Parabolic solar collector body and method

• US 5,069,540 A
• Filed: 10/18/1990
• Issued: 12/03/1991
• Est. Priority Date: 10/18/1990
• Status: Expired due to Fees

• Current Assignee: Warren W. Gonder
• Original Assignee: Warren W. Gonder
• Inventors: Gonder, Warren W.
• Primary Examiner(s): Arnold, Bruce Y.
• Assistant Examiner(s): RYAN, JAY
• Application Number:
  US07/599,446
• Time in Patent Office: 411 Days
• Field of Search: 350/614, 350/628, 350/629, 350/641, 350/, 156/245, 126/438, 126/442
• US Class Current: 359/853
• CPC Class Codes: F24S 23/74 with trough-shaped or cylindro-parabolic reflective surfaces
• CPC Class Codes: F24S 23/82 characterised by the material or the construction of the reflector
• CPC Class Codes: G02B 5/10 with curved faces
• CPC Class Codes: G02B 7/183 specially adapted for very large mirrors, e.g. for astronomy, or solar concentrators
• CPC Class Codes: Y02E 10/40 Solar thermal energy, e.g. solar towers

Abstract

A solar collector structure and method of fabrication are disclosed, the solar collector being of the linear, parabolic reflector-type. The parabolic reflector body includes an elongated layered structure having a concave parabolic reflective surface. The reflector body is supported and reinforced by a longitudinal beam member bonded to the convex backside of the layered structure. The layered structure includes a first reflective layer and a supporting molded layer formed of an amorphous hard-curing adherent material such as concrete or stucco. The entire reflector body structure is fabricated on an elongated convex mold. The method of fabrication includes forming the mold using a screed-moving apparatus which moves longitudinally along the mold. As the parabolic reflector body is formed on the mold, the screed-moving apparatus is again used to shape portions of the reflector body. A means for fabricating a parabolic reflector body, including both the elongated mold and the molded and reflective portions of the reflector body, together with the reinforcing longitudinal beam member, is also disclosed.

Claims

1. A parabolic reflector body fabricated on an elongated, convex parabolic mold, the reflector body being of the type which concentrates solar energy along a focal line, comprising:

an elongated layered structure having a parabolic concave first side, a convex second side opposite said first side and generally parallel longitudinal edges, the layers of said structure including

a reflective layer on said concave first side which contacts and conforms to the mold during fabrication, and

a support layer bonded to said reflective layer on said convex second side, said support layer being predominately formed of an amorphous hard-curing adherent material applied over said reflective layer in a moldable state and conformed generally to the convex shape of the mold, and

a tubular beam member bonded to said support layer by adherence of said beam member to amorphous hard-curing adherent material along a side of said beam member, said beam member extending longitudinally parallel to said edges of said layered structure.

2. A parabolic reflector body as in claim 1 in which said beam member is a steel pipe bonded to said support layer by means of a cementing agent.

3. A parabolic reflector body as in claim 1 in which said layered structure extends lengthwise between first and second ends and said beam member is positioned centrally on said second side of said layered structure approximately midway between said longitudinal edges, said beam member being longer than said layered structure and extending beyond said first and second ends and including cylindrical support surfaces on the portions of said beam member extending beyond said first and second ends whereby the reflector body, when removed from the mold, is supported for rotational movement about the axis of said beam member by said cylindrical support surfaces.

4. A parabolic reflector body as in claim 1 further including a plurality of structural members extending between said beam member and said second side of said layered structure to provide additional structural support to the reflector body.

5. A parabolic reflector as in claim 1 including reinforcing members embedded in the amorphous, hard-curing material of said support layer.

6. A parabolic reflector body fabricated on an elongated, convex parabolic mold, the reflector body being of the type which concentrates solar energy along a focal line, comprising:

an elongated layered structure having a parabolic concave first side, a convex second side opposite said first side and generally parallel longitudinal edges, the layers of said structure including

a reflective layer on said concave first side which contacts and conforms to the mold during fabrication, and

a support layer bonded to said reflective layer on said convex second side, said support layer being predominately formed of an amorphous hard-curing adherent material applied over said reflective layer in a moldable state and conformed generally to the convex shape of the mold, and

a beam member in the form of a closed-ended length of tubular steel embedded partially into amorphous hard-curing adherent material on said support layer and extending longitudinally parallel to said edges of said layered structure.

7. A parabolic reflector body as in claim 6 in which said beam member is positioned centrally on said second side of said layered structure midway between said longitudinal edges.

8. A parabolic reflector body as in claim 6 in which said beam member includes at least one opening for ingress and egress of fluids from the interior of said closed-ended length of tubular steel, whereby fluid storage is provided within said beam member.

