Abstract:
A solar cell collector unit that materially contributes to a more efficient use and conservation of green energy includes a first metal sheet having alternating corrugated crest and valley portions on an upper surface and alternating open channels on an under surface and having a first dimension with a first peripheral edge about its entire perimeter. A second substantially flat metal sheet having a second dimension with a second peripheral edge about its entire perimeter and less than the first dimension. The first and second metal sheets overlie one another with flattened copper tubing disposed within the open channels and sandwiched there between, while crimping and folding the first peripheral edge over the second peripheral edge to form nested protuberances about its perimeter to provide stiffness and rigidity there about and forming a low cost single solar cell unit. Then deformation along the valley portions and a portion of the second metal sheet forms plural pin-less rivets thereon to provide additional stiffness and rigidity.

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
       [0001]    NONE 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to a collector module unit, known as a PYROPEG solar cell module unit, for absorbing heat from incident solar energy and removing the absorbed heat by a heat transfer liquid, and particularly to a low cost solar cell module design and method of fabrication and assembling of a linear solar cell collector module unit. Such low cost solar cell module design and method of fabrication and assembling materially contributes to a more efficient use and conservation of energy that becomes accessible to many more people through out the world, especially those in underserved areas and communities. This lends too many more people using solar as an alternative green energy source, which automatically reduces greenhouse gases, thereby enhancing the quality of the environment. 
         [0004]    2. Description of the Related Art 
         [0005]    Due to ever increasing usage of non-renewable energy sources such as fossil fuels, much attention is being directed toward solar energy. Solar energy has been found to be effective in providing space and water heating. 
         [0006]    In the prior art, many solar heat collectors are attractive in performance but lack in cost-effectiveness in design, fabrication and assembling. Many of the prior art solar heat collector systems require several years of operation to return the initial investment, turning many potential users away from solar energy as an alternative energy source. Therefore, there is a huge need for a simple, efficient and most importantly, an inexpensive solar heat collector module unit. 
         [0007]    Over the years, many patents have been issued for collecting and transferring solar heat energy. Some of the solar collector module units of these patents generally have their components located within an enclosure comprising one or more elongated, generally rectangular heat absorbing metallic panels, each comprising two relatively thin plates of heat absorbing metal, such as aluminum or copper, which are deformed to tightly enclose about a plurality of parallel heat transfer pipes, preferably made of copper. The upper plate of heat absorbing metal covers substantially the top semi-cylindrical portions of the heat transfer fluid conducting pipes, while the lower plate is deformed to surround the bottom semi-cylindrical portions of the fluid transfer pipes. 
         [0008]    The plates and pipes are secured together by a plurality of metallic rivets, staples or other means, preferably of stainless steel, which traverses the edges of the pipe enclosing deformed portions of the two plates. Thus, the pipes are effectively resiliently secured in position, thereby readily accommodating differences in expansion of the plates and the heat transfer fluid pipes. 
         [0009]    The frame for embodying these solar collector module units are fabricated from U-shaped stainless steel of aluminum channels which are bolted or welded together. The ends of the plates are bolted to oppose channels. Headers for the heat transfer fluid conduits are welded to opposite ends of the plates, hence permitting a single passage of heat transfer fluid across the length of the heat absorbing plates or, by appropriate design of the internal configuration of the headers. 
         [0010]    This design arrangement allows the heat transfer fluid to be directed along one portion of the heat absorbing plates in one direction to a second header and returned along the remaining portion of the heat absorbing plates in the opposite direction to exit from a first header at the same end that the heat transfer fluid entered the first header. In addition, conventional pads of rigid foam type insulation may be supported by bottom frame elements secured to the channels beneath the heat absorbing plates. A standard dimension of glazing material, such as glass or suitable transparent plastic, may be sealingly secured to the top surfaces of the channels forming the frame for the solar collector module units. 
