Thin film solar collector

Abstract

A solar collector is provided that is formed from relatively thin polymer sheet(s). The sheet(s) are welded together to integrally define a storage tank, a plurality of fluid flow channel (e.g. risers), and other desired features within the collector. The storage tank is located at a first end of the panel and a heat exchanger is provided within the storage tank. The heat exchanger is arranged to transfer heat from the storage tank to a target fluid (such as water) that is to be heated or preheated by the collector. The collector is arranged so that when it is installed, the collector may be positioned with the storage tank located generally above the fluid flow channels. The storage tank and the fluid flow channels are arranged such that when the collector is installed and filled with a working fluid, a thermosiphon effect will cause the collection of hot water within the storage tank.

1 . A solar collector comprising: 
 a front sheet formed from a polymer film;    a back sheet formed from a polymer film, wherein the front and back sheets are welded together to define a storage tank and a plurality of fluid flow channels that open into the storage tank, the storage tank being located at a first end of the panel; and    a heat exchanger disposed in the storage tank, the heat exchanger having inlet and outlet ports.    
   
   
       2 . A solar collector panel as recited in  claim 1  further comprising an insulated box that covers the storage tank, but leaves the majority of the portion of the front sheet that defines the fluid channels exposed to facilitate the collection of solar energy.  
   
   
       3 . A solar collector panel as recited in  claim 1  wherein the front and back sheets are formed from a single sheet polymer film.  
   
   
       4 . A solar collector panel as recited in  claim 1  further comprising a fill port that may be used to facilitate filling the fluid flow channels and the storage tank portions of the solar collector with a working fluid.  
   
   
       5 . A solar collector panel as recited in  claim 1  wherein the front and back sheets are further welded to define tie down channels on top and bottom ends of the solar collector panel, the tie down channels being arranged to receive a tie down mechanism and not being in fluid communication with either the storage tank or the fluid flow channels.  
   
   
       6 . A solar collector panel as recited in  claim 1  further comprising a glazing sheet formed from a polymer film, wherein the glazing sheet is welded to the front sheet.  
   
   
       7 . A solar collector panel as recited in  claim 6  wherein the glazing sheet is substantially transparent.  
   
   
       8 . A solar collector panel as recited in  claim 1  further comprising an insulation sheet formed from a polymer film, wherein the insulation sheet is welded to the back sheet.  
   
   
       9 . A solar collector panel as recited in  claim 1  wherein the front and back sheets are further welded together to define a manifold and the plurality of fluid flow channels open into the manifold at an opposite end of the fluid flow channels from the storage tank, the solar collector panel further comprising a manifold spacer that helps maintain the manifold in an open position.  
   
   
       10 . A solar collector panel comprising: 
 a front sheet formed from a polymer film;    a back sheet formed from a polymer film, wherein the front and back sheets are welded together to define a plurality of fluid flow channels and a storage tank; and    a heat exchanger disposed in the storage tank, the heat exchanger having inlet and outlet ports.    
   
   
       11 . A solar collector system comprising: 
 a front sheet formed from a polymer film;    a back sheet formed from a polymer film, wherein the front and back sheets are welded together to define a collector sheet having a storage tank, a plurality of fluid flow channels and a plurality of tie down channels, the fluid flow channels being in fluid communication with the tank and arranged to open into the tank, the tie down channels being isolated from the storage tank and fluid flow channels and being arranged to receive a tie down mechanism;    a fill port that may be used to facilitate filling the fluid flow channels and the storage tank portions of the collector sheet with a working fluid;    a heat exchanger disposed in the storage tank, the heat exchanger having inlet and outlet ports; and    an insulated box that covers the storage tank, but leaves the majority of the portion of the front sheet that defines the fluid channels exposed to facilitate the collection of solar energy.    
   
   
       12 . A collector system as recited in  claim 11  wherein the collector sheet is replaceable.  
   
   
       13 . A solar collector system comprising: 
 a front sheet formed from a polymer film;    a back sheet formed from a polymer film, wherein the front and back sheets are welded together to define a collector sheet having a plurality of fluid flow channels; and    a fill port that may be used to facilitate filling the fluid flow channels with a working fluid.    
   
   
       14 . A solar collector system as recited in  claim 13  wherein the front and back sheets are further welded together to define an integral storage tank.  
   
   
       15 . A solar collector system as recited in  claim 14  further comprising a heat exchanger positioned within the storage tank.  
   
   
       16 . A solar collector system as recited in  claim 13  wherein the front and back sheets are formed from a single sheet or tube of polymer material.  
   
   
       17 . A solar collector system as recited in  claim 13  wherein the welds used to connect the polymer films together include riser welds that define a plurality of parallel risers within the collector panel and reinforcement welds positioned near the end of at least some of the riser welds.  
   
   
       18 . A solar collector panel as recited in  claim 1  further comprising an insulating sheet formed from a polymer film, wherein the insulating sheet is welded to at least one of the front and back sheets in a region over the storage tank.