AU2013200236B2

AU2013200236B2 - A Solar Collector Header Attachment Arrangement

Info

Publication number: AU2013200236B2
Application number: AU2013200236A
Authority: AU
Inventors: Glen BOLITHO; Gregory Chapman; Jospeh Reardon
Original assignee: Rheem Australia Pty Ltd
Current assignee: Rheem Australia Pty Ltd
Priority date: 2011-01-12
Filing date: 2013-01-17
Publication date: 2014-06-12
Anticipated expiration: 2031-12-22
Also published as: AU2013200236A1

Abstract

A solar collector header mounting support (6.330) has hook means (6.336) adapted to engage a complementary engagement member (6.047) of a housing, and a header recess (6.332) adapted to retain a header (6.018). The recess includes header gripping ribs (6.331, 6.333, 6.335) to grip the header resiliently.

Description

P4512AU04 1 A SOLAR COLLECTOR HEADER ATTACHMENT ARRANGEMENT Field of the invention [001] This invention relates to a header attachment arrangement for a solar collector housing. Background of the invention [002] Solar collector panels generally include a heat transfer fluid circuit having risers and headers enclosed in a box with a transparent lid, usually of glass or other transparent material, to permit the solar energy to impinge on the risers. There is a need for a robust housing for solar collectors in which the various components can be secured and which can be readily assembled. Summary of the invention [003] According to an embodiment of the invention, there is provided a solar collector header mounting support including hook means adapted to engage a complementary engagement member of a housing, and a header recess adapted to retain a header. [004] The header recess can include a "C" shaped recess. [005] The recess can extend over an arc greater than 1800. [006] The recess can include at least one gripping projection. [007] The recess can include three gripping projections. . [008] The gripping projections can define a diameter less than the diameter of the header. [009] The recess can be resiliently deformable to grip a header. [010] The mounting support can include an intermediate section between the hook and the header recess. [011] The intermediate section can be resilient [012] The mounting support can include a face adapted, in use, to contact a wall of a solar collector housing.

P4512AU04 2 [013] According to another embodiment of the invention, there is provided a solar collector header support assembly including a header support as claimed in any one of claims 1 to 11, and a housing having a wall formed of an extrusion, the extrusion including an internal, downward-facing channel including an attachment projection adapted to engage with the hook means. [014] The lower end of the face acts as a fulcrum to translate the weight of the collector plumbing to increase the engagement force between the hook and the engagement member of the housing. Brief description of the drawings [015] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [016] Figure 1 is a schematic illustration of a solar collector. [017] Figure 2 is a partial section view of a solar collector having pipe risers. [018] Figure 3 is a partial section view of a solar collector according to another embodiment of the invention. [019] Figure 4 illustrates a novel extrusion adapted for forming the walls of a solar collector enclosure suitable for use with a header support according to an embodiment of the invention. [020] Figure 5 illustrates a corner assembly adapted for use with the extrusion of Figure 4. [021] Figure 6 is a partial view of a solar collector housing having a header arrangement according to an embodiment of the invention. [022] Figure 7 is a perspective illustration of a header support according to an embodiment of the invention. [023] Figure 8 shows an alternative header support member. [024] The numbering convention used in the drawings is that the digits in front of the full stop indicate the drawing number, and the digits after the full stop are the element reference numbers. Where possible, the same element reference number is used in different drawings to indicate corresponding elements.

P4512AU04 3 [025] It is understood that, unless indicated otherwise, the drawings are intended to be illustrative rather than exact representations, and are not necessarily drawn to scale. The orientation of the drawings is chosen to illustrate the features of the objects shown, and does not necessarily represent the orientation of the objects in use. Detailed description of the embodiment or embodiments [026] The invention will be described with reference to the drawings. [027] Figure 1 is a simplified illustration of a solar collector 1.002 having an enclosure box 1.004. The box includes side walls 1.006 with a peripheral seat 1.010 for a glass cover (not shown). The glass is sealed to the box around the peripheral seat. [028] The heat transfer path includes an upper and lower header 1.018, 1.016 and a plurality of riser pipes 1.014 providing a fluid path between the hollow headers. An inlet for the heat transfer fluid (htf) is provided at 1.022, and an outlet for the heated htf is provided at 1.020. Similar arrangements can be used for both direct and direct htf systems. [029] Solar collectors are exposed to ambient weather conditions, so the exposed edges and joins of the glass, the wall extrusions, and the corner mouldings should be sealed to prevent water penetration within the enclosure. [030] Figure 2 illustrates a section of a first embodiment of a solar collector. The wall extrusion 2.024 (described in detail in Figure 4) includes an external overhang 2.040 which can serve for use in lifting the collector by installers when installing to collector on a roof, and an external channel 2.025 which can be used for fixing the collector assembly to its rooftop mount. [031] The glass cover 2.034 is seated on a peripheral seat provided by the channel and cooperating corner assemblies, and is sealed thereto. [032] The risers 2.014 in this embodiment are located under and in thermal contact with an absorber sheet 2.032 adapted to absorb solar energy and deliver it to the risers 2.014 by thermal conduction. Thus the solar energy can pass through the glass and impinge on the absorber sheet from whence the heat is thermally conducted to the risers for delivery to the outlet header.