         [0011]    In another prior art solar collector heat exchanger unit design, manufacture of such solar collector heat exchanger units are made in a very simple way by a mechanical rolling process. This process is defined by a rolling device with a groove means for compressing a pair of aluminum strips and a copper pipe lying between the pair of aluminum strips. The rolling device includes a pair of rollers and grooves disposed therein and are positioned directly opposite one another and having a shape corresponding to the shape of a pipe that is fed between the aluminum strips, so that a heat exchanger member with a greater total wall thickness at the pipe portion than at the fin portion is obtained after the passage of the strips and the copper pipe between the rollers. 
         [0012]    Also, a guide means is positioned in front of the rollers and there between for supporting the pipe as the strips and the pipe are fed between the pair of rollers, so that the copper pipe is fed centrally to the grooves in the rolls. 
         [0013]    Note that it is not necessary that the rolling process application have to include the pair of separate sheet strips, but it can be a single strip sheet that can be folded along its middle for forming two strip portions can be utilized just as well. Each of the separate strips or strip portions can have mating pre-deformed cavities for receiving the flattened or deformed pipe or one of the folded strips can be substantially flat without a pre-deformed cavity and the other folded strip can have a pre-deformed cavity for receiving a pre-deformed cavity having a closed loop configuration so that only one sheet abuts against the copper pipe and welded thereto. Additionally, the folded strip sheet with the closed loop configuration should have a larger width from the beginning, so that this folded strip sheet after the pre-deformation has substantially same width as the other substantial flat strip folded sheet without the pre-deformed cavity. 
         [0014]    This permits the peripheral edged to be substantially the same. At one end of the strip sheets, a raised peripheral edge defines a slot there between and spaced to receive the opposite edge of a similar solar collector unit to form a larger heat exchange module. The pre-deformed cavity in each of the separate sheets having a configuration that allows both sheets to abut against the pipe and are welded thereto Also, the copper pipe is pre-flattened in advance. 
         [0015]    Another solar collector prior art type shows an upper corrugated-like upper plate panel with an array of crest and valley or dimple sections defining channels there between and a lower generally flat plate panel that is attached to the upper plate panel so that the channels will provide fluid flow paths there through between inlet and outlet fluid headers. The valleys or dimple sections are spot welded to the lower plate panel and the upper plate and lower plate panels are seam welded at their peripheral ends. This seam welding ensures that the volumes of the channel flow paths are water or fluid tight. Note that the valley or dimple sections could be arranged in a rectangular array so that there are a number of parallel lateral flow passages intersected by a number of parallel longitudinal flow passages. 
         [0016]    Also, the valley or dimple sections could be arranged in an array so that the flow passages extend in directions with both lateral and longitudinal components that are diagonally extending across the face of the solar collector. Also, it is well know that upper and lower plate panels may be corrugated or dimpled providing the requisite lateral and longitudinal flow paths there between. 
         [0017]    This solar collector device includes a casing made of a material, such as, aluminum and comprising a base surrounded by upstanding peripheral walls and having an open top. The interior of the casing below the lower plate panel has insulating material such as polyurethane foam or the like disposed therein. A framework is mounted atop the side walls for closing and covering the open top by a glass sheet or light transparent member by a glazing gasket. The purpose of the glass sheet or light transparent member is to prevent the heated air from the vicinity of the upper plate panel or absorber plate panel from escaping the collector and being lost to the atmosphere. 
         [0018]    In conventional solar collector units, the solar energy is incident on absorbed by a metallic plate having so-called “black body” coating thereon which effectively converts it to a black body type heat radiator. This black body surface is encased within a glazing of a transparent ceramic or plastic material and the inner surface of such glazing permits the transfer of light there through, but reflects back towards the heat absorbing black body plate substantially all infrared radiation emitted by the black body plate. As heat is developed in the black body plate, it is then transferred to the fluid pipes or fluid flow paths or channels disposed between the upper and lower plate panels. A layer of insulation is disposed below and/or surrounding the lower surface of the black body plate and the pipes and the fluid flow paths to prevent the loss of heat to the outside of the solar collector units. 
