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The work in IEA-SHC Task 39 includes the study of polymeric materials in solar thermal applications from a polymer-engineering point of view [17]. An overview of selected absorber designs of polymeric materials is presented in Table 1. Depending on the absorber and the manifold, five different concepts are shown for the design of commercial polymeric solar absorbers: (1) pipe+pipe, (2) panel+pipe, (3) panel+endcap, (4) film+pipe, (5) panel. While the concepts (1) to (4) are based on extruded absorbers and injection moulded manifolds, which are connected by mechanical fixing, gluing or welding, the panel concept is based on blow — or roto-moulded components with integrated semi-finished fittings. Advantages of the panel concept are a reduced number of processing steps, the use of semi-finished components (fittings) and the possible realization of more complex absorber designs. However, panel concepts (5) are limited in the length of the absorber. An important prerequisite for concepts (1) to (4) is the use of similar materials, especially thermoplastics, for the absorber and the manifold. Compared to absorbers with pipe geometry, absorbers with flat surfaces exhibit a better functionality/material-ratio (less material is required) and a better applicability of functional layers.
A large potential for innovative development of components and systems by using polymers is expected in the solar thermal industry as successfully demonstrated in other industry sectors. A short presentation of various polymer applications in solar collectors, heating system designs, overheating protection and the analysis of different absorber designs from a polymer-engineering point of view is given. A complete, updated review with evaluation and experiences will be prepared as a final deliverable of IEA-SHC Task 39. It will additionally include the state of the art of polymeric applications in small, medium-sized heat — and seasonal thermal stores and patented ideas. The official Task 39 website is: http://www. iea-shc. org/task39.
Acknowledgements — The lead of Subtask A of IEA-Task 39 "Polymeric materials in solar thermal applications" is supported by ENOVA SF and the Research Council of Norway (RENERGI).
Table 1. Characterisation of different absorber designs from a polymeric engineering point of view [17]. |
1) Pipe-pipe absorber (EPDM) |
2) Pipe-pipe absorber (thermoplastics) |
3) Panel-header |
4) Film-pipe |
5) Panel |
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Source: G. Wallner |
Source: Solar-Flex |
Source: FAFCO |
Source: [18], Sarnafil |
Source: Texsun |
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Materials |
Thermoplastics, elastomers |
Thermoplastics |
Thermoplastics |
Thermoplastics |
Thermoplastics |
Design |
Absorber: extruded (EX) elastomer Manifold: injection moulded (IM) thermoplastic |
Absorber: EX thermoplastic pipe Manifold: IM thermoplastic pipe |
Absorber: EX thermoplastic panel Manifold: IM thermoplastic header |
Absorber: EX thermoplastic film Manifold: IM moulded fittings |
Absorber: blow — moulded thermoplastic panel Manifold: blow — moulded with IM parts |
Components |
2 components: pipes, header; size and format: module length variable, width limited; |
2 components: pipe is semifinished; size and format: variation in length; |
2 components: size and format: length variable, limited in width; |
Film, fittings are semi-finished; size and format: length variable, width limited; |
Film, fittings are semi-finished; size and format: limited in length+width |
Production process |
3 steps: EX: pipes IM: header mechanical joining |
3 steps: EX: pipes IM: header mechanical joining |
3 steps: EX: panel IM: header joining: welding |
2 steps: EX + rolling: film joining: welding |
2 steps: EX: film, BM: panel joining: — |
Coating |
after EX difficult |
after EX difficult |
after EX: easily |
after EX: easily |
after EX |
Additional functions |
Snap connectors in IM — header |
Snap connectors in manifold and pipe |
Snap connectors in manifold and pipe |
Snap connectors in fittings |
Snap connectors in panel |
Investments |
medium: EX, IM low: joining |
medium: EX, IM low: joining |
medium: EX, IM, welding |
medium (EX) |
low (mould) |
Quantities |
medium |
medium |
medium |
high |
medium |
Auto- matisation |
low: joining high: components |
low: joining high: components |
medium: joining high: components |
high |
high |
Labour |
intensive |
intensive |
less intensive |
less intensive |
low |
Application |
pool heating, unglazed |
pool heating, unglazed |
pool heating, unglazed; DHW and space heating, glazed |
Pool heating and DHW preheating, unglazed; |
pool heating, unglazed; DHW heating, glazed |
EX: Extrusion, IM: Injection moulding, BM: Blow moulding; |
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