Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02727328 2011-01-10
SINGLE FACE CORRUGATED PLASTIC OR ALUMINUM SOLAR
COLLECTOR
This application claims priority to Provisional Application 61/293,641 filed
on 01/09/2010, the entire disclosure of which is incorporated by reference.
TECHNICAL FIELD & BACKGROUND
There are basically three types of solar heating systems today available
on the market. The first system involves photovoltaic cells that convert
sunlight to
electricity via a silicon reaction. This system has high potential for the
future with
numerous applications. At the present time, homes that use this type of solar
system are still expensive, with a typical mass-produced system still costing
$40.00 per square foot. Installation requires electricians, structural
advisers or
architects making installation expensive, which results often in a $50,000
dollar
home owner investment for a return of $1,000 per year in energy savings. The
second type of solar heating system involves parabolic mirrors that are
computer
controlled to utilize an accurate focal point of the sun to superheat water
resulting
in steam generated electricity. This type of system has limited use at this
time
and is primarily confined to commercial and government experimental projects.
The third type of system is a hydro-thermo system that sits in the sun and
transfers the sun's heat into water through a circulation pump. These are
medium
cost systems that use copper tubing and extruded tubular plastic sheets to
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circulate water in sunlight to heat pools or hot water tanks. Installation for
this
type of system requires electricians, plumbers and structural engineers and a
complete system typically cost $20,000 per installation. Since this system is
limited in energy usage, the return on investment is about $500.00 per year at
best. All 3 systems require professional installation crews and regular
maintenance.
What the market really needs is a solar collector that has a positive return
on investment within three years. It may be great to be green and save the
planet
however it must also be affordable and worthwhile. The solar panel hot air
heater
achieves this by maximizing efficiency, simplicity of installation and low
initial cost
with no maintenance.
The invention relates to the design of a solar collector that has a very
positive return on investment. All existing green energy systems tend to have
a
large initial cost and require professional installation. The net result is
that most
other green and solar systems are limited to utilities or government
institutions.
This solar heater design is affordable, shippable, can easily be installed and
delivers sufficient energy to pay for itself in less than a couple years.
The method used is to take advantage of low cost single-faced corrugated
plastic or aluminum. Single-faced corrugated plastic or aluminum already has
the
solar advantage of maximum surface area by virtue of the corrugation. The
sealed solar collector also facilitates air flow within the corrugation to
extract
heat. The invention incorporates photovoltaic cell powered blower units to
create
and maintain air flow in an interlaced pattern within the corrugations. This
self-
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powering solar collector then delivers hot air to modified clothes dryers, pre-
heat
fresh air intake to furnace, swimming pools, heat pumps, direct heat for
buildings
and other self-powered solar heater settings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described by way of exemplary
embodiments, but not limitations, illustrated in the accompanying drawings in
which like references denote similar elements, and in which:
Figure 1 illustrates an environmental perspective view of a house
incorporating the single-side corrugated solar collector system, in accordance
with one embodiment of the present invention.
Figure 2 illustrates an overhead perspective view of a single-side
corrugated plastic or aluminum sheet rolled out using a standoff anchor,
deflection brackets and blower brackets, in accordance with one embodiment of
the present invention.
Figure 3 illustrates a cut away top side perspective view of a blower
bracket with deflection brackets in combination with the single-side
corrugated
plastic sheet, in accordance with one embodiment of the present invention.
Figure 4 illustrates a cut away top side perspective view of a deflection
bracket that utilizes a cut-out exposing seal tooth method, in accordance with
one embodiment of the present invention.
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Figure 5 illustrates a side perspective view of a blower bracket exposing
the interior seals and motors of a fan, in accordance with one embodiment of
the
present invention.
Figure 6 illustrates a top side perspective view of an assembled
redirection blower bracket with photovoltaic panels, in accordance with one
embodiment of the present invention.
Figure 7 illustrates a side perspective view of a corrugated plastic or
aluminum sheet, deflection brackets and a clear plastic cover sheet
windshield,
in accordance with one embodiment of the present invention.