         [0019]    The above mentioned prior art solar collector heat exchange units, which take on many different designs and structures are disclosed and described in U.S. Pat. Nos. 3,145,707, 3,555,756, 4,056,094, 4,182,308, 4,237,971, 4,245,620, 4,325,359, 5,431,149, 5,576,276, U.S. Publication No. 2004/0060555, and Great Britain U.S. Pat. No. 2,099,134 to name just a few. 
         [0020]    It is apparent that many of the prior art solar collector heat exchange units were designed and constructed to curtail manufacturing costs and time. Many attempted to economically fabricate by utilizing standard shapes and sizes of existing materials, eliminating the need for expensive machining or molding of materials, and eliminating complex installation procedures. However, these prior art solar collector units still lacks a cost effective way of mass producing, assembling and installation in a simple and cheap way in order to be economically attractive. 
         [0021]    However, the disclosed invention is designed and constructed to provide a cost effective way of mass producing, assembling and installing in a simple and cheap way in order to be economically attractive and overcome the above cost and time issues. This will attract and allow more people throughout the United Sates and the World to utilize solar energy as an alternative energy source. 
       SUMMARY OF THE INVENTION 
       [0022]    The present invention is designed and constructed to provide a very simple process to manufacture a relatively inexpensive and durable effective thermal solar collector cells and modules with a minimum use of required machinery and tools. Such low cost and easy method of fabricating materially contributes to a more efficient use and conservation of energy for all people throughout the world, especially those in underserved communities to go green. This low cost and easy method of fabricating would allow the solar collector cells to be ready for easy assembling by other solar module manufacturers, installers or other independent contractors. These solar cells can be utilized as off-the-shelf products in the development of new products or resources by other manufacturers of thermal solar collector modules. 
         [0023]    Also, with more people being able to afford and use solar energy as an alternative green energy source, will automatically and materially enhance the quality of the environment by reducing greenhouse gas emissions. 
         [0024]    In addition, the above low cost and easy method of fabricating with a minimum use of required machinery and tools contributes to the establishment of multiple fabrication facilities that will generate many green jobs and opportunities. 
         [0025]    According to one aspect of the present invention a PYROPEG solar collector module embodying this invention comprises at least two heat exchanger solar cells with plural pipe tubing channels mounted on a specially designed aluminum frame or a galvanized two-part frame assembly, an insulating back material (polyurethane foam, polystyrene foam, styrofoam and other insulating types of material) with an optional metal back plate (galvanized, aluminum or stainless steel). A regular top cover (regular glass, tempered glass or polycarbonate sheet), glass hold down frame and screws, cell hold down clamps, frame assembling screws, and inlet and outlet cell fluid connectors. These solar module elements will be made available in a “kit”, complete with all necessary components and easy to follow instructions. The potential user will be able to assemble the solar collector module with considerable ease, time and savings. 
         [0026]    It is preferred that the dual solar cells have an overall preferred dimension of 32″ in height, 47″ in width and 2¼″ in thickness. This size is important because any contractor may use regular construction supply material yielding minimum waste. The size is also easily handled by one person during installation. 
         [0027]    The PYROPEG solar cells of the present invention comprises at least two elongated, generally rectangular heat absorbing thin metallic plates cut from a 4′×8′ galvanized sheet metal with at least a thickness of 0.016″. One of the at least two elongated, generally rectangular heat absorbing thin metallic plates includes an upper plate and a lower substantially flat plate. Then the upper plate is mounted on a 45 ton press and activated to imprint a spiral special design of continuous plural corrugated sections defining alternating crest portions, valley portions and inclined portions extending between and connected to the crest and valley portions. Also, the 45 ton press folds an entire perimeter of the upper plate at a 90 degree angle and ½″ height defining first peripheral edges. The other one of the at least two elongated, generally rectangular heat absorbing thin metallic plates includes a lower substantially flat plate. 
