficiency of the solar heat collector, particularly when the solar heat collector is operated in a cold climate.
One method that has been applied to provide thermal insulation while allowing the transmission of radiant energy is the use of a pair of glass plates that are spaced apart to form an intervening air space. A single plate of glass has an insulation value of R1, with this value being increased to R2 when a second plate is installed to provide a separate air space. Evacuating the air within the space between the glass plates can provide substantially higher insulation values of R30 to R50, at the cost of a need to provide air tight seals around the edges of the glass plates and of a need to provide a structure that can withstand a pressure of about 15 psi acting on each of the plates. However, the use of structures including evacuated spaces for thermal insulation has been the brittleness and relatively low strength of the glass materials generally used and by a lack of reliability of such structures in large thermally insulating systems because small leaks result in a loss of vacuum.
The patent literature includes a number of descriptions of structures for reducing the transfer of heat through the use of spaced-apart glass plates on opposite sides of an evacuated space. For example, U.S. Pat. No. 2,216,332 describes a window including a pair of spaced-apart glass plates and a pipe extending within the wall from the space between the glass plates. The pipe extends to a valve that can be opened to withdraw air form the space between the plates or to return air to this space. A supporting structure, composed of slotted, interlocking vertical and horizontal spacers dividing the space between the plates into a number of smaller rectangular spaces, extends between the plates to help resist the atmospheric pressure acting on the plates when air is removed from this space.
U.S. Pat. No. 3,990,201 describes a An evacuated dual pane window structure is provided for reducing heat loss through the window structure. The window structure comprises a pair of closely spaced panes of glass having a spacing of less than 0.25 inch with a spacer means positioned between and uniformly spaced in the area between the panes, and sealing means such as an 0-ring positioned around the perimeter and between the panes of glass. A vacuum=pump may be provided for evacuating the area between the panes of glass for reducing thermal losses through the window structure. Reflective coatings may ;′ be provided on the inside surfaces of the glass. A plurality of windows of the above structure may be connected by manifold piping to a single vacuum pump, which is actuated by a thermostat when a preset temperature differential exists between the outside and the inside of the building where the windows are used.
U.S. Pat. No. 4,184,480 describes a conventional flat plate solar heat collector provided with a contoured vacuum insulation window supported solely about its peripheral edge portions. The window is a composite formed from a pair of minimum thickness complementarily contoured glass sheets, which with the exception of their peripheral portions which are sealed together, are spaced apart from one another so as to provide an evacuated chamber therebetween and thus insulate one sheet from the other. The window formed by the nested or complementary contoured glass sheets is contoured in both its longitudinal and lateral directions, such that in its longitudinal direction the window is composed of a plurality of sinusoidal corrugations whereas in its lateral direction the peaks of such corrugations are contoured in the form of paraboloids so as to provide maximum uniform tensile strength to the window such that it may withstand the forces generated thereon by the atmosphere. However, the size of the insulated glass member is limited by the forces, principally caused by the air pressure acting on the two glass sections, and possibly additionally by manufacturing and transportation difficulties associated with handling and forming large pieces of glass. What is needed is a method for a way to provide a thermally insulating cover over a larger and taller solar heat collector.
Other patents describe methods for sealing the interface between glass plates and structural framing members and for providing channels for the evacuation of air between the glass plates to form thermally insulating structures. For example, U.S. Pat. No. 6,383,580 describes a vacuum insulating glass (IG) unit and method-of making the same. An edge-mounted pump-out structure is provided, including a pre-positionable insert capable of receiving a pump-out tube therein. Following formation of the edge-mounted pump-out structure and its positioning on the unit, an edge seal is formed for hermetically sealing off the low pressure space located between the substrates.
U.S. Pat. No. 6,506,272 describes a A vacuum insulating glass (IG) unit. In certain embodiments, the internal cavity is evacuated (i.e., pumped out) via a pump-out aperture. A cover with one or more sealing element(s) may be provided over the pump-out aperture so that during the pump-out process air flows out of the internal cavity and through space(s) between adjacent sealing elements or sealing element portions. Following evacuation or pumping out, the sealing element(s) is/are heated and the sealing member may be pressed downwardly toward the substrate. This causes the heat-softened sealing element(s) to expand horizontally and merge with one another so as to form a hermetic seal around the pump-out aperture and between the sealing member and the substrate.
