SOLAR FURNACE AND METHODS OF USE THEREOF

Abstract

A solar furnace for heating a target having a heliostat with a reflective surface having a reflective portion, a surface altering mechanism capable of altering the shape of the reflective portion, and a target having a target area, the reflective surface capable of reflecting radiant energy toward a target.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This patent application is a continuation of non-provisional patent application Ser. No. 12/916,066, filed on Oct. 29, 2010. This patent application claims the benefit of the priority of provisional patent application 61/601,513, filed on Feb. 21, 2012, and the PCT patent application PCT/______/______ filed on Feb. 21, 2013. Each of the non-provisional patent application Ser. No. 12/916,066, PCT patent application PCT/______/______ and the provisional patent application 61/601,513 are incorporated herein by reference.

BACKGROUND

Manufacturing processes for plastic products typically include heating various forms of plastic (e.g., pellets, powders, sheets, etc.) and forming the plastic into the desired shape. Two very common forms of plastic molding are rotational molding and vacuum molding.

Rotational molding includes a hollow mold that can rotate in all three axis of the three dimensional Cartesian coordinate system. The hollow mold is typically formed from a metal or similarly heat-conductive material. A quantity of plastic powder is placed inside the hollow mold. The hollow mold is then moved into an oven where the heat source substantially surrounds the hollow mold. The hollow mold is then rotated and heated in the oven.

As the hollow mold is rotated and heated in the oven, the plastic powder continually falls to the bottom of the inner surface of the hollow mold. The heated hollow mold heats the plastic powder on the bottom inner layer of the hollow mold. The melted plastic powder bonds together (e.g., sinters) to form a complete plastic layer in the bottom inner surface of the hollow mold. Continually rotating the mold forms a plastic layer on all inner surfaces of the hollow mold. The hollow mold can be removed from the oven once the complete plastic layer is formed on the inner surface of the hollow mold. The hollow mold is then allowed to cool and then opened and the molded plastic product removed from the hollow mold. Typical products formed in a rotational molding system are tanks, boats, shipping containers and other shapes.

Vacuum molding includes a frame for supporting a sheet of rigid plastic over a positive (raised or convex) or a negative (sunken or concave) shaped mold. A heat source is directed at the plastic sheet and a vacuum is applied to the area around and in some instances inside the mold, softening the plastic sheet and making it flexible. The vacuum draws the heated plastic sheet down onto or into the mold to form the desired shape. Then the heat source is removed and the molded plastic sheet is allowed to cool and become ridged again. Then the vacuum is removed and the molded plastic sheet can be removed from the mold. Typical products formed in a vacuum molding system are boat hulls, showers, shipping trays, and equipment covers.

In both rotational molding systems and vacuum molding systems, the energy cost for the heat portion of the manufacturing process is an ever larger portion of the end product cost.

SUMMARY OF THE INVENTION

The present disclosure pertains to a solar furnace for heating a target having a heliostat having a reflective surface having a reflective portion, a surface altering mechanism capable of altering the shape of the reflective portion, and a target having a target area, the reflective surface capable of reflecting radiant energy toward a target.

In one aspect of the disclosure, the surface altering mechanism allows for the alteration of the size of the target area. In another aspect of the disclosure, the surface altering mechanism allows for the reflected radiant energy to impinge upon a target area at various distances from the reflective surface. In another aspect of the disclosure, the heliostat has a plurality of surface altering mechanisms capable of altering the reflective surface to a multi-curved shape. In another aspect of the disclosure, the target has a plurality of target areas, and the heliostat has a first surface altering mechanism capable of altering the shape of a first reflective portion and a second surface altering mechanism capable of altering the shape of a second reflective portion, the first reflective portion capable of reflecting radiant energy toward a first target area and the second reflective portion capable of reflecting radiant energy toward a second target area. In another aspect of the disclosure, the solar furnace has a plurality of heliostats capable of reflecting radiant energy toward a target area. In another aspect of the disclosure, the target has a plurality of target areas, and the solar furnace has at least one first heliostat capable of reflecting radiant energy toward at least one first target area and at least one second heliostat capable of reflecting radiant energy toward at least one second target area. In another aspect of the disclosure, the surface altering mechanism of the at least one first heliostat allows for at least one first target size and the surface altering mechanism of the at least one second heliostat allows for at least one second target size.

In another aspect of the disclosure, the heliostat has a failsafe mechanism capable of decreasing the amount of wind captured by the reflective surface. In another aspect of the disclosure, the solar furnace has a directional reflector capable of altering the direction of the radiant energy reflected by the reflective surface.

In another aspect of the disclosure, a solar furnace has at least one heliostat having a reflective surface having a reflective portion, and a target having at least one target area, the reflective surface capable of reflecting radiant energy toward a target area, an at least one first reflective surface capable of reflecting radiant energy toward an at least one first target area, and an at least one second reflective surface capable of reflecting radiant energy toward an at least one second target area. In another aspect of the disclosure, the at least one first target area has a first target size and the at least one second target area has a second target size.