         [0028]    Next, the upper plate is laid upside down or inside out and two holes are punched through the corrugated crest portions at a perimeter of the corrugated sections that is in close proximity to the ½″ folds at opposite sides. One of the two holes then allows an inlet connector with a top portion to pass there through and a lower portion to be attached to one end of the flattened copper pipe tubing. The other one of the two holes then allows an outlet connector with a top portion to pass there through and a lower portion to be attached to the other end of the flattened copper pipe tubing. 
         [0029]    Prior to the flattened copper tubing being inserted into the open channels and attached to the inlet and outlet connectors, a regular circular ½″ copper tubing is placed in a bender apparatus where the circular ½″ copper tubing is bent into a specified or spiral-like shape of three bends of 180 degrees and in sequential manner, where each bend is opposite to one another in direction and having a 3½″ bend radius. After the circular ½″ copper tubing is bent, it is then laid in an apparatus composed of two metal plates, whereby a pressure force (about 20,000 P.S.I.) is applied to the copper tubing and flattens it to a preferred thickness of ¼″. Note that other sizes could be utilized, if desired, to one of ordinary skill in the art at the time the invention was made. 
         [0030]    Next a hole is drilled in a top portion of the flattened copper tubing contiguous to both ends thereof. Then each of the ends of the flattened copper tubing is crimped closed and sealed by silver soldering. Other means for sealing the closed ends may be selected from the group consisting of brazing, welding and adhesive bonding. Thereafter, the flattened copper tubing is then positioned in the formed open channels and the inlet and out connectors is now passed through the two punched holes of the corrugated crest portions with the lower portions of the connectors being welded to the top of the flattened copper tubing above and in alignment with the holes at both ends thereof. However other types of securing means, such as mechanical fasteners, soldering and adhesive bonding, to name just a few, can be utilized by one of ordinary skill in the art, at the time the invention was made. 
         [0031]    In a further aspect of the present invention, the flatten copper tubing is then positioned in the formed open channels with the upper plate being upside down and the lower plate is placed on the upside down upper plate over the flattened copper tubing, which closes the open channels. The upper plate has a dimension that is greater about its perimeter than a dimension of the lower plate about its perimeter so that the peripheral edges of the upper plate extends beyond the peripheral edges of the lower plate. Then the three parts, the upper plate, the flattened copper tubing and the lower plate are put together and mounted into a folding apparatus where the ½″ folded peripheral edges of the upper plate can be folded over the peripheral edges of the lower plate for securing the upper and lower plates at their peripheral edges about their entire perimeters and compressing the flatten tubing between the upper and lower plates as a newly formed solar cell unit. 
         [0032]    This newly formed solar cell unit is then mounted onto a pressing ram type apparatus for further pressing the folded peripheral edges of the upper plate and the peripheral edges of the lower plate with an even and uniform pressure force of about 80,000 P.S.I. that creates a first mating upstanding raised protuberance on an upper portion of the folded peripheral edge of the upper plate and a second upstanding raised protuberance on a portion of the folded peripheral edge of the lower plate, where the lower plate mating protuberance is forced into an underneath open surface of the raised protuberance of the upper plate. Also, the pressing die operation creates a third upstanding raised protuberance at the peripheral edge of the upper plate that folds over and underneath the peripheral edge of the lower plate. The above uniform pressure force is applied to ram pressing member where an upper male part and a lower female part of a die are mounted. When the upper male die part presses into the lower female die part it creates the first, second and third protuberances with a dimension of ¼″ in width and ⅛″ in height. 
         [0033]    The third upstanding raised protuberance is forcibly crimped into an underneath open cavity of the second raised protuberance, while at the same time forcing the second protuberance into the open cavity of the first raised protuberance for rigidly securing the upper and the lower plates together as a single cell unit. To further secure the upper and lower plates together as a single unit, the end of the folded peripheral edge outward of the third raised protuberance is attached from the selected group consisting of welding, soldering and adhesive or epoxy bonding to an under surface of the lower plate inward of the second raised protuberance. 