U.S. Pat. No. 5,902,652 describes a method for providing pillars to space apart thermally insulating glass panels that are spaced apart, a method for providing an improved edge seal around the glass panels, and a method for providing an improved pump-out tube for use during construction of the panels.
SUMMARY OF THE INVENTIONVarious difficulties and shortcomings of prior-art thermally insulating systems including evacuated spaces are overcome through the use of the present invention. A dome-shaped central space within a thermally insulating system is provided for holding the heat-receiving portion of a solar heating system. The mechanical weakness of glass panels extending adjacent evacuated spaces is overcome by curving the panels and, optionally, additionally by providing a panel with an impact-resistant film coating and by composing a panel of a ceramic glass material. In applications where transparency is not needed, a strong and resilient material, such as a metal, is used in place of the glass. The reliable, long-term use of large thermally insulating systems is achieved through the use of vacuum sustaining units to make the systems tolerable of small leaks.
In accordance with a first aspect of the invention, a thermally insulating system including a thermally insulating structure and a vacuum sustaining unit is provided, with the thermally insulating structure including an internal space. The vacuum sustaining unit includes a first input tube connected to the internal space, a pressure sensor sensing a pressure within the internal space, and a vacuum pump evacuating air from the internal space in response to a signal from the pressure sensor indicating that a pressure within the internal space has risen above a predetermined level.
In accordance with a first embodiment of the invention, the thermally insulating structure includes a floor structure and a dome-shaped structure, extending upward from the from the floor structure. The dome-shaped structure includes an internal surface forming a central space extending from the internal surface to the floor structure, and an external surface. Preferably, the heat-receiving portion of solar heating system is disposed within the central space. The internal space extends within the dome-shaped structure, separate from the central space and between the internal and external surfaces. The dome-shaped structure transmits solar radiation from outside the dome-shaped structure to the central space within the dome-shaped structure.
Preferably, the floor structure includes a flat inner plate, a flat outer plate, a frame, and a second input tube. The flat inner plate and the flat outer plate are each composed of a strong and resistant material. The frame holds the flat inner and outer plates in a spaced-apart relationship, forming an inner space extending within the frame and between the flat inner and outer plates. The second input tube connects the inner space within the floor structure with the vacuum sustaining unit.
In accordance with a first version of the first embodiment, the dome-shaped structure comprises an inner transparent dome, and outer transparent dome, a gasket, and at least one bracket. The inner transparent dome includes the inner surface, a first lower surface, and a lower flange extending outwardly around the first lower surface. The outer transparent dome includes the external surface, a second lower surface, and an upper flange extending outwardly around the second lower surface.
In accordance with a second version of the first embodiment, the dome-shaped structure includes a dome-shaped framework having a plurality of frame openings. An inner transparent curved sheet and an outer transparent curved sheet are held in a spaced-apart relationship within each of the frame openings, with the spaces between the transparent curved sheets being connected to one another to form the internal space. The dome-shaped framework may additionally include a removable frame section, an access door that can be opened to provide access to the central space, or an opening extending around a lens concentrating solar radiation within the central space.
In accordance with a second embodiment of the invention, the thermally insulating structure comprises a plurality of thermally insulating panels. Each of the thermally insulating panels includes flat inner and outer panels and a frame. The flat inner and outer panels are each composed of a strong and resilient material, The frame holds the flat inner and outer panels in a spaced-apart relationship, forming an inner space extending within the frame and between the inner and outer plates. The inner space within each of the thermally insulating panels is connected to the vacuum sustaining unit, by a common evacuation tube, or by openings extending through adjacent portions of the frames of adjacent thermally insulating panels.
