Solar-powered thermal insulating tape

• US 8,344,293 B1
• Filed: 09/29/2009
• Issued: 01/01/2013
• Est. Priority Date: 09/29/2008
• Status: Active Grant

• Current Assignee: Jared J. Mccabe, Jason Mccabe
• Original Assignee: Jared J. Mccabe, Jason Mccabe
• Inventors: McCabe, Jared J., McCabe, Jason
• Primary Examiner(s): Hoang, Huan
• Assistant Examiner(s): Huang, Min
• Application Number:
  US12/569,000
• Time in Patent Office: 1,190 Days
• Field of Search: 219/482, 137/341
• US Class Current: 219/482
• CPC Class Codes: F16L 53/38 using elongate electric heating elements, e.g. wires or ribbons
• CPC Class Codes: F24S 25/10 extending in directions away from a supporting surface
• CPC Class Codes: F24S 30/422 Vertical axis
• CPC Class Codes: H02S 20/10 Supporting structures directly fixed to the ground H02S20/30 takes precedence
• CPC Class Codes: H02S 20/30 Supporting structures being movable or adjustable, e.g. for angle adjustment
• CPC Class Codes: H02S 40/38 Energy storage means, e.g. batteries, structurally associated with PV modules
• CPC Class Codes: H05B 1/0227 Applications
• CPC Class Codes: H05B 3/565 flat cables
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y02E 70/30 Systems combining energy storage with energy generation of non-fossil origin

Abstract

A solar-powered heat tape system for gas well regulators and other remotely located equipment is herein disclosed. The system comprises a solar power panel mounted atop a mast which provides electrical power to a rechargeable battery system through a charge controller. The output power of the battery is then routed through an AC power inverter. The AC power is then routed to a length of electrical heat tape that is used the keep gas regulators and other equipment from freezing during cold weather. All major electrical components with the exception of the solar panel and the heat tape are contained in a weatherproof and lockable electrical cabinet. The system thus provides electrical power at remote locations to protect plumbing, miscellaneous equipment, testing equipment, telemetry equipment, and the like from freezing.

Claims

1. An insulating and protective means for a device, comprising:

an energy collection and distribution means, comprising;

a mast;

a solar panel;

an azimuth adjustment bracket located at a top end of said mast, comprising;

a panel mounting arm;

an upper portion comprising a channel-shaped bracket having two (2) upwardly extending opposing leg portions;

a pivot pin extending horizontally through said azimuth adjustment bracket and said panel mounting arm;

a pair of locking fasteners inserted through a pair of diametrically opposed adjustment slots; and

,

a lower portion comprising a bottom opening receiving said top end of said mast and having a radial adjustment fastener;

wherein said panel mounting arm provides an attachment means for said solar panel to said azimuth adjustment bracket; and

,

a power distribution box in electrical communication with said solar panel and mounted at an intermediate position on said mast, further comprising a securable enclosure; and

,

at least one electrical heat tape in electrical communication with said energy collection and distribution means;

wherein said solar panel collects thermal energy and converts said thermal energy to electrical energy and transmits said electrical energy to said power distribution box;

wherein said azimuth adjustment bracket provides selectable directional adjustment and positioning of said solar panel, further comprising angular positioning with respect to a vertical center via said pivot pin and secured with said pair of locking fasteners;

wherein said selectable directional adjustment and positioning of said solar panel further comprises radial positioning along a horizontal plane via rotating of said azimuth adjustment bracket and securing with said radial adjustment fastener;

wherein said angular positioning and said radial positioning maximizes collection of solar energy;

wherein said power distribution box provides electrical power from said electrical energy and distributes electrical power to said at least one electrical heat tape;

wherein said at least one electrical heat tape is placed on said device to provide said insulating and protective means; and

,

wherein said insulating and protective means provides a stand-alone thermal protection to said device.

2. The insulating and protective means of claim 1, wherein said solar panel further comprises a rectangular photovoltaic unit rated at approximately 80 Watts.

3. The insulating and protective means of claim 1, wherein said panel mounting arm further comprises:

a “

Y”

-shape body extending upwardly along a rear surface of said solar panel secured to outer rear surfaces of said solar panel with a plurality of panel brackets affixed thereto using fasteners.