In another aspect of the disclosure, the solar furnace has a directional reflector capable of altering the direction of the radiant energy reflected by the reflective surface. In another aspect of the disclosure, a solar furnace has a heliostat having a reflective surface having a reflective portion, the reflective surface capable of reflecting radiant energy, and a light pipe capable of receiving the reflected radiant energy and directing the reflected radiant energy toward a target. In another aspect of the disclosure, the solar furnace has a collector capable of directing the reflected radiant energy into the light pipe. In another aspect of the disclosure, the solar furnace has a recapture area having a plurality of sidewalls defining the periphery of the recaptured area, the sidewalls lined with a reflective surface capable of reflecting radiant energy toward the target. In another aspect of the disclosure, the solar furnace has a computer for orientating the reflective surface. In another aspect of the disclosure, the solar furnace has a computer for altering the shape of the reflective surface.

Another aspect of the disclosure is a method of heating a target utilizing a solar furnace having the steps of altering the shape of a reflective surface utilizing a surface altering mechanism, reflecting radiant energy toward the target area of the target, and heating the target area with the reflected radiant energy. Another aspect of the disclosure is a method further having the step of placing a target in the focal point of a reflective surface of a heliostat. Another aspect of the disclosure is a method further having the steps of placing a target in close proximity to a second end of a light pipe, and reflecting radiant energy toward a first end of a light pipe. Another aspect of the disclosure is a method further having the steps of touching a target to a second end of a light pipe, and reflecting radiant energy toward a first end of a light pipe. Another aspect of the disclosure is a method further having the step of reflecting radiant energy toward a collector. Another aspect of the disclosure is a method further having the step of placing a target in a recapture area having a plurality of sidewalls defining the periphery of the recaptured area, the sidewalls lined with a reflective surface capable of reflecting radiant energy toward the target. Another aspect of the disclosure is a method further having the step of reflecting radiant energy toward a directional reflector.

With those and other objects, advantages and features on the invention that may become hereinafter apparent, the nature of the invention may be more clearly understood by reference to the following detailed description of the invention, the appended claims, and the drawings attached hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments of the present invention and together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. In the drawings, like reference numbers indicate identical or functionally similar elements. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a solar furnace according to an exemplary embodiment.

FIG. 2 is a perspective view of a heliostat according to an exemplary embodiment.

FIG. 3a is a perspective view of a heliostat according to an exemplary embodiment.

FIG. 3b is a side view of a heliostat according to an exemplary embodiment.

FIG. 4 is a side view of a heliostat according to an exemplary embodiment.

FIG. 5 is a perspective view of a solar furnace according to an exemplary embodiment.

FIG. 6a is a side view of a heliostat according to an exemplary embodiment.

FIG. 6b is a side view of a heliostat according to an exemplary embodiment.

FIG. 6c is a side view of a heliostat according to an exemplary embodiment.

FIG. 7 is a perspective view of a solar furnace according to an exemplary embodiment.

FIG. 8 is a schematic view of a heliostat computer according to an exemplary embodiment.

FIG. 9 is a perspective view of a solar furnace according to an exemplary embodiment.

FIG. 10 is a plan view of a solar furnace according to an exemplary embodiment.

DETAILED DESCRIPTION

In the following detailed description, reference is made to the accompanying drawings which form a part hereof and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural or logical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.

The present disclosure pertains to a solar furnace 100, as shown in FIG. 1, for reflecting radiant solar energy 102 from a radiant energy source 101, such as the sun, onto a target 300 by way of a reflective surface 210 thereby increasing the temperature of the target 300. The use of radiant solar energy 102 reduces or eliminates the need for electricity or fossil fuel heat sources such as natural gas to heat the target 300. The use of radiant solar energy 102 can be the sole energy source used to increase the temperature of the target 300 or can be used in combination with traditional energy sources such as electrical heating coils.

In one embodiment, as shown in FIG. 1, the solar furnace 100 can have at least one heliostat 200 and a target 300. The target 300 can be any object in which reflected radiant energy 106 is impinged upon for the purpose of increasing the temperature of the object. For example, the target 300 can be a blow molding mechanism, injection molding mechanism, rotational molding mechanism, a food processing system such as a coffee bean roaster, a boiler for generating steam, a heat storage system containing meltable compounds such as salts or other heat storage medium, an evaporator such as a maple syrup evaporator, a water tank mold, or the like. For example, where the target 300 is a blow molding mechanism, the reflective surface 210 reflects radiant energy 106 toward the extruder of the blow molding mechanism, thereby causing the reflected radiant energy 106 to impinge upon the extruder. The temperature of the extruder increases causing the medium, such as plastic, inside the extruder to melt, thereby allowing the plastic to be blow molded to a desired shape. In one embodiment, the target 300 can be coated with solar absorptive paint to increase the absorption of impinging reflected radiant energy 106.

The heliostat 200 can have a reflective surface 210 for reflecting radiant energy 106. For example, the reflective surface 210 can be a minor, polished surface, plastic sheet, membrane, or the like, and can be made of metal, glass, plastic, laminate, vinyl, biaxially-oriented polyethylene terephthalate, the like, or any combination thereof. The reflective surface 210 can be any contour allowing for the reflection of radiant energy 106. For example, the reflective surface 210 can be planar, concave, convex, or multi-curved. Radiant solar energy 102 impinges on the reflective surface 210 whereby a first portion, or reflected radiant energy 106, of the radiant solar energy 102 is reflected off of the reflective surface 210, and a second portion 103 of the radiant solar energy 102 is absorbed by the reflective surface 210. The relative quantities of the reflected radiant energy 106 of the radiant solar energy 102 and the absorbed second portion 103 of the radiant solar energy 102 is determined by the types of material in the reflective surface 210 and the surface finish of the reflective surface 210.

