This invention relates to a thermal solar fluid heater. More particularly, this invention relates to a thermal solar fluid heater incorporating a channel system. BACKGROUND ART

The following references to and descriptions of prior proposals or products are not intended to be, and are not to be construed as, statements or admissions of common general knowledge in the art. In particular, the following prior art discussion does not relate to what is commonly or well known by the person skilled in the art, but assists in the understanding of the inventi ve step of the present invention of which the identification of pertinent prior art proposals is but one part.

A solar pool heater made from polymer materials will generally expand and contract due to changes in temperature. The temperature changes are required to perform the function of heating up water passing through the solar pool heater but the expansion and contraction potentially applies an undesirable force to fixed mounting points of the solar pool heater. Over time, this may result in fatigue, fracture or functional fai lure of the mounting points.

Furthermore, previous solar pool heater bodies are described that have four or less ports. In the present specification, the word "port" may be understood to include an attachment to another solar pool heater body or pipe through which water may pass. Prior arrangements are described as having a plurality of solar pool heater bodies that incorporate a single form of body to create an array. The array may be mountable, for example, on a roof inclined for best exposure to the sun. Because a single form of the body comprises a small number of ports in a fixed configuration, only a corresponding limited number of array

configurations are possible. All required configurations have previously been achieved through different forms of solar heater bodies with ports in different locations to cover the different variations required of various applications.

These minor variations may have been required to satisfy the requirements involved in supplying a range of slightly different products and adds to the expense of the product, as well as the complexity of the installati on process.

Additionally, solar pool heaters are described that include mechanical fasteners or interlocking mechanical parts to form a solar pool heater body. Joints can potentially be structurally weak points in the solar pool heater body and can be damaged by hail storms and bird attacks.

Finally, prior solar pool heaters have been described that have a larger than a standard pal let size and come in different sizes, increasing the costs of storage and transport.

An object of the present invention is to ameliorate the aforementioned disadvantages of the prior art or to at least provide a useful alternati ve thereto.

STATEMENT OF INVENTION

The invention according to one or more aspects is as defined in the independent claims. Some optional and/or preferred features of the invention are defined in the dependent claims.

Accordingly, in a first statement of the invention there is provided:

A thermal solar body moiintable to a substrate using a mounting device fixed to the substrate, wherein part or all of the thermal solar body in contact with the mounting device can move relative to the mounting device.

Preferably, the invention may be further characterised by the part or all of the thermal solar body in contact with the mounting device being movable relative to the mounting device in a predetermined direction without applying

substantial tension or compression to the mounting device or to the part of the thermal solar body in contact with or immediately adjacent to the mounting device.

The thermal solar body may substantially consist of a group of parallel pipes. The thermal solar body may substantially consist of a single or multiple pipes bent to form a planar structure. The thermal solar body may substantially consist of a single, integrally or unitarily formed piece, including multiple conduits, pipes or channels. Preferably, the thermal solar body substantially consists of a single piece with multiple channels, pipes or conduits through the body. The thermal solar body may be connected to the mounting device with a connecting mechanism. The connecting mechanism may allow movement of all or part of the thermal solar body relati ve to the mounting device. The

connecting mechanism may include a channel, a rail, a roller and/or an elastically defonnable attachment. Preferably, the connecting mechanism includes a channel.

The connecting mechanism may allow reciprocal translation of the thermal solar body relative to the substrate in one direction. However, the connecting mechanism may allow reciprocal translation of the thermal solar body relative to the substrate in one to two perpendicular directions, or a vector comprising the sum of movement in the two dimensions. The connecting mechanism may allow reciprocal translation of the thermal solar body relative to the substrate in one to three perpendicular directions, that is along, for example, a substantially horizontal axis x, a substantially vertical axis y and another horizontal axis z, or a vector comprising the sum of movement in two or three of the dimensions. Each of the axes, x and y, or x, y and z, are perpendicular to one another.

Preferably, the connecting mechanism allows translation of the thermal solar body relative to the substrate in one direction. The line of travel of the

connecting mechanism relative to the thermal solar body may be linear or nonlinear, including curved. Preferably, the line of travel is linear. The substrate may be a roof. The substrate may be a wall. The substrate may be a mountable surface at ground level, such as a concrete slab or other natural or man-made stmcture. The substrate may be any mountable surface with exposure to sunlight. Preferably the substrate is a roof, including a roof covered by tiles, metal sheeting or other covering. The substrate may include roof supports, such as structural underlining beams or other structures for attachment of the mounting device. The mounting points to which the mounting devices may be mounted on the roof may be the roof supports, or the tiles, metal sheeting or other coverings only. The mounting points on the roof may be another mountable surface on the roof.