4. The insulating and protective means of claim 1, wherein said power distribution box further comprises:

said enclosure further comprising;

an access door comprising a side-hinged panel having a water-proof seal and a hasp located along a bottom edge for providing access into an interior;

a locking unit in operable conjunction with said hasp to maintain said access door in a closed state; and

,

mounting fixtures for mounting said enclosure to said mast;

a charge controller mounted in said interior in electrical communication with said solar panel;

a battery mounted in said interior in electrical communication with said solar panel;

an inverter mounted in said interior in electrical communication with said solar panel, further comprising an integral electrical outlet; and

,

a power switch in electrical communication with said inverter and said battery;

wherein said charge controller provides regulation of variable input voltage from said solar panel to a constant 12-volt direct current voltage to said battery and said inverter;

wherein said inverter provides said electrical power by converting said constant direct current voltage into 110-volt alternating current voltage;

wherein at least one electrical heat tape is removably electrically connected to said duplex electrical outlet; and

,

wherein said power switch provides a selectable distribution of said electrical power.

5. The insulating and protective means of claim 4, wherein said inverter comprises an approximate power rating of four-hundred Watts.

6. The insulating and protective means of claim 1, wherein said at least one electrical heat tape further comprises a resistor wire-type heating cable with an in-line thermal switch.

7. The insulating and protective means of claim 6, wherein said at least one electrical heat tape each comprises a power consumption rating of approximately eighty Watts.

8. The insulating and protective means of claim 1, further comprising an insulating cover applied to an outside surface of said at least one electrical heat tape, further comprising:

an insulating layer comprising a pliable material capable of being wrapped tightly around said device; and

,

a water-proof sealing tape layer comprising an adhesive-backed plastic or metallized tape which provides a means to secure said insulating layer to and a water-proof outer layer over said insulating cover.

9. The insulating and protective means of claim 8, wherein said pliable material further comprises one of the following list:

fiberglass, polyethylene, neoprene foam sheet, and rockwool.

10. An insulating and protective means for a device, comprising:

an energy collection and distribution means, comprising;

a mast;

a solar panel;

a panel mounting arm, comprising a “

Y”

-shape body extending upwardly along a rear surface of said solar panel secured to outer rear surfaces of said solar panel with a plurality of panel brackets affixed thereto using fasteners;

an azimuth adjustment bracket located at a top end of said mast, comprising;

an upper portion comprising a channel-shaped bracket having two (2) upwardly extending opposing leg portions;

a pivot pin extending horizontally through said azimuth adjustment bracket and said panel mounting arm;

a pair of locking fasteners inserted through a pair of diametrically opposed adjustment slots; and

,

a lower portion comprising a bottom opening receiving said top end of said mast and having a radial adjustment fastener; and

,

a power distribution box in electrical communication with said solar panel and mounted at an intermediate position on said mast, further comprising a securable enclosure;

wherein said panel mounting arm provides an attachment means for said solar panel to said azimuth adjustment bracket;

at least one electrical heat tape in electrical communication therewith said energy collection and distribution means, further comprising a resistor wire-type heating cable with an in-line thermal switch; and

,

an insulating cover applied thereto an outside surface of said at least one electrical heat tape, further comprising an insulating layer comprising a pliable material capable of being wrapped tightly around said device and a water-proof sealing tape layer comprising an adhesive-backed plastic or metallized tape which provides a means to secure said insulating layer thereto and a water-proof outer layer over said insulating cover;

wherein said solar panel collects thermal energy and converts said thermal energy to electrical energy and transmits said electrical energy to said power distribution box;

wherein said azimuth adjustment bracket provides selectable directional adjustment and positioning of said solar panel;

wherein said selectable directional adjustment and positioning of said solar panel further comprises angular positioning with respect to a vertical center via said pivot pin and secured with said pair of locking fasteners;

wherein said selectable directional adjustment and positioning of said solar panel further comprises radial positioning along a horizontal plane via rotating of said azimuth adjustment bracket and securing with said radial adjustment fastener;

wherein said angular positioning and said radial positioning maximizes collection of solar energy;

wherein said power distribution box provides said electrical power from said electrical energy to said at least one electrical heat tape;

wherein said at least one electrical heat tape is placed on said device to provide said insulating and protective means; and

,

wherein said insulating and protective means provides a stand-alone thermal protection to said device.

11. The insulating and protective means of claim 10, wherein said power distribution box further comprises:

said enclosure further comprising;

an access door comprising a side-hinged panel having a water-proof seal and a hasp located along a bottom edge for providing access into an interior;

a locking unit in operable conjunction with said hasp to maintain said access door in a closed state; and

,

mounting fixtures for mounting said enclosure to said mast;

a charge controller mounted in said interior in electrical communication with said solar panel;

a battery mounted in said interior in electrical communication with said solar panel;

an inverter mounted in said interior in electrical communication with said solar panel, further comprising an integral electrical outlet; and

,

a power switch in electrical communication with said inverter and said battery;

wherein said charge controller provides regulation of variable input voltage from said solar panel to a constant 12-volt direct current voltage to said battery and said inverter;

wherein said inverter provides said electrical power by converting said constant direct current voltage into 110-volt alternating current voltage;

wherein at least one electrical heat tape is removably electrically connected to said duplex electrical outlet; and

,

wherein said power switch provides a selectable distribution of said electrical power.