As shown in FIG. 2, the reflected radiant energy 106 is reflected off of the reflective surface 210 at an angle δ corresponding to the angle α of the radiant solar energy 102. As a result, the reflected radiant energy 106 is reflected off of the reflective surface 210 in a dispersed fashion as the reflected radiant energy 106 is reflected in different δ angles corresponding to the different α angles.

In one embodiment, as shown in FIG. 3a and b, the heliostat 200 can have a surface altering mechanism 220 that allows for the creation of a planar, concave, convex, or multi-curved reflective surface 210. As shown in FIG. 5, A concave reflective surface 210 can focus or concentrate the reflected radiant energy 106 onto a target 300, thereby increasing the amount of reflected radiant energy 106 impinging the target area 310. The ability to alter the focus, and thus the focal length, of the reflected radiant energy 106 by way of the surface altering mechanism 220 allows for the reflected radiant energy 106 to be isolated to a target area 310, where the target area 310 can have different sizes and be located at different distances from the reflecting surface 210. In one embodiment, a convex reflective surface 210 can disperse the reflected radiant energy 106 away from the target area 310, thereby reducing the amount of reflected radiant energy 106 impinging the target area 310.

In one embodiment, the surface altering mechanism 220 can have a bolt 222 that engages the back of the reflective surface 210. The bolt 222 is threaded to allow for a nut 223, for example, a wing-nut, to be secured to the bolt 222. A frame 224 engages the perimeter of the reflective surface 210. In one embodiment, the frame 224 secures the reflective surface 210 in a taught position. In one embodiment, the reflective surface 210 is secured to the frame 224 by way of a securing mechanism. The securing mechanism can have a groove 232 running the longitudinal length of each portion of the frame 224, as shown in FIG. 4, and a clip 234, where the groove 232 receives the reflective surface 210 and the clip 234 where the reflective surface 210 is juxtaposed between the clip 234 and the groove 232. The groove 232 and clip 234 are sized in a manner that upon the groove 232 receiving the clip 234 tension or friction between the groove 232 and the clip 234 are formed thereby securing the clip 234 and the reflective surface 210 into the groove 232. A crossbar 226 engages the frame 224 in at least two locations on the frame 224. The crossbar 226 has a hole for receiving the bolt 222. The bolt 222 passes through the hole in the crossbar 226 and a mating nut 223 touching the crossbar 226 is threaded onto the bolt 222. In one embodiment, the nut 223 is tightened and the bolt 222 is pulled through the hole thereby applying a rearward force to the reflective surface 210. The rearward force applied to the bolt 222 pulls the reflective surface 210 until a desired axis displacement is achieved, thereby creating a concave reflective surface 210. In one embodiment, the nut 223 is loosened and the bolt 222 is pushed through the hole thereby applying a forward force to the bolt 222. The forward force applied to the bolt 222 pushes the reflective surface 210 until a desired axis displacement is achieved, thereby creating a convex reflective surface 210. In one embodiment, where the target area 310 is greater than the reflective surface 210, a convex reflective surface 210 allows the reflected radiant energy 106 from the reflective surface 210 to be dispersed thereby increasing the size of the target area 310 to cover more or all of the target 300. The rearward or forward force can be applied at any desired angle in relation to the reflective surface 210, for example, a right angle, an acute angle, or an obtuse angle. The application of the rearward or forward force at an acute or obtuse angle creates an asymmetrical concave or convex reflective surface 210, respectively.

In one embodiment, the target area 310 can have varying sizes, for example, the target area 310 can encompass the entire target 300 or a portion of the target 300 by changing the focal length of the reflective surface 210. More specifically, a first focal length of 50 feet can allow for a target size of four feet, while a second focal length of 100 feet can allow for a target size of two feet. In one embodiment, the ability to change the focal length of the reflective surface 210 allows for the reflected radiant energy 106 to impinge upon targets 300 positioned at varying distances from the reflective surface 210. For example, a first focal length of 50 feet allows for the reflected radiant energy 106 to be focused upon a target 300 located 50 feet from the reflective surface 210 while a second focal length of 100 feet allows for the reflected radiant energy 106 can be focused upon a target 300 located 100 feet from the reflective surface 210.

In one embodiment, the heliostat 200 can have a plurality of surface altering mechanisms 220 creating a multi-curved reflective surface 210 with a plurality of reflective portions on the reflective surface 210. A reflective portion is a section of the reflective surface 210 specifically tailored by a surface altering mechanism 220 that reflects radiant energy 106 toward a target area 310 with a desired shape and/or size. The reflective portion allows the reflective surface 210 to reflect the desired amount of radiant energy 106 toward a desired target area 310 while avoiding the reflection of radiant energy 106 toward other areas of the target 300. For example, the heliostat 200 can have two surface altering mechanisms 220 positioned at desired locations on the reflective surface 210 where a first surface altering mechanism 220 is capable of altering the shape of a first reflective portion, a second surface altering mechanism is capable of altering the shape of a second reflective portion, the first reflective portion is capable of reflecting radiant energy 106 toward a first target area 310, and the second reflective portion is capable of reflecting radiant energy 106 toward a second target area 310, thereby concentrating or focusing the radiant energy 106 on two target areas 310. In one embodiment, a plurality of surface altering mechanisms 220 can position the reflective surface 210 in a plane curve configuration. For example, the heliostat 200 can have two surface altering mechanisms 220 positioned at desired locations on the reflective surface 210 thereby creating a narrow/tall reflection or a wide/short reflection.

