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Title:
A PROCESS FOR REALISING SOLAR PANELS.
Document Type and Number:
WIPO Patent Application WO/2009/007862
Kind Code:
A1
Abstract:
A process for realising solar panels, of a type in which incident solar energy is transmitted to a liquid present and circulating in cavities predisposed internally of the panels, comprising following main stages: forming slabs (1) exhibiting, on at least a first surface (10) thereof a plurality of reliefs or projections (11) arranged in a predetermined design; possible covering of the surface of the first surface (10) with a glass-based material or the like; stable and solid coupling in a single body of two slabs (1) for superposing the first surface (10) of one on the first surface (10) of another such that the tops of at least part of the relative reliefs or projections (11) are reciprocally contactingly facing.

Inventors:
STEFANI FRANCO (IT)
Application Number:
PCT/IB2008/051874
Publication Date:
January 15, 2009
Filing Date:
May 12, 2008
Export Citation:
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Assignee:
SYSTEM SPA (IT)
STEFANI FRANCO (IT)
International Classes:
F28F3/12; B28B3/02; B28B3/12; B28B5/02; B30B5/06; C04B35/00; F24J2/48; F24S10/55
Domestic Patent References:
WO2004065085A12004-08-05
WO2006099894A12006-09-28
Foreign References:
DE4240252A11993-08-05
EP1500480A22005-01-26
JPH10107194A1998-04-24
GB2045423A1980-10-29
DE4240252A11993-08-05
EP1500480A22005-01-26
Attorney, Agent or Firm:
GIANELLI, Alberto (Via M. Vellani Marchi 20, Modena, IT)
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Claims:

Claims.

1 ). A process for realising solar panels, of a type in which incident solar energy is transmitted to a liquid present and circulating in cavities predisposed internally of the panels, wherein it comprises following main stages: forming slabs (1) exhibiting, on at least a first surface (10) thereof, a plurality of reliefs or projections (1 1) arranged in a predetermined design; possible covering of the surface of the first surface (10) with a glass-based material or the like; stable and solid coupling in a single body of two slabs

(I) for superposing the first surface (10) of one on the first surface (10) of the other such that tops of at least part of the relative reliefs or projections

(I I) are reciprocally contactingly facing.

2). The process of claim 1 , wherein the stable and solid coupling in a single body or panel (2) of the two slabs (1) by superposing the first surface (10) of one on the first surface (10) of another is performed following at least partial welding by fusion of the contacting facing surfaces of the tops of the reliefs or projections (11) and the subsequent cooling up to reaching a stable solid state.

3). The process of claim 2, wherein the at least partial fusion of the facing contacting surfaces of the tops of the reliefs or projections (11) is obtained by subjecting the coupled two slabs (1) to at least a heat cycle comprising an initial heating stage, an eventual treatment at a predetermined temperature and a stage of cooling up to reaching a stable solid state. 4). The process of claim 3, wherein the forming of slabs (1) exhibiting on a first surface (10) thereof a plurality of reliefs or projections (11) arranged

in a predetermined design is realised via a pressing operation of ceramic powders.

5). The process of claim 3, wherein the forming of slabs (1) exhibiting on at least a first surface (10) thereof a plurality of reliefs or projections (11) arranged in a predetermined design, is realised via a pressing operation of ceramic powders to which, after possibly coating the first surface (10) with glass-based or like material, a first firing is performed.

6). A plant for actuating the process of claims from 1 to 4, wherein the pressing of ceramic powders is realised continuously starting from a layer of ceramic powders (3) which is fashioned by interaction between a supply hopper (13) and a conveyor belt (4) and is supported by the conveyor belt

(4) which is in turn slidably supported on a rest plane of a press (5); an upper half-die or matrix (6, 6') operating on the rest plane which slidably supports the conveyor belt (4), which upper half-die or matrix (6, 6') is predisposed inferiorly to a punch (7).

7). The plant of claim 6, wherein the upper half-die or matrix (6) is made of rubber or a like material.

8). The plant of claim 7, wherein the upper half-die or matrix (6) is associated to a ring- wound belt (8) which acts as a die-bearing belt.

9). The plant of claim 8, wherein the ring-wound die-bearing belt (8) supports at least a second matrix; the ring-wound die-bearing matrix (8) being sized and predisposed to be positioned with respect to the punch (7) such that while one of the upper half-dies or matrices (6) is located in a work position below the punch (7), the other of the upper half-dies or matrices (6) is located in an inactive position without interfering therewith.

10). The plant of claim 6, wherein it comprises a ring- wound belt (8') which is sized and predisposed to be positioned between the punch (7) bearing an upper half-die or matrix (6') and the rest plane of the press (5).

11). The plant of claim 6 or 7 or 8 or 10, wherein it comprises, arranged in an ordered succession downstream of the press (5) along a belt conveyor line (9); a device (17) for covering the whole first surface (10) of the slabs (1) with a thin uniform layer of glassy material, or glaze; a raising device (14), which rotates some of the slabs (1) by 180° about a longitudinal axis parallel to a direction of motion of the line, and centredly deposits the slabs (1) on others of the slabs (1) in transit on the conveyor line (9) in an original arrangement with the first surface (10) facing upwards, a continuous kiln (12) for actuation of the heat cycle.