         [0034]    Note that the area between the upper and lower plates contiguous to the first second and third protuberances can also have a weld, solder, adhesive or epoxy means thereat for a further rigid securement. After this pressing operation the folded edges at all four pressed corners are soldered or epoxied to further add strength and rigidity to the single solar cell unit. 
         [0035]    According to another aspect of the present invention, the upper plate includes a plurality of stamped dimple-like circular depressions or pin-less rivets along the valley portions and the lower plate includes a plurality of complimentary stamped dimple-like circular depressions or pin-less rivets for mechanically securing the upper and lower plates together as a single unit. The clinching operation is performed on the single cell unit after the last operation where the raised protuberances are formed on the upper and lower plates at their peripheral edges. 
         [0036]    During the clinching operation, the pressed and formed single cell unit is then placed in a clincher machine where at least 16 circular depression like or pin-less like rivets that is at least ¼″, will be impressed into the upper and lower plates in an even and uniform manner. Note that the valley portions have a dimension that is at least ¾″. However, the dimensions of the valley portions and the circular depression like or pin-less like rivets can be of various sizes to one of ordinary skill in the art, at the time the invention was made. 
         [0037]    These pin-less or circular depression like rivets will effectively secure the upper and lower plates and conform them into a single body unit, which forms a continuous channel there between for encloses the flattened copper tubing therein. The enclosed flattened copper tubing lies in a uniform contact relationship with the upper and lower plates by pressure from the at least 16 pin-less or circular depression like rivets and the raised protuberances of the folded peripheral edges of the upper and lower plates. The solar cells are spray painted with a non-reflective black paint. This process assists the already galvanized unit in protecting itself from the environmental elements. 
         [0038]    The clinching operation completes the mechanical operation of the now formed single cell unit by adding to it additional stiffness and rigidity. 
         [0039]    Thereafter, 45 degree angular inlet and outlet copper tubing members are then soldered to each inlet and outlet connectors to complete the fabrication of the single solar cell unit. 
         [0040]    Once the single solar cell unit is to be utilized as a dual module of the preferred embodiment of the present invention can now be created with the following components. A specially shaped design extruded aluminum frame of a specified length comprising four pre-cut aluminum frame pieces with at least three (3) screw channels formed along an interior surface and extending to the corner edges thereof. The at least three (3) screw channels extend substantially along all of the frame pieces at upper, intermediate and lower locations thereon. Each corner edge of all of the frame pieces have at least three (3) drilled screw holes therein that will align with the at least three (3) screw channels. This will allow screws to be inserted through screw holes at the four corner edges of frame pieces and into the screw channels to secure the four-piece frame pieces together to define a dual solar cell module frame housing unit. 
         [0041]    The at least a pair of the frame pieces further includes an at least three (3) supporting ledges, an upper ledge at an upper section that includes the screw hole, an intermediate ledge at an intermediate section thereon and a base, foot or bottom ledge projected inward at a lower end thereof. and the intermediate ledge is shorter than the base or bottom ledge. This permits other solar cell module elements to be inserted therein without interfering with each other. 
         [0042]    The upper screw channel is formed on an undersurface of the upper ledge adjacent an end thereof, the intermediate screw channel is formed on and extend from an interior surface of the at least a pair of the frame pieces contiguous to and above the intermediate ledge and the lower screw channel is formed on an interior upper surface of the bottom ledge, which is spaced at a location close to but spaced from the end thereof. Note that the intermediate screw channel has a three-fold purpose, the first being to receive securing screws through the corner screw holes to secure the frame pieces about at least a pair of single solar cell units, the second being the utilization only of the intermediate screw channel solely for holding the frame when assembling them together and third, the intermediate screw channel is used as rest support for the single solar cell unit peripheral edges. 