In one embodiment, the heliostat 200 can have a failsafe mechanism for decreasing the amount of wind captured by the reflective surface 210. By decreasing the amount of wind captured by the reflective surface 210, damage to the heliostat 200 caused by wind exerting a force on the reflective surface 210 is avoided. In one embodiment, as shown in FIG. 4, the failsafe mechanism has at least one clip 234 and a groove 232 for receiving the at least one clip 234. The clip 234 has a tension point where once a specific amount of force or load is applied to the clip 234, the clip 234 dislodges from the groove 232 thereby releasing the reflective surface 210 from the frame 224. In one embodiment, the tension point of the clip 234 is determinant of the composition of the clip 234. For example, where the clip 234 is made of polyoxymethylene material, the clip 234 has a high tension point thereby requiring a high load to dislodge the clip 234 from the groove 232. As another example, where the clip 234 is made of a low-durometer polymer, the clip 234 has a low tension point thereby requiring a low load to dislodge the clip 234 from the groove 232.

In one embodiment, the failsafe mechanism has a cutter 236, a support member 237, and wind capturing surface 238. As shown in FIGS. 6a-c, the support member 237 engages the frame 224 in a manner that allows for the support member 237 to traverse a specified distance or pivot around a hinge 239. The cutter 236 can be any object sufficient to pierce the reflective surface 210, for example, a blade, point, pin, or the like. The cutter 236 engages the proximate side, or side closest to the reflective surface 210, of the support member 237, and the wind capturing surface 238 engages the distal side, or the side furthest from the reflective surface 210, of the support member 237. The wind capturing surface 238 captures wind thereby exerting a force on the support member 237. The wind capturing surface 238 can be any size or shape that captures wind. In one embodiment, the area of the wind capturing surface 238 is designed where once a specific amount of force or load is applied to the wind capturing surface 238, the support member 237 traverses a distance or pivots around a hinge 239 causing the cutter 236 to pierce the reflective surface 210. The fail safe mechanism can have a wind capturing surface 238 and cutter 236 for capturing a frontward wind and piercing the reflective surface 210 from the front of the reflective surface 210 and a wind capturing surface 238 and cutter 236 for capturing a rearward wind and piercing the reflective surface 210 from the rear of the reflective surface 210.

In one embodiment, the heliostat 200 has at least one surface altering motor, for example, a stepper motor, hydraulic motor, or the like, each coupled to a surface altering mechanism 220 for operating the coupled surface altering mechanism 220.

In one embodiment, the heliostat 200 has a pivoting mechanism for orienting the reflective surface 210 to maximize the amount of reflected radiant energy 106 impinging upon the target 300. The pivoting mechanism can orient the reflective surface 210 about a vertical axis and/or a horizontal axis. The heliostat 200 can have at least one pivoting motor, for example, a stepper motor, hydraulic motor, or the like, coupled to a pivoting mechanism for operating the coupled pivot mechanism.

In one embodiment, the solar furnace 100 can have a plurality of heliostats 200 or a field of heliostats 200. As shown in FIG. 7, the reflective surfaces 210 of each heliostat 200A-H can be positioned in a manner dependent on the desired temperature and/or the amount of reflected radiant energy 106 needed to impinge upon the target 300. Temperature can be controlled by increasing or decreasing the number of reflective surfaces 210 and/or increasing or decreasing the focus of each reflective surface 210 used to reflect radiant energy 106 on the target 300. The target area 310 of the reflective surfaces 210 can be positioned at varying locations on the target 300. In one embodiment, the solar furnace 100 can have a plurality of heliostats 200 and the target 300 can have a plurality of target areas 310, where the plurality of heliostats 200 reflect radiant energy 106 toward a plurality of target areas 310. For example, the solar furnace 100 can have at least one first heliostat 200 capable of reflecting radiant energy 106 toward at least one first target area 310 and at least one second heliostat 200 capable of reflecting radiant energy 106 toward at least one second target area 310. In one embodiment, the solar furnace 100 can have a plurality of target areas 310 of different sizes and/or shapes.

In one embodiment, the solar furnace 100 has a heliostat computer 400. In one embodiment, the heliostat computer 400 can maintain proper orientation of the reflective surface 210 in relation to the desired target area 310 and location of the radiant energy source 101 to maximize the amount of radiant solar energy 102 reflected by the reflective surface 210 toward the target 300. The heliostat computer 400 maintains proper orientation of the reflective surface 210 by communicating with the pivoting motors. The communication between the heliostat computer 400 and the pivoting motors allows the pivoting motors to be remotely controlled, rather than requiring manual adjustment. For example, utilizing sensors, the latitude, longitude, time, and date of the position of the reflective surface 210 is provided to the heliostat computer 400. The heliostat computer 400 calculates the compass bearing and angle of elevation of the sun in relation to the reflective surface 210. Given the location of the target 300, the heliostat computer 400 sends control signals to the pivoting motor, thereby positioning the reflective surface 210 in the desired orientation. The heliostat computer 400 can be programmed to repeat this sequence of steps thereby maintaining the desired orientation of the reflective surface 210 in relation to the target area 310 and radiant energy source 101.

