Absorber designs from a polymer-engineering point of view

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.

3 Summary

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

Blustration,

example

QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture.

Source: G. Wallner

Source: Solar-Flex

Source: FAFCO

Source: [18], Sarnafil

Source: Texsun

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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