In accordance with a first version of the second embodiment, the thermally insulating panels are aligned along a surface, such as a wall, floor, or ceiling, within a building, or are disposed within an element of a building, such as a wall ceiling, or floor, between elongated members within the element.
In accordance with a second version of the second embodiment, the thermally insulating panels form a box structure, extending around a central space, and a first door structure. The box structure includes an access opening. The door structure is movable between a closed position, extending within the access opening, and an open position. An insulating panel within the door structure is connected to the vacuum sustaining unit by a path including a flexible hose. The box structure may extend within a refrigerator, a container, or a railroad car.
A solar heat collector typically includes a heat receiving structure through which a fluid, such as water, is circulated to be heated by solar radiation. The heat receiving structure comprises elements such as piping, tubing, a reservoir tank, and a thermally conductive structure to absorb heat from radiant energy and to transmit the heat to the fluid. Preferably, a transparent cover is placed over the heat receiving structure, allowing the passage of radiant energy, so that the vessel is heated by sunlight, while minimizing the conduction of heat, allowing the heat receiving structure to rise to a relatively high temperature without substantial heat losses to the atmosphere around the solar heat collector. The effectiveness of the thermal insulation in preventing heat loss to the atmosphere has a significant effect on the overall efficiency of the solar heat collector, particularly when the solar heat collector is operated in a cold climate or if it is desired to operate the solar heat collector at a relatively high temperature needed for the production of mechanical power to drive an electrical generator. For example, a copending U.S. patent application Ser. No. 12/009,092, filed Jan. 16, 2008, the disclosure of which is incorporated herein by reference, describes a solar heating system including dome-shaped apparatus that is heated by solar radiation. Other descriptions of solar heating systems including dome-shaped heat receiving structures are found in the disclosures of U.S. Pat. Nos. 4,057,048, 4,136,670, 4,305,383, and 5,427,628, each of which is incorporated herein by reference.
The dome-shaped structure 112 includes an outer transparent dome 116 and an inner transparent dome 118, each including a hemispherical portion 120 and a flange 122. A number of alignment brackets 124 fasten the dome-shaped structure 112 to a floor structure 126 by means of bolts 128, with a resilient gasket 130, disposed between the flanges 122 of the transparent domes 116, 118, sealing an internal space 132 therebetween, and allowing the evacuation of the internal space 132 by a vacuum sustaining unit 133. An input tube 134 from the vacuum sustaining unit 133 extends through the resilient gasket to draw air from the space 132 between the transparent domes 116, 118. The flanges 122 may be formed as integral portions of the transparent domes 116, and 118, as shown in
The thermal insulation system 110 is additionally prepared for the installation of solar heat collecting apparatus (not shown) which preferably has overall dome-shaped structure, within the dome-shaped central space 114 by providing a fluid inlet tube 136 and a fluid outlet tube 138, each of which extends from an area 140 outside the dome-shaped structure 112 into the dome-shaped inner space 114, for the circulation of a fluid through the solar heat collecting apparatus.
Preferably, the floor structure 126 is formed as a thermally insulating vacuum panel structure including a flat inner plate 142, a flat outer plate 144, and a frame 146, which are attached and sealed to one another so that an internal space 148 is formed, with the internal space 148 being evacuated by the vacuum sustaining unit 133 through an evacuation tube 150. Preferably, the flat plates 142, 144 are composed of a tough, resilient material, such as a metal or a reinforced plastic, since transparency is not needed. The floor structure 126 may also include a number of spacers 152 extending between the panels 142, 144 to resist the tendency of the pressure acting on these panels 142, 144 to push these panels 142, 144 together. The spacers 152 may, for example, be cylindrical or elongated.
It is noted that the shape of the hemispherical portions 120 of each of the transparent domes 116, 118 is considered ideal for resisting internal and external pressure. Evidence of this is seen in the design of tanks for storing gas at relatively high internal pressures, which are generally spherical or cylindrical with hemispherical ends, and in the design of deep diving equipment, including diving helmets and submersible vehicles, which generally include spherically shaped surface for resisting high external pressures. Nevertheless, if additional structure is needed to maintain the space 132 between the transparent domes 116, 118, spacers (not shown) may be attached to extend between the transparent domes 116, 118.