In one embodiment, the solar furnace 100 has a plurality of heliostat computers 400 where each heliostat 200 is coupled to a heliostat computer 400 thereby allowing for each heliostat 200 to be controlled by an individual heliostat computer 400. By coupling a heliostat 200 to a heliostat computer 400 individually dedicated to the coupled heliostat 200, the number of heliostats 200 affected upon damage, malfunction, or the like to a heliostat computer 400 or supporting infrastructure is decreased. For example, where the solar furnace 100 has a plurality of heliostats 200 and a plurality of heliostat computers 400, and each heliostat 200 is solely coupled to an individual heliostat computer 400, if the communication infrastructure coupling one heliostat computer 400 to one heliostat 200 becomes damaged, only one heliostat 200 is rendered inoperative and the other heliostats 200 can continue functioning.

In one embodiment, the heliostat computer 400 can alter the shape or contour of the reflective surface 210 by communicating with at least one surface altering motor. The communication between the heliostat computer 400 and the surface altering motor allows the surface altering motor to be remotely controlled, rather than requiring manual adjustment. For example, where the desired contour of the reflective surface 210 is concave and the desired target area 310 location is the focal point, utilizing sensors, the focal length is provided to the heliostat computer 400. The heliostat computer 400 sends control signals to the surface altering motor to arrange the contour of the reflective surface 210 so that the curve has a focal length corresponding to the sensor-determined distance between the reflective surface 210 and the target 300. In one embodiment, the operator may provide the distance between the reflective surface 210 and the target 300, and the heliostat computer 400 arranges the contour of the reflective surface 210 so that the curve has a focal length corresponding to the distance between the reflective surface 210 and the target 300 by adjusting the surface altering motor accordingly.

In one embodiment, where the heliostat 200 has a plurality of surface altering mechanisms 220 creating a plurality of reflective portions on the reflective surface 210, the heliostat computer 400 communicates with the surface altering motors corresponding to the surface altering mechanisms 220 to create reflective portions thereby altering the contour of the reflective surface 210.

In one embodiment, the heliostat computer 400 operates the orientation of all reflective surfaces 210 of the solar furnace 100 by orienting the reflective surfaces 210 about a vertical axis and/or a horizontal axis. The heliostat computer 400 can position one reflective surface 210 with a compass bearing and angle that differs from another reflective surface 210. For example, where the target area 310 of a water tank mold measures 12′×12′, and the reflective surfaces 210 are 3′×3′, 16 reflective surfaces 210 could reflect radiant energy 106 toward a target 300 each impinging a 3′×3′ target area 310 upon the water tank mold covering the 12′×12′ surface. By way of an additional example, where the target area 310 of a water tank mold measures 12′×12′, and the reflective surfaces 210 are 3′×3′, 32 reflective surfaces 210 could reflect radiant energy 106 toward a target 300 each impinging a 3′×3′ target area 310 upon the water tank mold, so that each 3′×3′ target area 310 receives reflected radiant energy 106 from two reflective surfaces 210 thereby decreasing the required time to heat the water tank mold to a desired temperature in comparison to the example utilizing 16 reflective surfaces 210. In one embodiment, the heliostat computer 400 can simultaneously communicate with a plurality of pivoting motors to control the orientation of the reflective surfaces 210 and a plurality of surface altering motors to control the contour of the reflective surfaces 210, thereby creating a highly tailored target area 310. For example, where a target area 310 of a water tank mold measures 12′×12′, the reflective surfaces 210 are 3′×3′, and 16 reflective surfaces 210 are adjusted to provide a 3′×3′ reflection covering the 12′×12′ surface, additional reflective surfaces 210 are used to focus all the reflected radiant energy 106 from each additional reflective surface 210 upon a target area 310 measuring 1′×1′ located in the corner of the water tank mold, thereby greatly increasing the amount of reflected radiant energy 106 impinging upon the 1′×1′ target area 310.

FIG. 8 shows an illustrative heliostat computer 400 for providing an application for interfacing with a host. Heliostat computer 400 can include control circuitry 410, storage 420, memory 430, input/output (“I/O”) circuitry 440, and communications circuitry 450. In some embodiments, one or more of the components of the heliostat computer 400 can be combined or omitted (e.g., storage 420 and memory 430 may be combined). In some embodiments, the heliostat computer 400 can include other components not combined or included in those shown in FIG. 8 (e.g., a display), or several instances of the components shown in FIG. 8. Only one of each of the components is shown in FIG. 8.

Heliostat computer 400 can include any suitable type of computer. For example, heliostat computer 400 can include a portable electronic device that the user may hold in his or her hand, such as a digital media player, a personal e-mail device, a personal data assistant (“PDA”), a cellular telephone, a handheld gaming device, or a digital camera. As another example, heliostat computer 400 can include a larger portable electronic device, such as a laptop or tablet computer. As yet another example, heliostat computer 400 can include a substantially fixed electronic device, such as a desktop computer.

