High efficiency flat plate solar energy system

Abstract

A method of making a flat plate solar energy system includes steps of: providing a first metal sheet and a second metal sheet; stamping the first metal sheet to create channels; and fabricating a solar panel by joining the first metal sheet to the second metal sheet such that the channels form passageways between the two sheets. The passageways contain the flow of a working fluid that absorbs and transports heat by phase change. The method further includes steps of creating ports to allow the working fluid to enter and exit the solar panel; and providing a heat exchanger piped to the ports of the solar panel. Optional steps include attaching photovoltaic cells to the solar panel; extracting electricity from the photovoltaic cells; and providing a water storage tank.

What is claimed is: 
     
         1 . A method of making a flat plate solar energy system, the method comprising the steps of:
 providing a first metal sheet and a second metal sheet;   stamping the first metal sheet to create channels;   fabricating a solar panel by joining the first metal sheet to the second metal sheet such that the channels form passageways between the first metal sheet and the second metal sheet, said passageways capable of containing flow of a working fluid between the first metal sheet and the second metal sheet, said working fluid capable of absorbing and transporting heat by phase change;   creating ports to allow the working fluid to enter and exit the solar panel; and   providing a heat exchanger piped to the ports of the solar panel, the heat exchanger capable of removing heat from the working fluid.   
     
     
         2 . The method of  claim 1 , further comprising the step of coating the second metal sheet with solar thermal energy absorption layer. 
     
     
         3 . The method of  claim 1 , further comprising the step of attaching photovoltaic cells to the second metal sheet on the solar panel; and extracting electricity from the photovoltaic cells. 
     
     
         4 . The method of  claim 1 , further comprising the step of providing a water storage tank having a water-tight chamber to confine the heat exchanger within. 
     
     
         5 . The method of  claim 1 ,
 wherein the passageways are further capable of serving as a loop heat pipe, the passageways forming:
 an evaporation tube inside the solar panel that directs flow of the working fluid and allows the working fluid to evaporate inside the solar panel from a liquid phase; 
 a vapor tube inside of solar panel that contains and directs the flow of a vapor comprising a gas phase of the working fluid; and 
 a liquid tube inside of solar panel that contains and directs the flow of a liquid comprising the liquid phase of the working fluid; and 
   further comprising the steps of:
 installing an exit port on the solar panel connected to the vapor tube; 
 affixing an inflow port connected to the liquid tube; 
 piping the heat exchanger to the exit port such that the gas phase of the working fluid can flow out of the solar panel into the heat exchanger; and 
 piping the heat exchanger to the inflow port so that the liquid phase of the working fluid can flow out of the heat exchanger and into the solar panel. 
   
     
     
         6 . The method of  claim 5 ,
 wherein the solar panel comprises a top end and a bottom end, the top end intended to be at a higher elevation than the bottom end when placed in service;   wherein the step of stamping the first metal sheet to create channels comprises organizing the channels to form the passageways that result in:
 locating the vapor tube near the top end; 
 locating a first liquid tube near the top end; 
 locating a second liquid tube near the bottom end; 
 piping the first liquid tube to the heat exchanger so that liquid flows from the heat exchanger to the first liquid tube; and 
 piping the vapor tube to the heat exchanger and collecting the vapor as the working fluid flows through the evaporation tube toward the bottom end. 
   
     
     
         7 . The method of  claim 5 ,
 wherein the solar panel comprises a top end and a bottom end, the top end intended to be at a higher elevation than the bottom end when placed in service; and   wherein the step of making channels comprises organizing the channels to form the passageways that result in:
 making a pumping tube that enables bubble pump action to wet the evaporation tube near the top end; 
 connecting the pumping tube with a lateral tube leading to the evaporation tube; and 
 forming the evaporation tube with a larger diameter than the pumping tube. 
   
     
     
         8 . The method of  claim 5 ,
 wherein the solar panel comprises a top end and a bottom end, the top end intended to be at a higher elevation than the bottom end when placed in service; and   wherein the step of stamping the first metal sheet to create channels comprises organizing the channels to form the passageways that result in:
 locating the vapor tube near the top end; 
 locating the liquid tube near the bottom end; 
 making a pumping tube that enables bubble pump action to move the liquid so that there is evaporation near the top end; 
 forming the evaporation tube with a larger diameter than the pumping tube; and 
 making the pumping tube route the working fluid from the liquid tube near the bottom end to a point below the vapor tube near the top end and then turns the working fluid back to flow toward the bottom end where the working fluid connects to the evaporation tube.