P4512AU04 4 [033] A base plate 2.026 closes off the lower side of the enclosure. The extrusion includes a channel for receiving the edges of the base plate, and the corner assemblies (see Figure 5) also include seats 5.087 for the corners of the base plate. [034] Insulation 2.028 is provided between the collector risers and the base plate. [035] Figure 3 is similar to Figure 2, but the risers and absorber plate are replaced by a collector panel arrangement formed of two sheets between which riser channels are formed. [036] Figure 4 illustrates the wall extrusion profile. The wall 4.048 has upper formations including: external overhang 4.040 forming a corner cap attachment (channel A); internal glass seat seal formations 4.042, with serrations providing a keying surface for the sealant; internal corner cap attachment channel 4.044 (channel B); the top of channel 4.044 forms a glass seat rim 4.045; internal header and corner wall attachment channel 4.046 (channel C); internal corner wall attachment channel 4.052 (channel D); base plate receiving channel 4.056; external fixing channel 4.050. [037] Figure 5 illustrates a corner assembly according to an embodiment of the invention. The corner assembly includes a cap 5.070 and a wall segment 5.082. The cap and wall segment are adapted to conform to the wall extrusions. [038] The cap includes an overhang 5.072 which forms a continuation of the extrusion overhang 4.040. In addition the cap overhang includes a projection 5.074 which is adapted to be a close fit within the underside of the extrusion overhang 4.040. The cap includes a second projection 5.076 which is likewise adapted to fit below channel 4.044 of the extrusion. [039] The cap also includes a glass seat 5.080 and seal formations 5.078. The cap wall 5.079 extends downward below the glass seat and transversely thereto.

P4512AU04 5 [040] The corner wall segment includes a pair of intersecting walls 5.084, 5.086 with projecting spigots 5.088, 5.090, 5.092, 5.094, adapted for insertions in the channels C & D of the wall extrusion. The lower spigots 5.090, 5.094 can include drain channel slots. [041] A sealant injection point 5.096 communicates with a sealant channel 5.098 so that sealant can be injected into the sealant channel when the corner assembly is joined to the wall extrusions. A purge point 5.100 is provided at the top of the sealant channel and the end of the purge point is located so that the end of the purge point is visible beyond the edge of the extrusion, allowing the person injection the sealant to view the purge point to determine when the sealant channel is full. A similar sealing injection point, sealant channel and purge point are provided on corner wall 5.086. [042] The base plate seat 5.087 accommodates the corner of the base plate inserted in the base plate channel 4.056 of the wall extrusion. [043] The cap 5.070 and corner wall segment 5.082 can include a snap fit arrangement to attach the to the corner wall segment. [044] Where an absorber panel such as 3.038 (Figure 3) is used, an "L" shaped absorber panel support 5.083 is provided to locate the absorber panel 3.038 and prevent unwanted lateral movement. [045] Figure 6 is a partial section view of the upper header end of a solar collector housing. The collector is installed at an incline so the heated htf in the risers 6.014 will rise up to the header tube 6.018. The riser tubes are sealed to the header, for example, by brazing. The extrusion 6.024 supports the glass cover 6.034 on an upper ledge. The base cover 6.026 is attached to the wall extrusion 6.024 by slot 6.056. [046] The wall extrusion also supports the header 6.018 via a header support 6.330 attached to the extrusion in the channel 6.046, the projecting rib 6.047 engaging a hook 6.337 of the suspension support 6.330. The absorber 6.032 overlies the risers 6.014 and the header 6.018. [047] The header support 6.330 and the wall extrusion are formed to interconnect. The header support includes an arcuate header receptacle 6.332, an intermediate section 6.334, and an attachment hook 6.336. The wall extrusion has an P4512AU04 6 internal channel 6.046 having an attachment rib 6.047 projecting into the channel from channel wall 6.338. [048] The header receptacle is a "C" shaped channel, the cross-section of which can be greater than 1800. The header 6.018 is held in the channel receptacle by gripping points 6.331, 6.333, 6.335 which project inward from the header receptacle 6.332. The gripping points define a diameter which, in the relaxed state, is slightly less than the diameter of the header 6.018. The header recess is made of a resilient material so the header is a snap-fit in the recess. [049] When the header support is located in position in relation to the wall extrusion 6.024, the hook 6.336 engages the channel rib 6.047 and the face 6.337 of the header support is in contact with the wall 6.048. A corresponding header support is placed in the opposite end wall extrusion, and the collector's two headers with attached risers can be pushed into place in the corresponding header recesses. The overall length of the collector plumbing (two headers and several risers) from header to header is such that the faces 6.337 of the header supports are firmly held against the corresponding wall extrusions. The headers are gripped resiliently by the gripping projections 6.331, 6.333, 6.335. The weight of the plumbing assembly provides torque which tends to increase the engagement between the hook 6.336 and the rib 6.047. As the arc defined by the header recess is greater than 180, the headers are securely held by the header supports without the need for screw or rivet fastening. [050] In order to ensure reliable assembly, the intermediate portion 6.334 can be hollow and formed of resilient ribs 6.342, 6.344 which can deflect sufficiently to accommodate manufacturing tolerances or to provide a compressive contact between the housing wall 6.047 and the edge 6.337 of the header support. [051] The gripping points provide sufficient clearance for fitment of the copper header pipe and provide for thermal expansion of the header pipe. [052] Figure 7 illustrates a header support 7.330 according to an embodiment of the invention. The header support 7.330 is an elongate member having a wall channel rib engaging hook 7.336 and a header recess 7.332. The outer wall of the header recess has a number of cut-out sections 7.339 to receive the risers of the collector plumbing.