The thermal solar body may be modular. The thermal solar body may form part of a larger array of thermal bodies. There may be one standardised thermal solar body to suit a whole range of required arrays formed from the thermal solar body types according to various applications. Preferably, there is one thermal solar body type used for a variety of applications in which the thermal solar bodies of the invention may be used. The thermal solar bodies may be used in thermal heating applications for industrial or domestic fluid heating

applications. Most typically, the thermal heating application of the invention is for a man-made body of water such as a pool or spa. Typically, the capacity of a domestic spa or pool volume is up to 200,000L. This provides an example of the volume of a water body to which the invention may be applied and is non- limiting, the volume may be as large as 2,000,000L or greater.

The thermal solar body's overall dimensional size may be within the allowable dimensions to be transported using a standard pallet (1.165m x 1.165m).

Preferably, the thermal solar body's overall dimensional size is about 1.030m x about 1.1 10m.

In a second statement of invention, the invention provides: a thermal solar body having at least 8 ports, including at least one inlet and at least one outlet. Preferably, the thermal solar body is mountable to a substrate using a mounting device fixed to the substrate, wherein part or all of the thermal solar body in contact with the mounting device can move relative to the mounting device. The thermal solar body may have one or more of the aforementioned preferred or permissible features of the thermal solar body described in the first statement of invention.

The 8 or more ports on the thermal solar device may allow multiple thermal solar devices to be connected together to form an array that is larger than a single thermal solar device. The thermal solar devices in the larger array may be arranged on a single plane or in multiple planes. Preferably, the thermal solar bodies in the larger array are arranged on a single plane.

In a third statement of invention, the invention provides:

a thermal solar body that is integrally and/or unitarily formed whereby the thermal solar body by itself includes no fasteners or mechanically

interconnected parts. The thermal solar body may have one or more of the aforementioned preferred or permissible features of the thermal solar body described in the first and/or the second statement of invention.

The material used for the thermal solar body, according to any one of the statements of invention, may be high density polyethylene, other plastics, a rubber material, a metal or metal alloy or a composite of these materials.

Preferably the material used for the thermal solar body is high density

polyethylene (HDPE).

The thermal solar body, according to any one of the statements of invention, may be formed using a mould, or by blow moulding, 3 dimensional printing or a machining process suitable for the material used for the thermal solar body. Preferably, the thermal solar body is formed by a moulding or blow moulding process.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be better understood from the following non-limiting description of preferred embodiments, in which:

Figure 1 i s a top plan vi ew of the thermal solar body according to an

embodiment of the invention showing a top surface with exterior surface channels;

Figure 2 is an underside plan view of the thermal solar body showing the underside surface with parabolic cone shaped holes on the exterior surface;

Figure 3 is an isometric view from a top plan perspective of the thermal solar body showing the upper surface with exterior surface channels;

Figure 4 is a partial isometric cross sectional view of one corner of the thermal solar body showing the internal channel through the thermal solar body;

Figure 5 is a cross sectional side view showing a slot in the thermal solar body showing the thermal solar body mounted onto a roof with the mounting device; and

Figure 6 is a top plan view of the thermal solar body and the mounting device. DETAILED DESCRIPTION OF THE DRAWINGS

Preferred features of the present invention will now be described with particular reference to the accompanying drawings. However, it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention.

Referring to Figures 1 to 6, a thermal solar pool heater 1 includes a thermal solar body 10 and a mounting device 12,14, 16 attachable to a substrate in the form of a roof 34. The roof 34 may include support structures 30 such as rafters, joists or battens 32, as well as tiles or metal sheet covering 30.

The thermal solar body 10 is unitarily formed in a blow moulding

manufacturing process and includes an upper portion in the form of an upper tube 23 and a lower portion in the form of a lower tube or 25, the upper and lower portions 23,25 being spaced from, extending substantially parallel to one another and substantially the same length and co-extensive with each other.