Figure 8 illustrates a top side perspective view of a stand-off anchor used
in combination with a single faced corrugated plastic or aluminum solar
collector,
in accordance with one embodiment of the present invention.
Figure 9 illustrates a diagonal side perspective view of a clothes dryer
cover for the air intake of a single faced corrugated plastic or aluminum
solar
collector, in accordance with one embodiment of the present invention.
Figure 10 illustrates a cut away top side perspective view of an aeration
unit used in combination with a single faced corrugated plastic or aluminum
solar
collector, in accordance with one embodiment of the present invention.
Figure 11 illustrates a diagonal side perspective view of a duct work
booster fan used in combination with a single faced corrugated plastic or
aluminum solar collector, to pre-heat fresh air intake or heat building, in
accordance with one embodiment of the present invention.
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Figure 12 illustrates a diagonal perspective view of an aluminum version
of the corrugated solar collector and how the aluminum corrugations and closed
cell foam base, are uniquely assembled to achieve a greater efficiency per
square foot, in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
Various aspects of the illustrative embodiments will be described using
terms commonly employed by those skilled in the art to convey the substance of
their work to others skilled in the art. However, it will be apparent to those
skilled
in the art that the present invention may be practiced with only some of the
described aspects. For purposes of explanation, specific numbers, materials
and
configurations are set forth in order to provide a thorough understanding of
the
illustrative embodiments. However, it will be apparent to one skilled in the
art that
the present invention may be practiced without the specific details. In other
instances, well-known features are omitted or simplified in order not to
obscure
the illustrative embodiments.
Various operations will be described as multiple discrete operations, in
turn, in a manner that is most helpful in understanding the present invention.
However, the order of description should not be construed as to imply that
these
operations are necessarily order dependent. In particular, these operations
need
not be performed in the order of presentation.
The phrase "in one embodiment" is used repeatedly. The phrase generally
does not refer to the same embodiment, however, it may. The terms
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"comprising", "having" and "including" are synonymous, unless the context
dictates otherwise.
Figure 1 illustrates an environmental perspective view of a house (1) with
single-faced corrugated solar collectors (3) on the roof of the house (2), in
accordance with one embodiment of the present invention. These solar
collectors
(3) are in a series and /or parallel configuration. The design advantage of
the
single-faced corrugated solar collectors (3) is that they have multiple
possible
configurations in series, in parallel or in series and parallel of varying
lengths. In
northern climates, a continuous solar collector (3) has a distinct advantage
of
having an accumulated temperature increase. The intake air (4) is recommended
to be sourced from the highest ceiling for maximum efficiency, though fresh
outside air or other sources are acceptable. The intake air (4) enters via a
blower
assembly (20) that is powered by photovoltaic cells (34) and circulates
through
the singled-faced corrugated solar collector (3) where it gets heated by the
sun
and exits as exhaust air (5). The exhaust air (5) then travels via
distribution
tubing (14) where it is distributed for use. The tubing (14) is recommended to
travel to the duct booster assembly (13). The duct booster assembly (13) is
electrically connected to the household electrical system. The duct booster
assembly (13) uses the extra power advantage of the household electrical
system that can push a high volume of air throughout the house (1) via the
duct
work (12), supplementing the furnace (15) by pre-heating the fresh air intake.
The exhaust air (5) may also travel via the tubing (14) to a clothes dryer
(8), where a custom dryer cover (16) creates a closed air intake to the dryer
(8).
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The advantage is the hot air from the solar collector (3) is the primary
source of
heat for drying clothes. Simply placing the dryer (8) on air dry during sunny
days
will result in the dryer (8) utilizing the existing blower motor (21) to boost
the solar
collector (3) and the exhaust air (5) through the dryer (8). The exhaust air
(5)
may also be directed via tubing (14) to a swimming pool (6) and a hot tub (7),
where the exhaust air (5) is simply blown into the water (17) through aeration
to
heat the pool (6) or the hot tub (7).
The exhaust from the solar collector (3) can also supplement the operation
of heat pump (73). In much colder temperatures heat pumps (73) become very
inefficient. At temperatures above freezing the heat pump (73) can have 300
percent efficiency. However, the lower the outside ambient temperature reaches
the lower the efficiency of the heat pump (73). The result will eventually
enter the
negative in efficiency range.