         [0043]    Further, the preferred dual solar collector module includes a pair of single solar cell units within the dual solar cell module frame housing unit. An opening is drilled through the crest portion near a crimped silver soldered closed end of the flattened copper tubing member to receives the inlet and out connectors there through by soldering or welding or brazing to a top portion of the flattened copper tubing member over a hole formed in the flattened copper tubing member adjacent the crimped closed end to allow fluid medium to pass between the fluid inlet and outlet connectors to heat utilization device. Also, the module frame housing unit further includes back support plates (for the dual solar cell units) that rests on the bottom ledge for supporting and receiving an insulation material, such as Styrofoam, thereon, which extends outward in close proximity to the screw channel on the bottom ledge. 
         [0044]    Additionally, the corrugated upper plate with the inclined or angled portions, the top crest portions, the lower plate and a first inward portion of the folded and overlapped peripheral edge is positioned to rest on the insulation material. A second outward portion of the peripheral edge rests on the intermediate ledge and spaced from the intermediate screw channel. The dual solar cell unit defined by the upper plate with the inclined or angled portion, the top crest portions, the lower plate and the folded and overlapped peripheral edge is clamped down within the dual solar cell module frame housing unit by a plurality of hold-down clamps by screws and washers. The screws are screwed through the hold-down clamps and through screw holes in the intermediate ledge to compress the peripheral edges between the intermediate ledges and the hold-down clamps for adjusting compression force thereto. 
         [0045]    Also, this adjustable compression force will simultaneously press the above defined dual solar cell units into abutting engagement with the insulation materials. A screw head of hold down screw rests upon the hold down washers that rests upon an upper surface of the hold-down clamps. Also, the hold-down clamps have a first end that rests upon the intermediate screw channel member and a second end that rests upon the peripheral edges. 
         [0046]    The upper ledge serves as a rest member for supporting a cover glass thereon. The cover glass is at least ⅛″ in thickness and is held in place by at least a preformed one-piece 90 degree aluminum angular molding having a thickness that is at least 0.070″. In addition, the cover glass has a back cover that can be made from either galvanized or aluminum sheet metal or a composite material, if desired. The upper ledge has a sealing caulking paste or compound that is applied thereto, so that the cover glass will be secured and made weather resistant by the combination of the sealing caulking paste or compound and the downward pressure applied to the four frame pieces and the at least one-piece 90 degree angular molding. This at least one-piece 90 degree angular molding includes an upper rim portion that engages and extends along an upper surface of a peripheral end portion of the cover glass and a downward perpendicular leg portion of the at least one-piece 90 degree angular molding that projects around the upper portion of the upper part of the frame pieces. The at least one-piece 90 degree angular molding is secured to the upper portion of the upper part of the frame pieces by at least 8 sheet metal screws that extend through drilled holes in the at least one-piece 90 degree angular molding and through the screw holes of the frame pieces at a lateral side thereof to tightly secure the cover glass against the ledges of the frame pieces. Note that the sheet metal screws are disposed at a spaced distance below the upper screw channel to obviate any interference therewith. 
         [0047]    Finally, the dual module frame pieces are wire brushed to a polished finish. Then the inlet and outlet connectors are capped at the end portions of each of the 45 degree angular copper tubing opposite the end that is soldered, brazed or welded to the inlet and outlet connectors. A flexible hose or tube having one end connected to the outlet connector of a first one of the pair of single solar cell units and the other end is connected to the inlet connector of the second one of the pair of the single solar cell units. Optionally, a pair of hose clamps can be used to clamp each end of the flexible hose to provide a fluid-tight seal on each of the 45 degree angular copper tubing. Now the dual solar cell module unit is now ready for shipment. 
         [0048]    These and other features, aspects and advantages of the present will become better understood with regard to the following description, appended claims and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0049]    The present invention may be better understood, along with its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings. 
           [0050]      FIG. 1  illustrates an isometric view of a solar cell device according to the present invention. 
           [0051]      FIG. 2  illustrates a front cut sectional view of the solar cell device according to the present invention. This view shows details of the peripheral folded and overlapping edge and the pin-less or depression-like rivets 
           [0052]      FIG. 3  illustrates a full front view of the solar cell device according to the present invention. 