Extending between the upper and lower tubes 23,25 are exterior surface corrugations or a combination of ridges and channels 22 on the top side shown in Fig. 1. The exterior surface 22 includes a pair of side, outermost flanking ridges 22a,b that extend between the upper corners 23a,b of the thermal solar body 10 at each end of the upper tube 23 down to lower corners 25a,b at the respective ends of the lower tube 25.

As shown in Fig. 2, the thermal solar body 10 includes an array of exterior surface parabolic cone shaped dimples, craters protrusions or holes 26 on the underside. The holes 26 increase turbulence of fluid flowing within the thermal solar body 10 and the surface area to volume ratio.

Advantageously, the thermal solar body 10 includes multiple ports 24 at one or more corners of the substantially rectangular or square -shaped thermal solar body 10. Preferably, at least one comer includes a pair of ports 24. Still more preferably, the thermal solar body 10 includes eight ports 24 in total, with 4 pairs of ports, one pair of ports 24 at each corner. This provision of multiple ports gives a solar array designer/installer many options as to how to arrange multiple thermal solar bodies 10 in solar arrays on the roof 34, including options as to where fluid can enter or exit the thermal solar body 10.

The respective ends of the outermost ridges 22a,b are moulded to have recesses 22c to accommodate threadable caps, adapters or pipe connections (not shown) at axially aligned ports 24, that is, substantially axially aligned to the longitudinal axis of the upper or lower tubes 23,25. Where there are multiple ports 24 at a corner of the thermal solar body 10, at least on member 241 of the pair of ports 24 is laterally aligned relative to the upper and lower tubes 23,25 and aligned to be axially parallel to the lateral channels 22 extending between the upper and lower tubes 23,25. The outer wall of the upper or lower tube 23,25 immediately surrounding the base of the lateral aligned port(s) 24 has upper and lower recesses 23c,25c to accommodate threadable caps, adapters or pipe connections (not shown).

The thermal solar body 10 includes multiple slots 20 which are located in a centre portion 21 of the thermal solar body 10. The slots 20 are parallel to one another and spaced apart. The slots 20 are substantially identical in length and extend parallel to the channels 22. A top end 20a of each of the slots 20 is spaced about the same distance from the upper tube 23 as compared to the spacing between the lower tube 25 and a lower extent 20b of the slot 20. Each slot 20 includes rounded or radiussed ends 20a,b and straight side edges 20c. Each slot 20 may be spaced inwardly from the outermost side ridges 22a,b of the thermal solar body 10. Where the width of the thermal solar body 10 between the outermost side channels 22a,b is X, the slots 20 may be located between about 0.25 - 0.3X inwardly from one of the outermost side ridges 22a,b.

The mounting device includes an upper mounting part 16, preferably a pair of spaced upper mounting parts 16, each fixed to a substrate in the form of the roof 34 by a fastener 18. The upper mounting bracket 16 is adapted to receive, in an open channel 17, a portion along the length of the upper tube 23.

Where a single upper mounting bracket is employed, the upper tube 23 may be moved to a position in the upper mounting bracket 16 that is central along the l ength of the upper tube 23. However, preferably a spaced pair of upper mounting brackets 16 is used.

The upper tube 23 may be fed into an open side of the or each of the a mounting brackets 16a,b.

The two upper mounting parts 16 are fixed to the substrate using the fasteners which, in this embodiment, are each in the form of a screw 18. The upper mounting bracket 16 defines a channel 17 with a pair of parallel side walls 16a,b that are curved or folded inwardly towards their mutually opposed free edges 16c,d whereby to secure the bulb of the upper tube 23 (when viewed in section as in Fig. 5) whilst penriitting the central portion 21 , which is narrow in section to extend through the opening between the parallel side walls 16a,b. In effect, the thermal solar body 10 therefore is suspended, or hangs, from the upper bracket 16 when mounted to a roof 34 with a pitch or slope. Otherwise, the upper bracket 16 simply secures the upper tube 23 against substantial movement lateral to the upper tube's 23 long axis A.

Middle mounting brackets 14 are used to attach the central portion 21 via the slots 20 using a fastener 12 in each case. The two fasteners 12 are loosely fastened to the mounting bracket 14. The mounting bracket 14 is fixed to the substrate 34. The substrate 34 includes tiles 30 and roof supports 32.

