METHOD OF FORMING A SOLAR COLLECTOR HAVING MULTIPLE COMPOSITE PLIES
A solar collector for use in concentrating solar rays into a high flux density image is formed from laminate plies. Electricity is produced by superimposing the image onto a concentrated photovoltaic cell. Plies are cut from a composite sheet that is made up of carbon fibers in a thermoset polymer, where the carbon fibers run generally parallel with one another. By varying how the plies are cut from the sheet, carbon fibers in different plies are oriented at alternating angles in the plies. The plies arc stacked to form a laminate, where the carbon fibers in each ply are at an angle with carbon fibers in adjacent plies. The plies may include alignment tabs to control the angle between adjacent plies. Pressing the laminate in a heated die and cooling the die with forced convection and then a fluid bath forms a shell for the solar collector.
1. Field of Invention
The invention relates generally to a solar collector. More specifically, the present invention relates to a method of forming a solar collector with a substrate formed from a laminate of plies of a composite,
2. Description of Prior Art
Solar collection systems that concentrate solar energy generally employ a number of collectors; each having a reflective side configured to focus the reflected light. Focusing the reflected light typically entails forming an image that is cast onto a solar conversion cell. Collector configurations must be distinct and carefully shaped to focus the concentrated solar energy onto a solar conversion cell. A misshaped collector usually forms an out of focus image with a less homogenous flux density than a focused image, thereby reducing system efficiency.
Many obstacles exist when working a material so the reflective, or optical, side of each collector is sufficiently precisely configured to generate a desired image. Manufacturing obstacles are especially prevalent when solar energy collectors are mass produced. For example, while the ram and die of a metal stamping process may be precisely configured to form a collector shell, the stamped shell may not have the desired configuration. Internal stresses in the material being stamped can bend the shell from a desired configuration; where the internal stresses may be inherent in the material or introduced during stamping. Also, ram and die sets can wear over time and eventually form collector shells with undesired configurations.
Solar collectors are typically made from a material with some stiffness so the collectors can retain their shape long term and be useable for many years. Moreover, solar collection and conversion systems often consolidate the collectors into a solar array to boost the electricity generating capacity of the conversion system. Thus the material for the collectors should be strong enough to resist deformation, such as from routine handling or from creep, but also be light enough for handling and mounting.
SUMMARY OF THE INVENTIONProvided herein is a method of forming a solar collector for use in concentrating solar rays into a high flux density image. Electricity is produced by superimposing the image onto a concentrated photovoltaic cell. Plies are cut from a composite sheet that is made up of carbon fibers in a thermoset polymer, where the carbon fibers run generally parallel with one another. By varying how the plies are cut from the sheet, carbon fibers in different plies are oriented at alternating angles in the plies. The plies are stacked to form a laminate, where the carbon fibers in each ply are at an angle with carbon fibers in adjacent plies. The plies may include alignment tabs to control the angle between adjacent plies. Pressing the laminate in a heated die and cooling the die with forced convection and then a fluid bath forms a shell for the solar collector.
Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTIONThe method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.
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After the resin and the composite has cured, the die sets 44 are shown in
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The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.
Claims
1. A method of forming a solar collector comprising:
- providing a composite comprising substantially parallel elongated carbon fibers disposed in a thermosetting polymer;
- forming plies from the composite by cutting the composite into sections;
- stacking the plies into a laminate so that carbon fibers in each ply are oriented at an angle with carbon fibers in any adjacent ply;
- pressing the laminate into a shape having a concave side and a convex side;
- heating the laminate; and
- applying a reflective material to the concave side.
2. The method of claim 1, wherein the angle between carbon fibers in any adjacent ply is selected from the group consisting of 0°, 30°, 45°, 60°, and 900.
3. The method of claim 1, wherein the number of plies making up each laminate is selected from the group consisting of 6, 7, 8, 9, 10, 11, and 12.
4. The method of claim 1, further comprising providing tabs on each ply for precisely arranging each ply in the laminate.
5. The method of claim 1, wherein a portion of the step of pressing is a cold press for debulking the laminate that is at a pressure of about 200 psi to about 250 psi and wherein while heating the laminate the pressure is at about 70 psi.
6. The method of claim 1, wherein the laminate is set in a die that is disposed in a platen assembly and wherein the pressure and the heat is applied by the platen assembly.
7. The method of claim 6, further comprising removing the die from the platen assembly, cooling the die with a forced convection flow of fluid and then a fluid bath.
Type: Application
Filed: Dec 5, 2012
Publication Date: Jun 27, 2013
Inventor: Robert Romeo (Tucson, AZ)
Application Number: 13/706,072
International Classification: F24J 2/46 (20060101);