12). The plant of claim 6 or 10, wherein the predetermined maximum temperatures reached in the kiln (12) are comprised between 800 0 C and 1200 0 C.

Description:

TRANSL. RULE 12.3

- l -

A Process for Realising Solar Panels.

Technical Field

The invention relates to a process for realising solar panels, of a type in which the incident energy (solar) is transmitted to a liquid present and circulating in cavities predisposed internally of the panels themselves. Background Art

5 hi particular, though not exclusively, the process relates to the realisation of panels habitually used for example for covering walls and cladding buildings and which as well as their normal cladding function also perform a function of exploiting the incident solar energy. The process also relates to the realisation of panels which can be used as io radiating plates for heat energy exchange of buildings (i.e. both for heating and cooling).

Traditional solar panels are well known which, summarising, constitute equipment or plants specifically dedicated to capturing solar energy and converting it partly into heat energy for heating a liquid which flows inside

15 cavities the panels themselves are provided with. Normally these cavities are constituted by metal tubes connected to form a circuit which in the majority of cases is provided with a coil heat exchanger through which part of the heat energy captured is relinquished to another fluid for final use (for example hot water). In this equipment numerous applications have been

20 devised to improve plant performance.

In any case these are "dedicated" apparatus which have to be physically located in positions having good solar exposure, and which are however

"external" with respect to the body of the buildings. Further, the flat part which constitutes the panel normally exhibits a significant thickness. An aim of the present invention is to provide a new and simple process for realising solar panels (i.e. of the type in which the incident solar energy is transmitted to a liquid present and circulating in cavities predisposed internally of the panels) which are perfectly integrated in habitually-used elements, for example, for covering walls and cladding buildings. A further aim of the present invention is to give rise to a process for production of the integrated elements which can be realised continuously on a same forming line of the elements in which the elements are formed starting from raw materials in the form of powders.

"Technical" advantages of the invention are the very high duration and resistance to the majority of corrosive fluids, characteristics which are greatly due to the materials used for manufacture thereof. A further "technical" advantage of the process consists in the fact that it enables realising a product, i.e. a solar panel integrated in a wall-covering element and cladding for buildings, characterised by being extremely slim with respect to usual solar panels, though the slimness thereof in no way limits their use as typical covering elements for realising ventilated walls. Further advantages of the process consist in the use of low-cost raw materials which are very low pollutants, and low production costs. A further advantage of the process relates to the possibility of obtaining a product which, by its nature, satisfies any aesthetic requirement. Disclosure of Invention Further characteristics and advantages of the invention will better emerge from the detailed description that follows of some preferred but nonexclusive embodiments of the invention, illustrated by way of non-limiting example in the accompanying figures of the drawings, in which:

figure I is a schematic section of a plant of the invention, made along a vertical and longitudinal median plane; figures 2 and 3 are perspective views of two slabs during a stage of reciprocal coupling; figures 4 and 5 are enlarged-scale views of part of a schematic section made along a vertical and longitudinal median plane of a second embodiment of the invention.

The figures of the drawings illustrate a plant which actuates a process for realising solar panels, of a type in which the incident (solar) energy is transmitted to a liquid present and circulating in cavities predisposed internally of the panels. The process essentially comprises the following main stages: forming slabs I exhibiting, on at least a first surface 10 thereof, a plurality of reliefs or projections 1 1 arranged in a predetermined design: possible covering of the surface of the first surface IO with a glass- based material or the like (glaze); stable and solid coupling in a single body of two slabs 1 by superposing the first surface 10 of one on the first surface 10 of the other such that the tops of at least part of the relative reliefs or projections 1 1 are reciprocally contactingly facing. The stable and solid coupling in a single body or panel 2 of two of the slabs 1 by superposing the first surface 10 of one on the first surface 10 of the other is done following welding by at least partial fusion of the reciprocally-facing surfaces in contact of the tops of the relative reliefs or projections 1 1 and the subsequent cooling thereof to a temperature at which a stable solid state thereof is obtained. In particular the at least partial fusion of the reciprocally- facing contacting surfaces of the relative reliefs or projections 1 1 is obtained by subjecting the whole coupling of two slabs I to at least a heat cycle comprising an initial heating stage vip Io a predetermined temperature which depends on

RECTIFIED SHEET (RULE 91) ISA/EP

the material, a possible period maintained at that temperature and a stage of cooling up to the obtaining of a stable solid state.

