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TO HEAT
EXCHANGER 1T0 VACUUM
U.S. Patent Sep. 15, 1981 Sheet 1 of2 4,289,113
/4
FLUID
2%
EXPANSION /0
SUPPLY TAN K
TI
HEATED
HOT WATER
USAGE
g?
TO HEAT
EXCHAN GER 1 TO VACUUM
U.S. Patent Sep. 15, 1981 Sheet 2 of2 4,289,113
4,289,113 2
1
linear, bar-type, first support system within the cham
EVACUATED FLAT-PLATE SOLAR COLLECTORS her, and, in the most preferred embodiment, an addi
tional second support system employing a plurality of
BACKGROUND OF THE INVENTION support dowels within the chamber.
Solar collectors are used in many applications to The structural support system of this invention is
collect solar energy and to convert it to heat. In recent formed by the nonlinear spacing of supports within the
years, such collectors have enjoyed increasing popular pan. The major supports comprise a plurality of ?anged
ity, because, once installed, they provide a relatively bars positioned within the pan substantially parallel to
cost-free source of hot water for domestic usage and for each other and the pan sides of longer dimensions. The
home heating. Generally, a collector consists of a glass support bars are arranged symmetrically with respect to
covered array of ?uid-filled tubes carried on a flat plate. the longitudinal center line, but in a nonlinear fashion,
The plates are designed to optimize the absorption of with the distance between the bars decreasing as the
radiant sunlight and thus the conversion of the energy supports extend outwardly towards the edges of the
into thermal energy in the fluid passing through the pan.
tubes. The fluid in the tubes is circulated through a In addition to the major support system, it has been
thermal capacitor where a heat exchange occurs. Heat, discovered that further structural support can be pro
usually in the form of hot water, subsequently may be vided by an arrangement of dowels or pins as point-sup
drawn from the capacitor, to provide for domestic port means along the edges of the pan sides of shorter
needs or to supplement traditional heating systems. dimensions. These pins are spaced apart from the edges
Development of solar-heating systems in the northern approximately the same distance as the closest support
portions of this country, however, has been hampered bar is spaced apart from the pan sides of longer dimen
by the problem of heat loss to the ambient air in the sions. Where a plurality of pins is used, it is preferable
collector and eventually to the outside air. The solu that the pins along such edge be placed on the pan in an
tions to this problem to date have been less than satisfac arcuate manner, with the pins nearer the center being
tory. Caulking of the frame may be employed, but the spaced slightly farther from the edge than those nearer
ambient air in the collector still will carry heat from the the corners.
collector plate to the glass cover where it will dissipate The principle of operation of the support system
to the outside. A plurality of glass plates also may be described above is believed to be based upon the ability
employed to retard heat loss; however, the more cover of a symmetrical, but nonlinear, arrangement of sup
plates, the greater fraction of sunlight is absorbed or 30 ports to dampen the harmonic vibrations of the glass
re?ected by them and the lesser percentage of solar cover before stress fractures occur. Such fractures are
energy is available to the collector plate. Thus, it would known to result from transient shocks associated with
be most desirable for a solar collector to be formed in a
temperature changes, pump start-up, seal leakage, etc.
manner, whereby heat loss would be minimized, yet, at One advantage of my evacuated collector and sup
the same time, maintaining a single-sheet, glass-cover 35 port system lies in the reduction of the glass-sheet thick
construction. ness required to cover the evacuated collector; for ex
SUMMARY OF THE INVENTION ample, typically less than i" in thickness or }" under
This invention relates to an improved, flat-plate, solar normal vacuum conditions of over 29" of pressure. By
collector and solar systems containing such collector, as reducing the glass thickness, economy of manufacture is
well as the process of manufacturing such a collector afforded, as well as improved performance of the col
and the method of using it. In particular, this invention lector system; that is, more energy will be transmitted
concerns evacuation of a sealed collected as a means of by a thinner sheet of glass.