By marrying the two technologies the solar collector (3) can raise the outside
ambient air temperature from well below freezing to a level above freezing,
whereupon the heat pumps efficiency can raise the temperature to greater
levels
required for a hot water tank (72), or for any other requirement.
Figure 2 illustrates an overhead view of a solar collector (3) with a criss-
cross air flow pattern (22), in accordance with one embodiment of the present
invention. The solar collector (3) is assembled with the positioning of the
first
blower motor (21) at the front of the criss-cross pattern (22). The air
crosses the
individual corrugations (30) to the opposite side of the solar collector (3).
On the
opposite side of the solar collector (3), air flow is redirected through a
redirection
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bracket (25) where air flow crosses back over across the solar collector (3).
Air
flow reaches the opposite side and is again redirected via a redirection
bracket
(25) and crosses over again and is again redirected via redirection bracket
(25).
Eventually, the air flow and air pressure diminishes due to resistance and
friction.
Redirection booster blowers (47) can increase air flow and pressure at regular
intervals. These redirection blowers (47) suck air in as well as push air
outward.
By positioning the redirection blowers (47) at the criss-cross pattern (22),
the air
flow remains maximized at minimal pressure. By maintaining maximum air flow
volume at the criss-cross pattern (22), there is an efficiency gain as the
internal
air flow is forced to cover every square inch of the solar collector for full
heat
transfer from individual corrugations (30).
The blower assembly (20) completes the air flow at the solar collector (3)
by giving solar heated air a final push towards another solar collector (3) to
exit
as exhaust air (5). The blower assembly (20) is powered by photovoltaic cells
(34). This is a passive system that powers air flow automatically as the sun's
rays
hit the photovoltaic cells (34) and solar collector (3) in unison. The
advantage is
that the installation and future maintenance omits any external power source
or
sensor system. Research has discovered that, as you approach the polar areas
of the earth, the sun's angle striking the earth, is reduced substantially,
especially
during the winter solstice. The result is that the material of the solar
collector (3),
even at high noon with no air flow, is reduced in temperature. However the
design of the solar panel (3) with its criss-cross pattern, actually
accumulates
heat as air moves across the solar collector (3). The result is that air flow
on a
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sixty foot long panel has actually travelled 240 feet and has been found to
have a
resulting increase in exit temperature of twenty percent more than the solar
collector's (3) inert temperature. This is an advantage that can be accessed
by
configuring the solar collector (3) for maximum air flow distance. At the
equator,
the solar collector (3) should be configured and combined in parallel. The
result
is that you still have air volume and surface coverage, but not the extreme
temperature that may result in loss of material integrity and/or safety.
Figure 3 illustrates a cut away top side perspective view of the solar
collector (3), in accordance with one embodiment of the present invention. It
has
on one side a view of a blower assembly (20) and on the opposite side a cross-
sectional view of a redirection bracket (25). Air is powered through the
blower
assembly (20) and fills the bracket air cavity (31) with air. The air is then
defused
via a series of individual corrugations (30) and crosses over to the
directional
bracket (25). The air flows into the bracket air cavity (31) of the re-
directional
bracket (25) and air flow passes down the bracket air cavity (31) where the
second half of the bracket air cavity (31) forces the air through an opposing
series of individual corrugations (30) back across the solar collector (3). To
enclose the solar collector (3), a clear plastic sheet windshield (28) covers
and
encloses the individual corrugations (30). This boxing effect of the
windshield
(28) creates a closed environment that insulates the individual corrugations
(30)
from any wind robbing effect. The windshield (28) is anchored to the solar
collector (3) via a standoff fastener (18). The standoff fastener (18) anchors
the
solar collector (3) to the roof (2) at the center of the solar collector (3).