While, in the example of
Thus, through operation of the vacuum sustaining unit 133, the dome shaped structure 112 and the floor structure 126 become evacuated structures, with air being evacuated from the internal space 132 of the dome-shaped structure 112 and the internal space 148 of the floor structure 126. As the term is used herein, the evacuation of air does not mean that a perfect vacuum is achieved or approximated, but rather that a pressure low enough to substantially reduce the transfer of heat is achieved.
For example, the transparent curved sheets 336, 338 are composed of glass or of a transparent thermoplastic material. Shattering may be prevented by attaching an impact resistant film to one or more of the surfaces 345 of the transparent curved sheets 336, 338. Furthermore, significant strengthening may be achieved by composing either or both of the transparent curved sheets 336, 338 of a transparent ceramic material.
The mounting and latching of the door 386 will now be discussed with reference being made to
The lens 454 concentrates solar radiant energy on a dish-shaped absorber 456 located, for example at the focal plane of the lens, above a floor structure 458. The dish-shaped absorber 456 absorbs energy that heats the air within the internal space 446, and additionally reflects a portion of the solar radiant energy to heat the frame 448 and transverse elements 450. An electrically-driven fan 452 is preferably additionally provided to circulate air within the internal space 446. Preferably, the dish-shaped absorber 456 is spaced away from the floor structure 458, so that the fan 452 can circulate air both above and under the disk-shaped absorber 456. The dish-shaped absorber 456 may be covered with thermally absorbing and reradiating materials, such as rusty steel plates. The internal space 446 may additionally include a reservoir 460 holding fluid stored at the elevated temperature of the space 446 for later use. The reservoir 460 may be connected to a fluid path within the frame 448, within the transverse elements 450 or elsewhere. Other aspects of the dome-shaped structure 440 and the solar heat collecting dome 442 are as described above in reference to
Thus, through operation of the vacuum sustaining unit 133, the dome shaped structure 250 (shown in
Curving the transparent sheets 336, 338 as shown in
The insulating panel 610 includes a pair of side panels 612 held in a spaced-apart condition within a frame 614. An evacuation tube 616 extends through the frame to provide for the evacuation of air from the interior space 618 between the side panels 612, and seals 620 prevent, or at least minimize, the return of air into the interior space 618 following evacuation. In the example of
The thermal insulation panel 610 of
While
Versions of the thermal insulation panel 610 may be used within appliances to form internal spaces that can be cooled or heated to a desired temperature with very little transfer of heat to or from the ambient air. For example
Referring first to
Referring to
The vacuum sustaining unit 133 may be operated through the use of a rechargeable battery that is plugged into the electrical system of a truck carrying the container. Furthermore, the container 800 may additionally include a refrigeration system (not shown) sharing a power source with the vacuum sustaining unit 133. Alternatively, the unit 133 may not be provided with the container 800, with an external connection to a manifold tube 832 being instead provided for periodic use of an external version of the vacuum sustaining unit 133.
The insulating panels 610 within each of the door structures 856 are connected with the insulating panels 610 within a box structure 860 by means of a flexible tube 864 resting within a tray 866. Preferably, the tray 864 is installed near the roof of the railroad car 850, with the tubes 862 being attached near the top of the doors 854.
While the invention has been shown in its preferred embodiments and versions with some degree of particularity, it is understood that this description has only been given by way of example, and that many changes can be made without departing from the spirit and scope of the invention, as defined by the appended claims.
Claims
1. A thermally insulating system comprising:
- a thermally insulating structure including an internal space;
- a vacuum sustaining unit including a first input tube connected to the internal space, a pressure sensor sensing a pressure within the internal space;
- and a vacuum pump evacuating air from the internal space in response to a signal from the pressure sensor indicating that a pressure within the internal space has risen above a predetermined level.