The two fasteners 12 are not fixed to the thermal solar body 10, but allow translation of the central portion 21 of the thermal solar body 10 relative to the fasteners 12 in a direction parallel to the slots 20. This is achieved through a small gap 1 1 maintained between the fasteners 12 and the thermal solar body 10, such that the fasteners 12 and the thermal solar body 10 can slide past one another. However, bearings or rollers on the middle brackets 14 may be used as an alternative to firmly secure the central portion 21 against deflection out of the plane P in which the central portion 21 predominantly lies. In any case, the fasteners 12 restrict movement of the thermal solar body 10 in a direction perpendicular to the slots 20 and normal to the plane P of the central portion 21 and a planar surface of the thermal solar body 10. The fasteners 12 in combination with the brackets 14 therefore are adapted to contain the thermal solar body 10 such that it will not lift off the roof and, for this purpose, may have a large head 12a that is wider than the slot 20, or be secured through the bore of a washer or other ring so that the head 12a of the fastener 12 does not pull through the slot 20.

In the case where strong winds would otherwise cause the thermal solar body 10 to pi vot about the long axis X of the upper mounting parts 16, the brackets 14 retain the central portion 21 through the slots 20 and resist such rotation.

The one or two upper mounting brackets 16 restrict movement of the upper portion 23 in a direction normal to the plane P of the planar surface of the thermal solar body 10. The channel 17 in the two upper mounting parts 16 allows translation of the upper portion 23 of the thermal solar body relative to the substrate 34 in the direction parallel to the long axes L of the exterior surface channels 22 by being elongate, elliptical or stadium-shaped, rather than circular, in section traverse to the long axis A. The upper tube 23 retained in the upper bracket 16 is therefore able to reciprocate within the channel 17 as the thermal solar body 10 expands and contracts in a direction parallel to the long axes L of the channels 22.

The lower portion 25 is not connected to the mounting device and is free to move in any direction. The allowable translation of the upper, centre and lower portions 23, 21 and 25, respectively, in the direction parallel to the slots 20 are required for unrestricted thermal expansion and contraction of a single or an array of thermal solar bodies 10 in the direction parallel to the slots 20.

The slots 20 allow the fasteners 12 and the one or more mounting brackets 14 to be moved pre-installation in the direction of the slots depending on the location of the roof supports 32 or other substrate 34 member to which the fasteners 12 are attached. Therefore, the same thermal solar body 10 can be installed onto the roof supports 32 of various types of substrates 34 in most roofing

applications.

The eight ports 24 allow multiple thermal solar bodies 10 to be installed in any arrangement where each of the adjacent the thermal solar bodies 10 are on the substantially the same plane P, although extension piping, of course, can be used to bridge a shelf or wall on a roof 34 to allow an array to traverse minor obstacles associated with a non-planar roof line. These arrangements can be assembled by fastening two ports on any side of the thermal solar body 10 to two ports on the opposing side of another thermal solar body 10. The plurality of ports 24 provides improved flexibility of arrangement because a multiplicity of thermal solar bodies 10 can be combined in thermal solar body arrays in predominantly 2 dimensions and on roofs of varying dimensions, to service large or small capacity installations.

An internal channel 27 runs through the thermal solar body 10. Fluid flowing through the internal channel 27 will be heated due to solar heating of the exterior surface of the thermal solar body 10.

The thermal solar body 10 is manufactured using a blow moulding process that achieves a unitary and repeatable structure with no fasteners or mechanically interconnected parts to join the channels 22 and the respective joins between the upper and lower portions 23,25.

Throughout the specification and claims the word "comprise" and its derivatives are intended to have an inclusive rather than exclusive meaning unless the contrary is expressly stated or the context requires otherwise. That is, the word "comprise" and its derivatives will be taken to indicate the inclusion of not only the listed components, steps or features that it directly references, but also other components, steps or features not specifically listed, unless the contrary is expressly stated or the context requires otherwise.

In the present specification, terms such as "apparatus", "means", "device" and "member" may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items or components having one or more parts. It is envisaged that where an "apparatus", "means", "device" or "member" or similar term is described as being a unitary object, then a functionally equivalent object having multiple components is considered to fall within the scope of the term, and similarly, where an "apparatus", "assembly", "means", "device" or "member" is described as having multiple components, a functionally equivalent but unitary object is also considered to fall within the scope of the term, unless the contrary is expressly stated or the context requires otherwise.

Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and are based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, normally with the upper tube 23 uppermost.

It will be appreciated by those skilled in the art that many modifications and variations may be made to the methods of the invention described herein without departing from the spirit and scope of the invention.