12. The insulating and protective means of claim 10, wherein said solar panel further comprises a rectangular photovoltaic unit rated at approximately 80 Watts.

13. The insulating and protective means of claim 11, wherein said inverter comprises an approximate power rating of four-hundred Watts.

14. The insulating and protective means of claim 10, wherein said at least one electrical heat tape each comprises a power consumption rating of approximately eighty Watts.

15. The insulating and protective means of claim 10, wherein said pliable material further comprises one of the following list:

fiberglass, polyethylene, neoprene foam sheet, and rockwool.

16. A method for remotely insulating and protecting a device with a stand-alone system comprises the following steps:

providing an energy collection and distribution means, further comprising;

a mast;

a rectangular solar panel;

an azimuth adjustment bracket, further comprising;

an upper portion comprising a channel-shaped bracket having two (2) upwardly extending opposing leg portions;

a pivot pin extending horizontally through said azimuth adjustment bracket and said panel mounting arm;

a pair of locking fasteners inserted through a pair of diametrically opposed adjustment slots; and

,

a lower portion comprising a bottom opening receiving a top end of said mast and having a radial adjustment fastener;

a panel mounting arm providing an attachment means for said solar panel to said azimuth adjustment bracket, further comprising a “

Y”

-shape body extending upwardly along a rear surface of said solar panel secured to outer rear surfaces of said solar panel with a plurality of panel brackets affixed to using fasteners; and

,

a power distribution box in electrical communication with said solar panel and mounted at an intermediate position on said mast, further comprising;

a securable enclosure further comprising an access door comprising a side-hinged panel having a water-proof seal and a hasp located along a bottom edge for providing access into an interior, a locking unit in operable conjunction with said hasp to maintain said access door in a closed state, and mounting fixtures for mounting said enclosure to said mast;

a charge controller mounted in said interior in electrical communication with said solar panel;

a battery mounted in said interior in electrical communication with said solar panel;

an inverter mounted in said interior in electrical communication with said solar panel, further comprising an integral electrical outlet; and

,

a power switch in electrical communication with said inverter and said battery;

providing at least one electrical heat tape, each further comprising;

a resistor wire-type heating cable with an in-line thermal switch; and

,

an insulating cover applied to an outside surface of said at heating cable, further comprising an insulating layer comprising a pliable material capable of being wrapped tightly around said device and a water-proof sealing tape layer comprising an adhesive-backed plastic or metallized tape which provides a means to secure said insulating layer to and a water-proof outer layer over said insulating cover;

selecting a location at which to install said system being in close proximity to said device to be protected and insulated;

installing said mast portion in a grade surface being buried approximately two to three feet deep based upon anticipated frost conditions;

assembling said azimuth adjustment bracket and said panel mounting arm in said solar panel using said plurality of panel brackets;

insertingly placing said azimuth adjustment bracket onto said top end of said mast;

adjusting a radial position of said solar panel along a horizontal plane by rotating said azimuth adjustment bracket upon said mast to maximize collection of solar energy;

securing said radial position of said a solar panel by tightening said radial adjustment fastener of said azimuth adjustment bracket;

adjusting an angular position of said solar panel by pivoting a lower portion of said panel mounting arm in a forward and rearward motion within said azimuth adjustment bracket to maximize collection of solar energy;

securing said angular position by tightening said pair of locking fasteners;

mounting said power distribution box to an intermediate location along said mast with said mounting fixtures;

routing and connecting all electrical wiring from said solar panel to said power distribution box;

wrapping said at least one electrical heat tape unit around said device;

wrapping said insulating layer around said device and said at least one electrical heat tape;

positioning said in-line thermal switch outside of said insulating cover to expose said in-line thermal switch to ambient elements;

securing and water-proofing said insulating layer by applying said sealing tape layer around said insulating layer;

routing a plug portion of said at least one electrical heat tape unit into said enclosure and inserting into said electrical outlet of said inverter;

routing a plug portion of an additional electrical device into said enclosure and inserting into said electrical outlet of said inverter

securing said access door of said enclosure; and

,

moving said power to an “

ON”

position, thereby transferring electrical energy from said solar panel to said charge controller, wherein said charge controller transfers said electrical energy to said battery and said inverter, wherein said inverter coverts said electrical energy into electrical power, wherein said electrical power is transferred to said at least one electrical heat tape for providing insulating and protective means to said device as controlled by said in-line thermal switch.