reducing heat losses. More particularly, a structural For the purpose of illustration, my invention will be
support system is disclosed which permits thin, glass, 45 described in connection with the preferred embodi
cover sheets to withstand the stresses associated with ment; however, it is recognized that various changes
operation of the evacuated collector. and modifications may be made by those persons skilled
This invention relates to an evacuated, airtight, solar in the art, all within the spirit and scope of the inven
collector with a unique support system within the panel, tion. For example, the spacing of the supports will vary
to prevent fracture of the thin, transparent, glass sheet with the size of the collector, with one critical parame
through which radiant energy passes. The casing of the ter being not the exact spacing of the supports, but
collector panel may be constructed as a shallow, metal rather the symmetrical, nonlinear progression of sup
pan upon which a glass cover sheet is glazed and sealed. ports to the edges of the collector. Further, the support
The pan is formed with fully welded corners, to insure bars can be replaced by other structures, such as a series
that no leakage occurs from the pan, itself, and has at of pins spaced apart from each other at short intervals.
least three port holes: two for the header pipes of the Additionally, this invention may be practiced in pas
collector and one for the vacuum pump. The pump line sive solar applications, such as skylights and windows,
and header pipes are connected to the port holes in an where the space between two sheets of glass is to be
airtight manner. The collector plates sit within the pan, evacuated to minimize heat loss. In such passive appli
and, upon evacuation of the collector, heat loss from the cations, a similar support system may be employed with
plates to the outside environment is effectively mini~ a symmetrical, nonlinear progression of supports to the
mized. edges of the collector. In special applications, whether
The use of an evacuated solar panel with a glass passive or active, where the shape of the collector or
cover sheet places stress on the glass cover sheet and skylight or window is roughly square or circular, it may
subjects the glass to fracture. The invention concerns 65 be preferable to use a central pin and a series of concen
the use of a unique, glass-panel, support system for the tric square or circular support bars. In such cases, the
evacuated solar collector. In particular, the invention basic principle of symmetrical, nonlinear progression
involves an evacuated, solar-collector panel with a non still would be followed, with the distance between con
4,289,113
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centric squares or circles becoming smaller as the edge rial, such as chrome sulfate, nickel black, cupric oxide
is approached. or ebanol C," which maximizes sunlight absorption.
Furthermore, while the preferred method of con As can be seen in FIG. 2, the header pipers 48, oval
struction is to use a fully welded pan, other methods of tubes 44, the absorber plate 42 and the back plates 46
forming a casing, such as using a peripheral frame and a form an integrated collector-plate assembly, with slots
base element, are equally applicable. 60 and holes 62 fabricated in the absorber plate, to allow
BRIEF DESCRIPTION OF THE DRAWINGS the collector-plate assembly to slide over the structural
support system (discussed below) and rest in the evacu
FIG. 1 is a schematic diagram of a prior-art, solar ated chamber.
energy system; The preferred dimensions of the pan are as folllows:
FIG. 2 is a sectional, perspective view of the evacu length-76 inches; width34 inches; and depthl.25
ated solar collector of the invention; inches. It is also preferred that the pan be constructed
FIG. 3 is a top plan view of the solar collector; and with a 1.0-inch land on top upon which the glass cover
FIG. 4 is a sectional view along line 44 of FIG. 3.
may be glazed.
DESCRIPTION OF THE EMBODIMENTS As the result of a series of stress-fracture tests, it has
Referring to FIG. 1, there is shown a prior-art, solar been discovered that ?ve, properly placed, internal
energy system 10 utilizing fluid~type solar collectors 12. stays or longitudinal, flanged bars 50 can support the
Fluid is initially introduced into the collector from an glass cover 56 in a system of the dimensions described
outside source 14. In the collector, the ?uid is heated above. The preferred shape of the internal stays is an
and then is circulated via pump 16 to the heat capacitor inverted T bar, with the ?anged base resting in the
24 where heat is exchanged by an exchanger 18; for pan and the top of its stem contacting the glass cover.
example, a copper coil or ?nned tube immersed in the Other bar shapes, such as triangular bars, also may be
heat capacitor 24. The collector ?uid, depleted of heat, employed.
is returned to the collector for another cycle. The fluid The conventional engineering solution to the prob
circulator system is typically also provided with an lem of staying a ?at surface is to apply a formula such
expansion tank 20 and a release valve 22. The ?uid used as:
in the collector may be water, oil or solutions of ethyl
ene glycol or propylene glycol.