P4512AU04 7 [053] The ends of the header recess 7.332 are open to permit the header to be connected to a water storage tank by pipes passing through apertures in the housing wall. [054] The header assembly facilitates assembly of the collector plumbing while avoiding interference with other components of the solar collector. The header assembly does not block drainage channels, the skirt trim profile 6.346, cap locking mechanism, insulation, or absorber sheet. [055] As an alternative header support arrangement, two short supports 8.340 as shown in Figure 8 can be used. One such support being placed proximate either end of the header. [056] In this specification, reference to a document, disclosure, or other publication or use is not an admission that the document, disclosure, publication or use forms part of the common general knowledge of the skilled worker in the field of this invention at the priority date of this specification, unless otherwise stated. [057] In this specification, terms indicating orientation or direction, such as "up", "down", "vertical", "horizontal", "left", "right" "upright", "transverse" etc. are not intended to be absolute terms unless the context requires or indicates otherwise. These terms will normally refer to orientations shown in the drawings. [058] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of". A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear. [059] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention. [060] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims

1. A solar collector header mounting support including hook means adapted to engage a complementary engagement member of a housing, and a header recess adapted to retain a header.

2. A solar collector header mounting support as claimed in claim 1, wherein the header recess includes a "C" shaped recess.

3. A solar collector header mounting support as claimed in claim 2, wherein the recess extends over an arc greater than 180 0.

4. A solar collector header mounting support as claimed in any one of the preceding claims, wherein the recess includes at least one gripping projection.

5. A solar collector header mounting support as claimed in claim 4, wherein the recess includes three gripping projections.

6. A solar collector header mounting support as claimed in claim 5, wherein the gripping projections define a diameter less than the diameter of the header.

7. A solar collector header mounting support as claimed in any one of the preceding claims, wherein, the recess is resiliently deformable to grip a header.

8. A solar collector header mounting support as claimed in any one of the preceding claims, including an intermediate section between the hook and the header recess.

9. A solar collector header mounting support as claimed in claim 8, wherein the intermediate section is resilient

10. A solar collector header mounting support as claimed in any one of the preceding claims, including a face adapted, in use, to contact a wall of a solar

11. A solar collector header support assembly including a solar collector header mounting support as claimed in any one of claims 1 to 10, and a housing having a wall formed of an extrusion, the extrusion including an internal, downward-facing channel including an attachment projection adapted to engage with the hook means.

12. A solar collector header support assembly as claimed in claim 11, wherein the lower end of the face acts as a fulcrum to translate the weight of the collector P4512AU04 9 plumbing to increase the engagement force between the hook and the engagement member of the housing.