2. The thermally insulating system of claim 1, wherein
- the thermally insulating structure includes a floor structure and a dome-shaped structure, extending upward from the floor structure,
- the dome-shaped structure includes an internal surface forming a central space extending from the internal surface to the floor structure, and an external surface,
- the internal space extends within the dome-shaped structure, separate from the central space and between the internal and external surfaces, and
- the dome-shaped structure transmits solar radiation from outside the dome-shaped structure to the central space within the dome-shaped structure.
3. The thermally insulating system of claim 2, wherein the dome-shaped structure comprises:
- an inner transparent dome including the inner surface, a first lower surface and a lower flange extending outwardly around the first lower surface;
- an outer transparent dome including the external surface, a second lower surface, upwardly disposed from the first lower surface, and an upper flange extending outwardly around the second lower surface;
- a gasket extending between the lower flange and the upper flange to enclose a space extending between the inner and outer transparent domes to form the internal space; and
- at least one bracket holding the inner and outer transparent domes in a spaced-apart relationship.
4. The thermally insulating system of claim 3, wherein:
- the lower flange is formed as a separate piece within the inner transparent dome, and
- the upper flange is formed as a separate piece within the outer transparent dome.
5. The thermally insulating system of claim 2, wherein the dome-shaped structure comprises;
- a dome-shaped framework including a plurality of frame openings;
- an inner transparent curved sheet and an outer transparent curved sheet held within each frame opening within the plurality of frame openings, wherein the inner and outer transparent curved sheets are held in a spaced-apart relationship to form a portion of the internal space; and
- a plurality of openings connecting the portions of the internal space in adjacent frame openings to form the internal space.
6. The thermally insulating system of claim 5, wherein
- the dome-shaped framework additionally comprises a removable frame section, removable from outside the dome-shaped structure,
- the removable frame section extends around one of the frame openings, and
- the removable frame section holds the inner and outer transparent curved sheets within the frame opening in the removable frame section.
7. The thermally insulating system of claim 5, wherein
- the dome-shaped framework additionally comprises a door section mounted to be moved between an open position and a closed position, and a flexible tube extending between the door and an adjacent surface of the dome-shaped framework;
- access from outside the dome-shaped structure to the central space within the dome-shaped structure is provided with the door section in the open position and prevented with the door section in the closed position
- the door section extends around one of the frame openings,
- the door section holds the inner and outer transparent curved sheets within the frame opening in the door section, and
- the flexible hose connects the portion of the internal space between the inner and outer transparent curved sheets within the frame opening in the door section with the portion of the internal space within an adjacent frame opening.
8. The thermally insulating system of claim 5, wherein the dome-shaped framework additionally includes an opening extending around a lens concentrating solar radiation within the central space.
9. The thermally insulating system of claim 5, additionally comprising a Fresnel lens held above the dome-shaped structure to focus solar radiation on the dome shaped structure.
10. The thermally insulating system of claim 5, wherein the dome-shaped structure and the dome-shaped framework are elongated.
11. The thermally insulating structure of claim 5, wherein the inner and outer transparent curved sheets are curved around a circumference of the dome-shaped structure.
12. The thermally insulating structure of claim 5, wherein the inner and outer transparent curved sheets are curved to extend inward and upward.
13. The thermally insulating structure of claim 5, wherein a plurality of the transparent curved sheets are composed of a transparent ceramic.
14. The thermally insulating system of claim 2, wherein the floor structure includes:
- a flat inner plate composed of a strong and resilient material;
- a flat outer plate composed of a strong and resilient material;
- a frame holding the flat inner and outer plates in a spaced-apart relationship and forming an inner space extending within the frame and between the flat inner and outer plates; and
- a second input tube connecting the inner space within the floor structure with the vacuum sustaining unit.
15. The thermally insulating system of claim 2, wherein the internal surface of the dome-shaped structure extends around and over a heat receiving portion of a solar heating system.