This
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allows the individual corrugations (30) to expand into the redirection
brackets
(25) during hot sunny days and contract on cool nights. The stand-off fastener
(18) then supports the windshield (28). The windshield (28) is fastened to the
stand-off fastener (18) via a windshield fastener (32). The windshield (28),
by
being anchored in the center can also expand outward to the redirection
brackets
(25) by a retaining lip (27) that secures the edges of the outside edge of the
windshield (28). This still allows movement for expansion and contraction
within
the retaining lip (27). The center standoff fastener (18) keeps the windshield
(28)
from waving, buckling and breaking due to material movement. Any waving or
buckling would compromise the solar collector's (3) air seal.
The individual corrugations (30) move in and out of the redirection
brackets (25) while maintaining a constant seal of air within the bracket air
cavity
(31). The seal is maintained by a corrugated tooth seal (26) that is shaped to
match the individual corrugations (30). The pressure of the corrugated tooth
seal
(26) against the individual corrugations (30) is sufficient to maintain air
pressure
within the bracket air cavity (31). The individual corrugations (30), however,
still
have enough room to expand and contract. This corrugated tooth seal (26)
provides for internal air pressure within the individual corrugations (30) and
the
bracket air cavities (31) are maintained within seven pounds per square inch
of
atmospheric pressure even though the individual corrugations (30) expand and
contract. This design is required to maintain internal air integrity within
solar
collector (3) sizes that can exceed 50 feet or more. The cross-section of the
redirection bracket (25) has sandwiched the corrugated tooth seal (26) between
CA 02727328 2011-01-10
an inside tooth seal support (39) and an outside tooth seal support (40). When
the end user or installer combines the closed corrugated tooth seal (26) with
a
silicon sealer to create a flexible bond between the closed corrugated tooth
seal
(26) and the individual corrugations (30), a sufficient air seal is created.
Even
over a distance of 50 feet or more, the redirection brackets (25), the
corrugated
tooth seal (26) and the individual corrugations (32) work in combination to
keep
hot solar heated air within the bracket air cavity (31).
The blower assembly (20) is designed in combination with the redirection
bracket (25) with the added feature of a blower motor (21) that is powered by
photovoltaic cells (34). These blower motors (21) initiate air flow through
the
bracket air cavities (31) and individual corrugations (30). The air flow is
subsequently boosted at sufficient intervals by succeeding blower motors (21)
in
order to maintain maximum air flow with minimal pressure. In the cross-section
of
the redirection bracket (25), it can be seen that the corrugated tooth seals
(26)
are held in place by an inside corrugated tooth support (39) and by an outside
corrugated tooth support (40). It is noted that the outside tooth support (40)
is
designed shorter to allow for insertion of the closed corrugated tooth seals
(26).
The outside tooth support (40) is extended longer to create a stronger support
possible for the corrugated tooth seal (26). The redirection bracket (25) also
has
an outside tooth support (40) in order to facilitate and simplify the
insertion of the
redirection bracket (25) into the individual corrugations (30) during
assembly. The
bracket base extension (43) supports the individual corrugations (30) while
pressure is applied upward to the redirection bracket (25) opening the
corrugated
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tooth seal (26) for easy insertion of the individual corrugations (30).
Releasing
the upward pressure on the redirection bracket (25) also creates a spring
tight
pressure seal.
Figure 4 illustrates a cut away top side perspective view of a redirection
bracket (25) that has a cut-out exposing the closed corrugated tooth seal
(26), in
accordance with one embodiment of the present invention. The corrugated tooth
seal (26) is precisely patterned to match the individual corrugations (30) for
maximum seal. To accommodate future maintenance and wear and tear, the
corrugated tooth seal (26) has teeth on both sides. The corrugated tooth seal
(26) can also be removed and reinserted upside down to form and secure a new
seal. The individual corrugations (30) are exposed to any air flow and the
redirection bracket (25) has a bracket anchor (41) that is secured with a
plurality
of bracket anchor screws (42).
Figure 5 illustrates a side perspective view of the blower assembly (20), in
accordance with one embodiment of the present invention. The blower assembly
(20) includes a redirection bracket (25) with blower enclosure cut-outs (46)
on
either side. Near the blower enclosure cut-out (46) in the center of the
directional
bracket (25) is a redirection bracket seal (44) that stops air flow through
the
bracket air cavity (31). With the bracket air cavity (31) sealed, the air is
redirected
through the blower enclosure cut-outs (46) and enters the blower cover (45).