9. A parabolic reflector body fabricated on an elongated, convex parabolic mold, the reflector body being of the type which concentrates solar energy along a focal line, comprising:

an elongated layered structure having a parabolic concave first side, a convex second side opposite said first side and generally parallel longitudinal edges, the layers of said structure including

a reflective layer on said concave first side which contacts and conforms to the mold during fabrication, and

a support layer bonded to said reflective layer on said convex second side, said support layer being predominately formed of an amorphous hard-curing adherent material applied over said reflective layer in a moldable state and conformed generally to the convex shape of the mold,

a longitudinally-extending ridge of amorphous hard-curing adherent material disposed centrally on the convex second side of said layered structure, and

a beam member partially embedded in said longitudinally-extending ridge on said support layer, said beam member extending longitudinally parallel to said edges of said layered structure.

10. A parabolic reflector body fabricated on an elongated, convex parabolic mold, the reflector body being of the type which concentrates solar energy along a focal line, comprising:

an elongated layered structure having a parabolic concave first side, a convex second side opposite said first side and generally parallel longitudinal edges, the layers of said structure including

a reflective layer on said concave first side which contacts and conforms to the mold during fabrication, and

a support layer bonded to said reflective layer on said convex second side, said support layer being predominately formed of an amorphous hard-curing adherent material applied over said reflective layer in a moldable state and conformed generally to the convex shape of the mold,

a beam member bonded to said support layer and extending longitudinally parallel to said edges of said layered structure, and

a plurality of structural members extending between said beam member and said second side of said layered structure to provide additional structural support to the reflector body, said structural members being concrete slabs each bonded to said beam member adjacent one longitudinal edge thereof and to said layered structure adjacent an opposite edge thereof.

11. A parabolic reflector body as in claim 10 including an additional quantity of said amorphous, hard-curing adherent material on said second side of said layered structure adjacent each said longitudinal edge, said concrete slabs each being bonded to said beam member by a cementing substance and to said layered structure by partially embedding said opposite edge of said slab in the amorphous, hard-curing adherent material adjacent said one longitudinal edge.

12. Means for fabricating a parabolic reflector body, comprising:

an elongated mold having a convex top surface with a parabolic cross-section,

an elongated reflector body fabricated on said mold and detachable therefrom after fabrication, said body including a layered structure having a parabolic concave first side, a convex second side and generally parallel longitudinal edges, the layers of said body including,

a reflective layer on said concave first side in contact with and conforming to said mold,

a support layer bonded to said reflective layer, and support layer being predominately formed of an amorphous, hard-curing adherent material applied over said reflective layer in a moldable state and shaped to generally conform to the shape of said mold,

a longitudinally-extending central ridge of said amorphous, hard-curing adherent material centrally disposed on said support layer, and

a beam member extending longitudinally along said second side of said layered structure embedded in said central ridge.

13. Means as in claim 12 including two parallel edge ridges of said amorphous, hard-curing adherent material on said support layer extending longitudinally adjacent the edges of said layered structure, and including a plurality of structural members attached to said beam member and partially embedded in said edge ridges.

14. Means as in claim 12 in which said support layer is uncured and moldable, including a longitudinally-extending central ridge of said amorphous, hard-curing adherent material in a moldable state centrally disposed on said support layer, a beam member embedded in said central ridge, two parallel edge ridges of said amorphous, hard-curing adherent material in a moldable state on said support layer extending longitudinally adjacent the edges of said layered structure, and including a plurality of structural members attached to said beam member and partially embedded in said edge ridges.

15. A method of fabricating a parabolic reflector body of the type which concentrates solar energy along a focal line, comprising the steps of:

forming an elongated mold having a convex top surface with a parabolic cross-section by steps including,

providing a hard-curable, moldable material on a base surface,

guiding a screed having a parabolic shape over said moldable material by means of a screed-moving apparatus which moves longitudinally along said base surface, and allowing said moldable material to cure, and

forming an elongated layered structure on the mold by steps including applying a reflective layer of material having a reflective surface on the top of the mold with the reflective surface facing downwardly against the mold,

positioning a lattice of reinforcing members over the reflective layer,

forming a support layer on the reflective layer by steps which include applying an amorphous, hard-curing adherent material in a moldable state onto the reflective layer to a depth which covers the reinforcing members, and

shaping the support layer by guiding a screed over the amorphous, hard-curing adherent material by means of the screed-moving apparatus, whereby said reflective and support layers form the layered structure.

16. A method as in claim 15 including the step of bonding a beam member longitudinally to the support layer following the step of shaping the support layer.

17. A method as in claim 16 in which said step of bonding the beam member includes forming a longitudinally-extending central ridge of amorphous, hard-curing adherent material on the support layer while the support layer and the central ridge are in a moldable state and partially embedding the beam member into the central ridge.

18. A method as in claim 17 including attaching reinforcing members to the support layer by steps including:

providing a plurality of structural members for attachment between the elongated layered structure and the beam member,

forming two parallel ridges of amorphous, hard-curing adherent material on the support layer, one on each side of said central ridge, while the support layer and the two ridges are in a moldable state,

partially embedding at least one of the structural members into each said ridge, and

bonding a portion of each structural member to the beam member.