16. The thermally insulating system of claim 1, wherein
- the thermally insulating structure comprises a plurality of thermally insulating panels,
- each of the thermally insulating panels includes a flat inner plate composed of a strong and resilient material, a flat outer plate composed of a strong and resilient material, and a frame holding the flat inner and outer plates in a spaced-apart relationship and forming an inner space extending within the frame and between the flat inner and outer plates, and
- the interior space within each of the thermally insulating panels is connected to the vacuum sustaining unit.
17. The thermally insulating system of claim 15, wherein the interior space within each of the thermally insulating panels is connected to the vacuum sustaining unit by a common evacuation tube.
18. The thermally insulating system of claim 15, wherein interior spaces within adjacent thermally insulating panels are connected by openings extending through adjacent portions of the frames within the adjacent thermally insulating panels.
19. The thermally insulating system of claim 15, wherein the thermally insulating panels are aligned along an interior surface within a building.
20. The thermally insulating system of claim 15, wherein the thermally insulating panels are disposed between elongated members within a structural element within a building.
21. The thermally insulating system of claim 15, wherein
- the thermally insulating panels form a box structure, extending around a central space, and a first door structure,
- the box structure includes a first access opening.
- the door structure is movable between a closed position, extending within the first access opening, and an open position,
- access into the central space is provided with the door structure in the open position and prevented with the door structure in the closed position, and
- an insulating panel within the first door structure is connected to the vacuum sustaining unit by a path including a first flexible hose.
22. The thermally insulating system of claim 20, wherein
- the box structure is disposed within a refrigerator, and
- the first door structure is disposed within a pivotally mounted door of the refrigerator.
22. The thermally insulating system of claim 20, wherein
- the box structure is disposed within a container,
- the first access opening is disposed at an end of the container,
- the thermally insulating panels additionally form a second door structure, movable between a closed position, extending within the first access opening, and an open position,
- the first door structure is disposed within a first pivotally mounted door of the container,
- the second door structure is disposed within a second pivotally mounted door of the container,
- access into the central space is provided with each door structure in the open position and prevented with each door structure in the closed position. and
- an insulating panel within the second door structure is connected to the vacuum sustaining unit by a path including a second flexible hose
23. The thermally insulating system of claim 20, wherein
- the box structure is disposed within a railroad car,
- the first access opening is disposed within a first side of the box structure,
- the box structure additionally includes a second access opening, disposed within a second side of the box structure,
- the thermally insulating panels additionally form a second door structure, movable between a closed position, extending within the second access opening, and an open position,
- the first door structure is disposed within a first slidably mounted door of the railroad car,
- the second door structure is disposed within a second slidably mounted door of the railroad car,
- access into the central space is provided with either door structure in the open position and prevented with each door structure in the closed position. and
- an insulating panel within the second door structure is connected to the vacuum sustaining unit by a path including a second flexible hose.
24. Solar heating apparatus comprising:
- a heat receiving structure through which a fluid flows to be heated by solar radiation, and
- a thermally insulating structure, including a floor structure and a dome-shaped structure, extending upward from the floor structure, wherein the dome-shaped structure includes an internal surface forming a central space holding the heat-receiving structure and extending from the internal surface to the floor structure, an external surface, and an evacuated internal space extending within the dome-shaped structure, separate from the central space and between the internal and external surfaces, and wherein the dome-shaped structure transmits solar radiation from outside the dome-shaped structure to the central space within the dome-shaped structure.
25. The solar heating apparatus of claim 24, wherein the floor structure includes:
- a flat inner plate composed of a strong and resilient material;
- a flat outer plate composed of a strong and resilient material;
- a frame holding the flat inner and outer plates in a spaced-apart relationship and forming an evacuated inner space extending within the frame and between the flat inner and outer plates;
26. A thermal insulating unit, disposed with a container, comprising:
- a plurality of thermal insulating panels, wherein spaces within each of the thermal insulating panels are connected to one another and to an exterma;
- connection for evacuation of air through the external connection.
Type: Application
Filed: Apr 4, 2008
Publication Date: Oct 8, 2009
Inventor: B. Michael Flaherty (Stuart, FL)
Application Number: 12/080,585
International Classification: F24J 2/51 (20060101); B65D 81/38 (20060101);