Control circuitry 410 can include any processing circuitry or processor operative to control the operations and performance of heliostat computer 400, for example, a programmable logic controller (PLC), microprocessor, or the like. Control circuitry 410 can be used to run operating system applications, firmware applications, media playback applications, media editing applications, or any other application. In some embodiments, control circuitry 410 can drive a display and process inputs received from a user interface.

Storage 420 can include, for example, one or more storage mediums including a hard-drive, solid state drive, flash memory, permanent memory such as ROM, any other suitable type of storage component, or any combination thereof. Storage 420 can store, for example, application data (e.g., for implementing functions on heliostat computer 400), firmware, user preference information data (e.g., media playback preferences), authentication information (e.g. libraries of data associated with authorized users), wireless connection information data (e.g., information that can enable heliostat computer 400 to establish a wireless connection), and any other suitable data or any combination thereof.

Memory 430 can include cache memory, semi-permanent memory such as RAM, and/or one or more different types of memory used for temporarily storing data. In some embodiments, memory 430 can also be used for storing data used to operate heliostat computer applications, or any other type of data that can be stored in storage 420. In some embodiments, memory 430 and storage 420 can be combined as a single storage medium.

I/O circuitry 440 can be operative to convert (and encode/decode, if necessary) analog signals and other signals into digital data. In some embodiments, I/O circuitry 440 can also convert digital data into any other type of signal, and vice-versa. For example, I/O circuitry 440 can receive and convert physical contact inputs (e.g., from a multi-touch screen), physical movements (e.g., from a mouse or sensor), analog audio signals (e.g., from a microphone), or any other input. The digital data can be provided to and received from control circuitry 410, storage 420, memory 430, or any other component of heliostat computer 400. Although I/O circuitry 440 is illustrated in FIG. 8 as a single component of heliostat computer 400, several instances of I/O circuitry 440 can be included in heliostat computer 400.

Heliostat computer 400 can include any suitable interface or component for allowing a user to provide inputs to I/O circuitry 440. For example, heliostat computer 400 can include any suitable input mechanism, such as for example, a button, keypad, dial, a click wheel, or a touch screen. In some embodiments, heliostat computer 400 can include a capacitive sensing mechanism, or a multi-touch capacitive sensing mechanism.

In some embodiments, heliostat computer 400 can include specialized output circuitry associated with output devices such as, for example, one or more audio outputs. The audio output can include one or more speakers (e.g., mono or stereo speakers) built into heliostat computer 400, or an audio component that is remotely coupled to heliostat computer 400 (e.g., a headset, headphones or earbuds that can be coupled to communications device with a wire or wirelessly).

In some embodiments, I/O circuitry 440 can include display circuitry (e.g., a screen or projection system) for providing a display visible to the user. For example, the display circuitry can include a screen (e.g., an LCD screen) that is incorporated in electronics device 100. As another example, the display circuitry can include a movable display or a projecting system for providing a display of content on a surface remote from heliostat computer 400 (e.g., a video projector). In some embodiments, the display circuitry can include a coder/decoder (Codec) to convert digital media data into analog signals. For example, the display circuitry (or other appropriate circuitry within the heliostat computer 400) can include video Codecs, audio Codecs, or any other suitable type of Codec.

The display circuitry also can include display driver circuitry, circuitry for driving display drivers, or both. The display circuitry can be operative to display content (e.g., media playback information, application screens for applications implemented on the heliostat computer 400, information regarding ongoing communications operations, information regarding incoming communications requests, or device operation screens) under the direction of control circuitry 410. Alternatively, the display circuitry can be operative to provide instructions to a remote display.

Communications circuitry 450 can include any suitable communications circuitry 450 operative to connect to a communications network and to transmit communications (e.g., voice or data) from heliostat computer 400 to other devices within a communications network. Communications circuitry 450 can be operative to interface with the communications network using any suitable communications protocol such as, for example, Wi-Fi (e.g., a 802.11 protocol), Bluetooth®, radio frequency systems (e.g., 900 MHz, 1.4 GHz, and 5.6 GHz communication systems), infrared, GSM, GSM plus EDGE, CDMA, quadband, and other cellular protocols, VOIP, ZigBee®, or any other suitable protocol.

In some embodiments, communications circuitry 450 can be operative to create a communications network using any suitable communications protocol. For example, communications circuitry 450 can create a short-range communications network using a short-range communications protocol to connect to other devices. For example, communications circuitry 450 can be operative to create a local communications network using the Bluetooth® protocol to couple heliostat computer 400 with a Bluetooth® headset.

Heliostat computer 400 can include one more instances of communications circuitry 450 for simultaneously performing several communications operations using different communications networks, although only one is shown in FIG. 8. For example, heliostat computer 400 can include a first instance of communications circuitry 450 for communicating over a cellular network, and a second instance of communications circuitry 450 for communicating over Wi-Fi or using Bluetooth®. In some embodiments, the same instance of communications circuitry 450 can be operative to provide for communications over several communications networks.