For
the purpose of better understanding, the blower cover (45) is divided into its
two
halves. This view exposes the blower motor (21) that is sealed inside with the
air
flow (33) clearly indicating the function of the blower motor (21).
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Figure 6 illustrates a top side perspective view of a blower assembly (20),
following the air flow (33) passing through the individual corrugations (30)
and
entering the redirection bracket (25), in accordance with one embodiment of
the
present invention. The air is drawn into the redirection blower assembly (47)
and
into the blower motor (21). The blower motor (21) also pushes air forward
through the opposite side of the redirection bracket (25). A rubberized air
seal
(44) is drawn on the outside of the redirection bracket (25) with arrows
indicating
its intended location. There are also expansion end seals (24) that are
positioned
between the redirection brackets (25) to absorb any linear expansion of
redirection bracket (25). The redirection brackets (25) are anchored via
bracket
anchor screws (42) in the center of the redirection bracket (25). This way the
redirection brackets (25) expand outward from the center into the expansion
end
seals (24). This avoids an accumulation of expansion of redirection bracket
(25)
which may easily add unwanted length. There is also a photovoltaic cell
assembly (36) which is an accumulation of photovoltaic cells (34) attached to
a
solstice adjustment hinge (38). The solstice hinge (38) makes adjustments to
the
photovoltaic cells (34) according to the sun's angle during the different
solstice
cycles.
Figure 7 is a cross-sectional view of a solar collector (3) on both sides of a
directional bracket (25), in accordance with one embodiment of the present
invention. Figure 7 illustrates the attachment method of the individual
corrugations (30) and the attachment of the windshield (28) to the directional
brackets (25). The individual corrugations (30) are held via the corrugated
tooth
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seal (26) using the pressure of the directional bracket (25). The tooth seal
(26) is
supported by an inside tooth seal support (39) and an outside tooth seal
support
(40). The windshield (28) is held to the directional brackets (25) via a
retaining
bracket lip (27). This retaining bracket lip (27) holds the windshield (28)
securely
and still provides for expansion and contraction. There is also a standoff
anchor
(18) which has an internal screw (49) that anchors to the base of the stand-
off
anchor (18), sandwiching the individual corrugations (30) to a given
attachment
surface. The windshield (28) is then fastened by a screw (32) into the
standoff
anchor (18). The complete solar collector (3) is anchored to the roof (2) or
surface area by bracket anchor screws (42) at the base of the standoff anchor
(18).
Figure 8 illustrates a top side perspective view of a unique standoff anchor
(18) that allows an installer to sandwich two separate layers together without
having access to a previous layer, in accordance with one embodiment of the
present invention. Existing anchor technology requires access to a first layer
from above or below the layer in some way or another. By having the standoff
anchor (18) fastener inside, the installer can install the standoff anchor
(18) more
easily. The process begins by screwing the standoff anchor (18) and the
individual corrugation (30) into the roof (2) or surface area using an
internal 20
anchor screw (49). The stand-off anchor (18) accommodates the windshield (28)
and the windshield fastener (32). Without any effort, the windshield fastener
(32)
can be threaded into the stand-off anchor (18) to secure the windshield (28).
A
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standoff anchor indent (48) is placed in the individual corrugation (30) to
precisely position the stand-off anchor (18).
Figure 9 illustrates a diagonal side perspective view of a clothes dryer
cover (16) that can direct solar heated air from the solar collector (3) by a
dryer
tube (9) into the dryer air intake, in accordance with one embodiment of the
present invention. The clothes dryer (8) typically uses an electric element or
gas
burner to heat air and dry clothes. The clothes dryer (8) also has the option
of air
drying without using any electric or gas heat. By placing the clothes dryer
(8) in
air dry mode on a sunny day, the clothes dryer (8) would automatically take
advantage of the heated solar air to dry clothes. A gained advantage is that
the
clothes dryer (8) has its own built-in air blower that will boost the air
volume and
pressure. The clothes dryer cover (16) also has dryer cover imprints (29) at
appropriate locations to mark any dryer exhaust depending on machine and
model.