Once the heat capacitor 24 is charged, it may be used 30
to provide for domestic needs. Water for domestic
usage or space heating 28 can be heated by circulating
it via pump 26 to the heat capacitor 24. At the capacitor where S is the distance between stays; t is the thickness
24, the water is heated using a second heat exchanger 36 of the ?at surface; P is the pressure or load to be sup
and then is put to use. In most systems, an auxiliary, 35 ported by the surface; and C is a constant which insures
conventional heater 30, with attendant valves 32 and 34, dimensional consistency and is dependent on a number
is also connected to the system to provide a standby of factors, such as the material comprising the ?at sur
heating source. face, its elasticity, etc. It should be noted that the as
With reference to FIGS. 2 and 3, the evacuated solar sumption in conventional engineering practice is that a
collectors 12 and support system 50 of my invention are 40 plurality of uniformly spaced stays are necessary. Under
shown in the preferred embodiment. The evacuated such an analysis, I have found that as many as eight
chamber is formed by a shallow metal pan 40 and a glass longitudinal bars might be necessary to stay the glass
cover 56 glazed thereon, using a vacuum-tight sealant cover of my evacuated solar collector.
or gasket material 58. The pan 40 requires three ports, I have discovered, however, that the number of stays
two of which receive the header pipes 48 which pro 45 needed to support the glass cover can be unexpectedly
vide for fluid passage in and out of the collector, and the reduced by placing the stays in the collector in a nonu
third port receives the piping 54 from the vacuum niform fashion. The advantages of reducing the number
pump. Each of the ports are ?tted with such gaskets, as of stays are twofold in that economy of manufacture is
known in the art, to insure an airtight operation. A achieved and the effective heat-absorbing surface area
vacuum pump of known construction (not shown) is of the collector is increased.
used to provide evacuation. A pump with a power-rat As the result of a series of tests conducted on tem
ing of 0.3 horsepower or more is preferred, and it has pered glass of dimensions of 76" X 34" X 0125 (2/l6) at
been found that such a pump can provide a 99.9% vac a pressure of 15 psi, it was found that ?ve internal,
uum which is deemed more satisfactory then lesser continuous, longitudinal stays (about 70" long) would
vacuums. 55 provide the necessary support, so long as they were
As can be seen from the ?gures, particularly FIG. 2, placed in a symmetrical, but nonlinear, arrangement as
an assembly of metal piping and heat-absorbing plates follows: one along the longitudinal center line; a set of
sits within the evacuated chamber. The header pipes 48 two, each being 7 in from the center line; and a second
are typically constructed from an 0.5-inch copper tub
set of two, each being 6%" from the corresponding num
ing and are connected to each other by a plurality of
smaller tubes 44. Preferably, these tubes are 0.25-inch
ber of the ?rst set and 3%" from the inner edge of the
copper pipes pressed into an oval shape and silver-sol pan. The following table summarizes this relationship:
dered to the header pipes 48. The oval tubes 44 are TABLE I
sandwiched by an upper absorbing plate 42 and lower
back plates 46, which are spot-welded together to pinch 65 (for a glass sheet 76">< 34- X0125")
tightly the oval tube therebetween. The absorbing plate cz'l
42 and back plates 46 may be constructed of copper, and b=6.5"
the absorbing plate is preferably ?nished with a mate a=3.5"
4,289,113
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As can be seen from FIG. 4, c is the distance from the inch thick be employed as added protection against
central stay to the ?rst set of stays; b is the distance from
stress fractures.