In some embodiments, heliostat computer 400 can be coupled to a host device for data transfers, synching the communications device, software or firmware updates, providing performance information to a remote source (e.g., providing riding characteristics to a remove server) or performing any other suitable operation that can require heliostat computer 400 to be coupled to a host device. Several heliostat computers 400 can be coupled to a single host device using the host device as a server. Alternatively or additionally, heliostat computer 400 can be coupled to several host devices (e.g., for each of the plurality of the host devices to serve as a backup for data stored in heliostat computer 400).

Communication between the heliostat computer 400 and a server may be accomplished through any suitable network that may be provided by one or more communication interface, for example, WLAN, WAN, or LAN connection. Specifically, by way of example, the network may be a wireless internet connection established by way of the WLAN interface, a local area network connection established through the LAN interface, or a wide area network connection established by way of the WAN interface, which may include one of various WAN mobile communication protocols, such as a General Packet Radio Service (GPRS) connection, an EDGE connection (Enhanced Data rates for GSM Evolution connection), or a 3G connection, such as in accordance with the IMT-2000 standard. One or more of the data encryption techniques and security protocols (e.g., SSL or TSL protocols) may be further utilized in order to facilitate the secure transmission of the transaction data to the server.

In one embodiment, as shown in FIG. 9, the solar furnace 100 can have at least one directional reflector 500 for altering the direction of the reflected radiant energy 106.

The solar furnace 100 can have a directional reflector 500 where an unobstructed linear path for the reflected radiant energy 106 to travel does not exist between the reflective surface 210 and the target 300. For example, where the reflected radiant energy 106 travels at a substantially horizontal path, a directional reflector 500 can be positioned in the path of the reflected radiant energy 106 at an angle that allows for the reflected radiant energy 106 to be reflected at a substantial vertical path. In one embodiment, the solar furnace 100 has a plurality of directional reflectors 500, where one directional reflector 500 reflects radiant energy 106 from at least one reflective surface 210.

In one embodiment, the solar furnace 100 can have a light pipe 600 for transporting or directing the reflected radiant energy 106 toward a target 300. The solar furnace 100 can have a light pipe 600 when an unobstructed linear path for the reflected radiant energy 106 to travel does not exist between the reflective surface 210 and the target 300. The light pipe 600 can have a cylindrical shape with openings in the first end and the second end of the cylinder, where the reflected radiant energy 106 enters the light pipe 600 through the opening in the first end and the reflected radiant energy 106 exits the light pipe 600 through the opening in the second end. The interior surface of the light pipe 600 can be lined with reflective material thereby allowing the reflected radiant energy 106 to reflect through the light pipe 600.

In one embodiment, the light pipe 600 can have a collector 610 for capturing reflected radiant energy 106 and directing the reflected radiant energy 106 into the light pipe 600. The collector 610 can have at least one surface for directing reflected radiant energy 106 toward the opening in the first end of the light pipe 600. The collector 610 can engage the first end of the light pipe 600 and has a reflective surface for reflecting radiant energy 106 through the opening in the first end of the light pipe 600.

The reflected radiant energy 106 is reflected through the first end of the light pipe 600 and travels through the light pipe 600 by reflecting off the reflective interior surface of the light pipe 600. The second end of the light pipe 600 is oriented toward the target 300 thereby allowing for the reflected radiant energy 106 to exit the light pipe 600 through the second end and impinge the target 300.

In one embodiment, the light pipe 600 is positioned such that the second end of the light pipe 600 is in close proximity to the target 300 thereby causing the amount of reflected radiant energy 106 impinging on the target 300 after exiting the light pipe 600 to increase. In this embodiment, the target 300 can be stationary or moving. Where the target 300 is moving, for example, a target 300 on a conveyer belt, a plurality of targets 300 can be positioned in close proximity to other targets 300 thereby ensuring maximum utilization of the available reflected radiant energy 106 exiting the light pipe 600 and impinging on the targets 300. For example, a target 300 on a conveyor belt is placed in close proximity to another target 300 on the conveyor belt.

In one embodiment, the light pipe 600 is positioned such that the second end of the light pipe 600 touches or is in direct contact with the target 300 thereby allowing for the maximum amount of reflected radiant energy 106 to impinge on the target 300 after exiting the light pipe 600. For example, where the target 300 is a blow molding auger or injection molding auger, the second end of the light pipe 600 touches the auger thereby increasing the amount of reflected radiant energy 106 impinging the auger.

In one embodiment, as shown in FIG. 10, the solar furnace 100 can have a recapture area 700 for reflecting radiant energy 106 that does not impinge the target 300 after exiting the light pipe 600 toward the target 300. The recapture area 700 can have at least one sidewall 710. The interior surface of the sidewalls 710 is lined with reflective material allowing for the reflection of radiant energy 106. While the recapture area 700 can be any size that encompasses a target 300, the recapture area 700 is preferably large enough to contain a rotational molding mechanism. While sidewalls 710 of the recapture area 700 preferably make the shape of a circular paraboloid, the sidewall 710 can make any shape, for example, semi-circular paraboloid, a square, rectangle, polygon, or the like. Where the sidewalls 710 are positioned in the shape of a circular paraboloid, the target 300 is preferably positioned at the focal point of the circular paraboloid sidewalls 710.