To further strengthen the windshield (28) a hard wire truss (65) is
connected to the standoff anchor (19). The method for connecting the hard wire
truss (65) to the standoff anchor (19) is by creating a spring effect that
holds the
truss (65) at the top of the standoff anchor (60) and at the bottom of the
standoff
anchor (64). The standoff anchor (18) has a hole (62) by which the truss is
inserted to lock it into position and a groove (61) is formed into the top of
the
standoff anchor (60) to guide the direction of the truss. The resulting
sandwiching
of the standoff anchor (18), truss (65) and corrugations (30) binds the truss
securely at the standoff anchor base (64). The sandwiching of the standoff
CA 02727328 2011-01-10
anchor (18), truss (60) and the windshield (28) binds the truss (65) at the
top of
the standoff anchor (60). The result is a support for the span of the
windshield
(28) that does not interfere with windshield (28) contraction and expansion.
Figure 10 illustrates a unique aeration heater (50) that uses aeration to
heat a pool or any water source, in accordance with one embodiment of the
present invention. The aeration heater (50) fills with water to weigh down the
unit
even with air flow. The base can also be filled with sand or other heavy
material
to the water level (54). This will keep the aeration heater (50) submerged
when
air is injected. Air is injected through an air inlet (53) and is released in
the water
as fine hot air bubbles through the minute orifices (55). Heat transfer from
bubbles to water is strictly conductive. This is a very low cost but unique
solution
to the expensive, high energy consuming heat exchangers.
Figure 11 illustrates a duct booster assembly (13) which has an electric
AC motor (59) that is plug-in ready, in accordance with one embodiment of the
present invention. A regular electric cord and plug (58) powers this unit
without
the need for an electrician. The duct booster assembly (13) has a temperature
sensor switch (57) that can be positioned at any location in the hot air
exhaust
tube (10). The hot air that is being pushed down from the solar collector (3)
by
the photovoltaic powered blower assemblies (20) trigger the temperature sensor
(57) and activate the electric AC motor (59). The fan blades (60) can then
thrust
the hot air through the duct work (12) to heat the house (1). A house
thermostat
(56) can be set to limit house heat at a preset temperature. The advantage of
this
is that the duct booster assembly (13) is completely automatic, turning on and
off
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based on deliverable usable hot air from the solar panel (3). It is understood
that
in Northern climates the temperature outside may be 20 below zero on a sunny
day and the solar collector (3) may only raise the temperature to 60 degrees
Fahrenheit. The duct booster assembly (13) would not activate in this scenario
because the usable hot air preset temperature is 70.5 degrees and 60 degrees
would cool the house down. Again this emphasizes the advantage of using a
heat pump (73), married to a solar collector (3) for maximum advantage at much
lower temperatures. The duct booster assembly can also be used to pre-heat the
fresh air intake to the building. Most buildings houses, hospitals, apartment
buildings as an example require fresh air verses re-circulating indoor
polluted air.
The solar collector with booster assembly can pre-heat fresh outdoor air
making
the indoor heating system more efficient.
Figure 12 illustrates the unique design advantage of the aluminum version
of this solar collector, in accordance with one embodiment of the present
invention. With the plastic corrugated solar collector the corrugations (30)
and
base are plastic welded together in a single continuous action. With the
aluminum version the aluminum corrugations (69) are adhered to a closed cell
foam base (71). The closed cell foam base (71) creates the air seal and
insulates
the air and aluminum from the roof surface (2). To seal the air where the re-
directional bracket (25) meets the aluminum corrugations (69), a rubberized
filler
(70) is inserted between the aluminum ribs (68) to a width of approximately 1
inch. Covering the corrugated ribs (68) and rubberized seal (70) is a 2 inch
strip
of plastic or foam material (66). This 2 inch strip (66) acts as a flat
surface for the
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closed cell foam seal (67) to slide upon during expansion and contraction of
aluminum. In this manner the foam seal (67) does not require the matching
teeth
(26) that are present in the plastic version. Using this configuration the
aluminum
corrugations (69) can still be rolled up for shipping purposes in unlimited
lengths,
which is a key feature of the overhaul invention. The aluminum corrugation
(69)
is rated amongst the most conductive of heat and when combined with the
insulation gain of closed cell base (71) renders this invention highly
efficient. This
design will cost more per square foot, however it also has unique advantages.