the ?rst set to the second set of stays; and a is the dis What I claim is:
tance from the second set of stays to the inner edge of 1. In a solar collector for the conversion of solar
the pan. 5 radiation to thermal energy, which solar collector com
These ratios are believed to be effective over a wide prises:
range of collector sizes. Thus, for example, for a glass (a) a peripheral frame member;
cover of dimensions larger or smaller than the preferred (b) a lower sheet member;
embodiment, the lengths between stays would be sum (c) a single, upper, thin, glass sheet member;
marized as follows in Tables II and III: 10 (d) the frame member and lower and upper sheet
members forming a shallow, sealed chamber
TABLE II adapted to be evacuated to a subatmospheric pres
(for a glass sheet 90><4l><0.l25") sure or at a subatmospheric pressure;
(e) a chamber absorber means containing a fluid, to
c=8.5" permit the ?uid to absorb solar radiation passing
b=8.0" through the upper, thin, glass sheet member, and to
a=4.25" convert the solar radiation to thermal energy in the
TABLE III ?uid, to increase the temperature of the ?uid;
(f) means to introduce ?uid, at one low temperature,
(for a glass sheet 60"><27.5><0.l25) 20 into the absorber means and means to remove a
c = 5.75 higher temperature fluid from the absorber means;
b=5.25" (g) means to support the upper, thin, glass sheet mem
a=2.75 ber, the improvement which comprises
In some instances, it is preferred that an even number a plurality of spaced-apart, generally parallel, glass
of stays be employed. In such cases, a stay would not be 25 sheet support elements within the chamber, and
situated along the longitudinal center line, but symme extending substantially the length of the chamber
try, with respect to the center line, still would be main and positioned in a symmetrical, but nonlinear,
tained. For example, the glass sheet described in Table manner with respect to the longitudinal center line
II could be supported by six stays in lieu of ?ve. A ?rst of the chamber, so that the distance between the
set of stays would be positioned 3.5 inches on each side 30 longitudinal support elements decreases as the sup
of the center line, set apart from each other by a total of port elements extend outwardly in position toward
7 inches. A second set of stays would be located 7 the peripheral edge of the frame member, so that
inches from each of the ?rst stays and closer to the outer the support elements dampen the harmonic vibra
edge of the glass. The third set would be placed 6.5 tions of the supported, upper thin, glass sheet ele
inches from each of the second stays and 3.5 inches ment, prior to the occurrence of stress fractures in
from the edge. A similar arrangement using four stays the glass sheet element, thereby preventing frac
can be utilized with the cover described in Table III in ture of the glass sheet element, when the chamber
lieu of the ?ve-stay con?guration. , is under subatmospheric pressure.
It also has been found that, for oversized solar collec 2. The collector of claim 1 wherein the thin, glass
sheet element has a thickness of Eths of an inch or less.
tors, such as collectors wider than 50", it is preferable to
have seven longitudinal stays, rather than ?ve, with the 3. The collector of claim 1 wherein the support ele
distance between stays again varying in a symmetrical, ments comprise a generally inverted-shaped, T-bar ele
ment.
but nonlinear, manner from the center line to the edges 4. The collector of claim 3 wherein the base of the
of the collector. 45 inverted T-bar element rests on the lower member.
With reference to FIGS. 3 and 4, the nonlinear spac 5. The collector of claim 1 wherein the upper, thin,
ing of the longitudinal bars is shown. In addition, FIGS. glass element has a thickness ofabout 3/ 16ths of an inch
3 and 4 disclose the use of dowels or pins 52 as auxiliary or less, and the chamber has a subatmospheric pressure
supports along the sides of shorter dimensions. It has of 29 inches of mercury or less.
been found that a series of four dowels along each of 50 6. The collector of claim 1 wherein the frame element
these sides provides additional insurance against stress is rectangular in form, and the support elements are
fractures originating along these sides. In the preferred generally parallel to the sides of the frame element of
embodiment, along each of the shorter sides, two dow larger dimension.