The target 300 is placed into the recapture area 700 and positioned at the focal point of the circular paraboloid. Upon exiting the second end of the light pipe 600, radiant solar energy 102 enters the recapture area 700. Some of the reflected radiant energy 106 impinges the target 300 while some of the reflected radiant energy 106 passes to the side, above, or below the target 300 thereby passing the target 300. The reflected radiant energy 106 that passes the target 300 reflects off the reflective material on the sidewalls 710 towards the target 300 and impinges the target 300. In one embodiment, the reflected radiant energy 106 can reflect off the reflective material on multiple the sidewalls 710 before impinging the target 300.

The foregoing has described the principles, embodiments, and modes of operation of the present invention. However, the invention should not be construed as being limited to the particular embodiments described above, as they should be regarded as being illustrative and not as restrictive. It should be appreciated that variations may be made in those embodiments by those skilled in the art without departing from the scope of the present invention.

Modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described herein.

Claims

1. A solar furnace for heating a target comprising:

a heliostat having: a reflective surface having a reflective portion, a surface altering mechanism capable of altering the shape of the reflective portion, and

a target having a target area,

the reflective surface capable of reflecting radiant energy toward the target.

2. The solar furnace of claim 1 wherein the surface altering mechanism allows for the alteration of the size of the target area.

3. The solar furnace of claim 1 wherein surface altering mechanism allows for the reflected radiant energy to impinge upon a target area at various distances from the reflective surface.

4. The solar furnace of claim 1 wherein the heliostat has a plurality of surface altering mechanisms capable of altering the reflective surface to a multi-curved shape.

5. The solar furnace of claim 4 wherein the target comprises a plurality of target areas, and the heliostat comprises a first surface altering mechanism capable of altering the shape of a first reflective portion and a second surface altering mechanism capable of altering the shape of a second reflective portion, the first reflective portion capable of reflecting radiant energy toward a first target area and the second reflective portion capable of reflecting radiant energy toward a second target area.

6. The solar furnace of claim 1 wherein the solar furnace has a plurality of heliostats capable of reflecting radiant energy toward a target area.

7. The solar furnace of claim 6 wherein the target comprises a plurality of target areas, and the solar furnace comprises at least one first heliostat capable of reflecting radiant energy toward at least one first target area and at least one second heliostat capable of reflecting radiant energy toward at least one second target area.

8. The solar furnace of claim 6 wherein the surface altering mechanism of the at least one first heliostat allows for at least one first target size and the surface altering mechanism of the at least one second heliostat allows for at least one second target size.

9. The solar furnace of claim 1 wherein the heliostat further comprises a failsafe mechanism capable of decreasing the amount of wind captured by the reflective surface.

10. The solar furnace of claim 1 further comprising a directional reflector capable of altering the direction of the radiant energy reflected by the reflective surface.

11. A solar furnace for heating a target comprising:

at least one heliostat having a reflective surface having a reflective portion, and

a target having at least one target area,

the reflective surface capable of reflecting radiant energy toward a target area, an at least one first reflective surface capable of reflecting radiant energy toward an at least one first target area, and an at least one second reflective surface capable of reflecting radiant energy toward an at least one second target area.

12. The solar furnace of claim 11 wherein the at least one first target area has a first target size and the at least one second target area has a second target size.

13. The solar furnace of claim 11 further comprising a directional reflector capable of altering the direction of the radiant energy reflected by the reflective surface.

14. A solar furnace for heating a target comprising:

a heliostat having a reflective surface having a reflective portion, the reflective surface capable of reflecting radiant energy, and

a light pipe capable of receiving the reflected radiant energy and directing the reflected radiant energy toward a target.

15. The solar furnace of claim 14 further comprising a collector capable of directing the reflected radiant energy into the light pipe.

16. The solar furnace of claim 14 further comprising a recapture area having a plurality of sidewalls defining the periphery of the recaptured area, the sidewalls lined with a reflective surface capable of reflecting radiant energy toward the target.

17. A method of heating a target utilizing a solar furnace comprising the steps of:

loading a quantity of moldable material into a target,

altering the shape of a reflective surface utilizing a surface altering mechanism,

reflecting radiant energy toward the target area of the target,

heating the target area with the reflected radiant energy, and

removing the molded product from the target.

18. A method of claim 19 further comprising the step of placing a target in the focal point of a reflective surface of a heliostat.

19. A method of claim 19 further comprising the steps of:

placing a target in close proximity to a second end of a light pipe, and

reflecting radiant energy toward a first end of a light pipe.

20. A method of claim 19 further comprising the steps of:

touching a target to a second end of a light pipe, and

reflecting radiant energy toward a first end of a light pipe.

21. A method of claim 19 further comprising the step of reflecting radiant energy toward a collector.

22. A method of claim 19 further comprising the step of placing a target in a recapture area having a plurality of sidewalls defining the periphery of the recaptured area, the sidewalls lined with a reflective material capable of reflecting radiant energy toward the target.

23. A method of claim 19 further comprising the step of reflecting radiant energy toward a directional reflector.

24. A method of claim 19 further comprising the step of orientating, using a microprocessor, the reflective surface.

25. A method of claim 19 wherein the step of altering the shape of a reflective surface utilizing a surface altering mechanism is performed using a microprocessor.