The base of the solar collector is made of single-sided corrugated plastic
material. This material comes in rolls and can be cut to length. It is ideal
for
passing air through the interior and for absorbing solar heat. The result is
with the
right configuration the material can be used to create a low cost solar hot
air
generator. To achieve maximum result and complete surface coverage of
material, a criss-cross system was designed for the material. The air flows
into
the corrugation through a 12 inch blower intake. The air then crosses through
the
12 inch wide corrugation to the opposing side. On the opposing side a 24 inch
bracket accepts the air flow from the first 12 inch blower and directs the air
to the
second half of the 24 inch bracket. The air travels down the second 12 inches
to
another 24 inch bracket where the process repeats until the end of the
corrugation, where it exits hot from another 12 inch blower. Placing of more
blower units at various intervals allows air flow and heat transfer in longer
continuous lengths. The blowers also guaranty a relatively equal volume of air
to
all segments of the corrugation regardless of the configuration of the solar
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panels. Whether the panels are configured in series, parallel or combinations
of
series and parallel the air flow is equal throughout. A high powered booster
fan
can be hardwired to the house electrical system to assure sufficient air flow
for
house consumption. Using only the booster fan or any single suction or pushing
fan would result in air flow through the path of least resistance. Therefore
areas
of the solar collector would be neglected or receive minimal flow. The initial
blower unit that begins the air flow is a unique design that incorporates a
blower
motor that is powered by solar photovoltaic cells. The advantage is that the
blower activates when the sun hits the photovoltaic cells. This is ideal in
that the
same sun is now heating the corrugated plastics. This simplicity reduces
initial
cost and future maintenance cost. No need for complex sensors, or external
power required. This eliminates the needs for expensive electricians that are
required with other systems. The exit blower is also powered by its own solar
photovoltaic cells. This system can also continue to another corrugated sheet
as
often as required.
The corrugated plastic sheets are anchored to a roof or other solid surface
via fasteners at the center of the sheet at every predetermined interval that
is
equal to the width of the blower assembly and half the width of the deflection
bracket. These locations are imprinted in the manufacturing process to seal
the
air flow and simplify installation. Centering the anchoring system also allows
for
linear expansion of corrugated material towards the deflection brackets. The
brackets are designed to seal while allowing the corrugation movement for
expansions and contractions. Any expansion of material towards the ends is
19
CA 02727328 2011-01-10
absorbed in the corrugation by simply allowing the individual ribs to contract
in
and rise up. The anchoring system also anchors the top clear plastic sheet to
the
roof at its second level. This clear plastic sheet anchoring system also
allows for
clear plastic material to expand and contract with waving or other stress
concerns. The brackets on the sides are designed to redirect the air flow in
the
cross-over pattern. Each bracket is comprised of a single extrusion of plastic
with
incorporated claws that hold the closed cell foam teeth. At the top of the
extrusion is an over-hang lip that is designed to clamp the clear plastic
sheet
tightly while allowing the sheet to expand in and contract out. The extrusion
also
incorporates a base plate that extends beyond the front sufficient to secure
the
corrugated plastic while the top part of the bracket can be bent up to ease
insertion of the corrugated plastic under foam teeth. Release of the top of
the
bracket than applies sufficient force to seal air within the bracket interior
and
corrugation interior. The base of the bracket also extends past the cavity
sufficient in distance to accommodate an anchor, screw or other fastener.
Fasteners are to be located in the center of the bracket to allow for a secure
hold
in all wind conditions. Anchors can be located at the end of the brackets
provided
as long as they are not tightened to the point where they impede movement.
While the present invention has been related in terms of the foregoing
embodiments, those skilled in the art will recognize that the invention is not
limited to the embodiments described. The present invention can be practiced
with modification and alteration within the spirit and scope of the appended
CA 02727328 2011-01-10
claims. Thus, the description is to be regarded as illustrative instead of
restrictive
on the present invention.
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