The forming of the slabs 1 exhibiting on at least a first surface thereof 10 a plurality of reliefs or projections 11 arranged in a predetermined design, happens, in a first possible embodiment, via an operation of pressing of ceramic powders which is then, after the coupling of the facing slabs to one another, directly obtained by a single firing operation with which the solidity between the contacting surfaces of the reliefs or projections 1 1 contactingly facing one another is done at the same time as the vitrification of the bodies of the slabs which gives the whole assembly the final shape of the panel. At the end of this operation the two slabs 1 are reciprocally welded at the internal surfaces 10 thereof to form a monolithic panel in a single body 2 of which the external surfaces are constituted by the second surfaces 16 of the original slabs 1. A cavity is delimited internally of the monolithic panel 2, the surface of which cavity can have various conformations depending on the preselected shapes for the reliefs or projections 11, and which exhibits excellent and long-lasting characteristics of resistance to aggressive liquids. These characteristics are further improved by the presence of a layer of glassy material deriving from the fusion of the glaze distributed on the surface before firing.

The forming of the slab 1 exhibiting on at least a first surface 10 thereof a plurality of reliefs or projections 11 arranged in a predetermined design can be actuated via a pressing operation of ceramic powders to which, after a possible covering of the surface of the first surface 10 with glass-based material or the like, in particular glaze, is subjected to a first firing which has the aim of giving each slab a solid-state stability (with more or less complete vitrification). The whole process, in this case, comprises double- firing and includes, in order: a pressing operation of ceramic powders; a

covering of the surface of the first surface 10 with a glass-based material or the like (glaze); a first firing operation which has the aim of giving each single slab a solid-state stability (with more or less complete vitrification); the coupling of two slabs, already subjected to the first firing, by superposition of the first surface 10 of one on the first surface 10 of the other such that the tops of at least part of the relative reliefs or projections 11 are reciprocally and contacting coupled; a second firing operation at a sufficient temperature to realise welding by fusion of the reciprocally- facing contacting surfaces of the tops of at least part of the relative reliefs or projections 11 ; a cooling stage up to reaching a stable solid state of the panel.

During the pressing stage, or preferably during an intermediate stage prior to firing, through-holes 15 are made in one of the two slabs which will go to form the coupling, and in particular in the slab of the two slabs which will face the other superiorly to the other; the through-holes 15 have a double function, as during the process it allows free outlet of the vapours developing during the firing of the coupled assembly and also enables insertion of conduits destined to convey the flow of liquid internally of the solar panel realised with the process. The above-described process, with particular reference to the first illustrated embodiment, can advantageously be realised with a plant in which the ceramic powder pressing is realised continuously starting from a layer of ceramic powders 3 which is generated, for example, by interaction with the outlet mouth of a hopper 13 and a conveyor belt 4 on which the layer is supported. The conveyor belt 4 is in turn slidably supported on a rest plane of a press 5 with which an upper die or matrix 6, positioned inferiorly of a punch 7, cooperates, hi the illustrated embodiment the punch

7 is fixed while the underlying rest plane of the press 5 is mobile in a vertical direction against the punch 7.

The upper half-die or matrix 6 is made of rubber or the like and is preferably afforded on a ring-wound matrix-bearing belt 8 which supports at least a second matrix and is sized and predisposed to be positioned, with respect to the mobile punch 7, such that while one of the upper half-dies or matrices 6 is located in a work position inferiorly of the punch 7, the other is located in an inactive position without interfering therewith. The plant comprises, arranged in ordered succession downstream of the press 5 along a belt conveyor line 9; a device 17 for covering the whole first surface 10 of the slabs 1 with a thin uniform layer of glassy material, or glaze, preferably mixed with a medium; a raising device 14, which also rotates some of the slabs 1 by 180° about a longitudinal axis parallel to the direction of motion of the line, and centredly deposits the slabs 1 on other of the slabs 1 in transit on the conveyor line 9 in the original arrangement with the first surface 10 facing upwards, a continuous kiln 12 for actuation of the heating cycle.

In a further embodiment of the invention, upstream of the device 14 two tracts of line can be arranged in which the slabs 1 are formed, which then flow into a single line at the position of the device 14 itself. In this case one of the two tracts of line can be dedicated to the forming of the slabs 1 destined to be arranged inferiorly in the following coupling, while the other tract of line can be dedicated to the forming of slabs 1 destined to be arranged superiorly in the following coupling and provided with through- holes 15.

A further embodiment of the invention has a different structuring of the device which performs the pressing. The device comprises a second ring- wound belt 8' which is sized and predisposed to be positioned between the

punch (7), bearing an upper half-die or matrix 6' in a solid constraint, and the rest plane of the press 5. The second ring-wound belt 8' is realised in elastically deformable material (rubber, silicone rubber or the like), and is relatively thin such as to deform during the pressing operation in order to adhere to the recessed surface of the upper half-die or matrix 6\ The presence of the ring-wound belt 8' considerably contributes, including by virtue of the elastic return thereof, to facilitating the detachment of the upper half-die or matrix 6' once the pressing action has been completed. The predetermined maximum temperatures in the kiln 12 are comprised between 800 0 C and 1200 0 C.

Among the numerous advantages of the invention, of note are its simplicity, contained costs and the possibility of employing high levels of automation.




 
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