- els 52b are each placed in the middle of the C spans; that 7. The collector of claim 1 wherein the support ele
is, equidistant from the central stay and the stays on ments comprise at least five support elements.
each side of the central stay. Two additional dowels 52:: 8. The collector of claim 1 wherein the absorber
are each placed in the middle of the B spans; that is, means comprises a plurality of ?uid-?lled, generally
equidistant from the two stays on each side of the cen parallel tubes spaced apart by a generally ?at, heat
tral stay. In the pan of most preferred dimensions (leng absorbing and conductive plate element.
th76 inches; width-34 inches; depth-1.25 inches), it 9. The collector of claim 1 which includes a vacuum
has been found that the dowels 520 should be spaced 2} pump and means to connect the chamber with the vac
inches from the inside box edge, while dowels 52b uum pump, to maintain the chamber at subatmospheric
should be spaced 3.0 inches from the inside box edge. pressure.
An evacuated solar collector constructed in accor 10. The collector of claim 9 which includes pump
dance with the foregoing description will insure that a 65 means to circulate the ?uid through the absorber means.
properly seated glass cover i-inch thick will not de 11. The collector of claim 1 which includes a second
velop stress fractures. However, in the preferred em support means which comprises a plurality of point
bodiment, it is recommended that a glass cover 3/16 support elements positioned in the chamber and gener
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ally along the sides of the frame element of shorter a higher temperature ?uid from the absorber
dimension, to provide additional support to the upper, means; and
thin, glass element. (g) means to support the upper, thin, glass sheet mem
12. The collector of claim 11 wherein the point sup ber, the means to support generally parallel to the
sides of the frame element of larger dimension, the
port elements are positioned in a general arcuate form, improvement which comprises
so that the point supports nearer the longitudinal center a plurality of spaced-apart, generally parallel, glass
line are positioned farther from the short-dimension side sheet ?rst support elements within the chamber,
of the frame element than the point support elements and extending substantially the length of the cham
positioned near the corner of the frame element. ber and positioned in a symmetrical, but nonlinear,
13. The collector of claim 11 wherein the point sup manner with respect to the longitudinal center line
port elements are dowel elements having a diameter of of the chamber, so that the distance between the
about 5 an inch or more. longitudinal support elements decreases as the sup
14. In a solar collector for the conversion of solar port elements extend outwardly in position toward
radiation to thermal energy, which solar collector com the peripheral edge of the frame, and a plurality of
second point support elements positioned in a gen
prises: erally arcuate form, so that the point supports
(a) a peripheral, rectangular frame member; nearer the longitudinal center line are positioned
(b) a lower sheet member; farther from the short-dimension side of the frame
(c) a single, upper, thin, glass sheet member having a 20 element than the point support elements near the
thickness of Eths of an inch or less; corner of the frame element, the nonlinear and
(d) the frame member and lower and upper sheet arcuate positions of the ?rst and second support
members forming a shallow, sealed chamber elements dampening the harmonic vibrations of the
adapted to be evacuated to a subatmospheric pres upper, thin, glass sheet element, prior to the occur
sure or at a subatmospheric pressure; 25 rence of stress fractures in the glass sheet element.
(e) a chamber absorber means containing a ?uid in the thereby preventing fracture of the glass sheet ele
ment, when the chamber is under subatmospheric
chamber, to permit the ?uid to absorb solar radia
pressure.
tion passing through the upper, thin, glass sheet 15. The collector of claim 14 wherein the support
member, and to convert the solar radiation to ther elements comprise at least five support elements.
mal energy in the ?uid, to increase the temperature 16. The collector of claim 14 wherein the point sup
of the ?uid; port elements are dowel elements having a diameter of
(t) means to introduce the ?uid, at one low tempera about Q an inch or more.
i * i i 1
ture, into the absorber means and means to remove
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55
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