           [0053]      FIG. 4  illustrates a top view of the solar cell device according to the present invention. 
           [0054]      FIG. 5  illustrates a cutaway isometric view of the solar cell device&#39;s corner and folded peripheral edge being open according to the present invention. 
           [0055]      FIG. 6  illustrates a cutaway 3-D isometric view of the solar cell device&#39;s pressed and soldered corner and folded peripheral edge according to the present invention. 
           [0056]      FIG. 7  illustrates an isometric top view of the solar cell device as a dual module unit according to the present invention. 
           [0057]      FIG. 8  illustrates a front view of a preferred solar cell module unit with inlet and outlet connectors, glass cover, insulation, back plate, solar cell unit with clamping means for the peripheral folded and overlapping edge and a module frame with a plurality of screw channels there through for securing the frame together and screw clamps for holding down the glass cover according to the present invention. 
           [0058]      FIG. 9   a  illustrates a front cut view of the peripheral folded and overlapping edge at a left side perimeter of the present invention. 
           [0059]      FIG. 9   b  illustrates a front cut view of the peripheral folded and overlapping edge at a right side perimeter of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0060]    Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the accompanying drawings, it will be understood that they are not intended to limit the invention to the accompanying drawings. On the contrary, the present invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. 
         [0061]      FIG. 1  of the present invention shows an isometric cut-out view of an improved formed solar cell unit device  10  comprising an upper sheet metal plate  11  and a lower sheet metal plate  13 , preferably of extruded aluminum, with a flattened copper tubing  17  disposed and secured there between. It is hereby acknowledged that the metal plates  11  and  13  can be made out various other types of metals, if desired. The upper plate  11  and the lower plate  13  are cut from 4′×8′ galvanized sheet metal having a thickness of 0.020″ with the upper plate  11  being wider by at least ½″ over the entire perimeter than lower plate  13 . This wider perimeter defines a peripheral edge  12  around the entire fold of the upper plate  11  and being able to be folded over the outer perimeter portion of lower plate  13  defining a peripheral edge securing means  12  and  14 . The peripheral edge securing means  12  and  14  will be discussed in greater details below. Upper plate  11  has a stamped continuous corrugated design thereon. 
         [0062]    This corrugated design is formed by mounting the upper plate  11  on a 45 ton die press apparatus for imprinting or impressing a continuous form of plural alternating upstanding crest portions  15 , valley portions  19  and inclined or angled connecting portions  20   a ,  20   a ′,  20   b  and  20   b ′ on an upper surface when activated. Further, the alternating crest portions  15  and valley portions  19  creates a continuous form of channels or cavities  16  on an under surface thereof. The undersurface channels or cavities  16  are connected in a continuous form by the inclined and connecting portions  20   a ,  20   a ′,  20   b  and  20   b ′. The plural alternating upstanding crest portions  15  and the undersurface channels or cavities  16  forms a continuous spiral shape for receiving the flattened copper tubing  17  with a pair of inlet and outlet closed end portions (not shown). These closed ends are crimped and silver soldered to seal the crimped closed ends. A drilled hole is made adjacent the perimeter of the closed end portions. 
         [0063]    Preferably, these drilled holes are positioned at least a ¼″ from the crimped closed ends and have a dimension that is at least a ¼″. Note that various other sizes of the drilled holes and distances can be utilized, if desired. The upper plate  11  is laid inside out and two holes  22   a  and  22   a ″ in  FIG. 4 , two holes  22   a ′ and  22   a ″ in ( FIG. 7 ) and two holes  35   a  in  FIG. 8  are punched there through near the perimeter of the upper plate  11  to allow inlet and outlet connectors  21  and  22  shown in  FIG. 4 , inlet and outlet connectors  21 ′,  21 ″,  22 ′ and  22 ″ shown in  FIG. 7  and inlet and outlet connectors  40 ,  41  and  42  shown in  FIG. 8  to be inserted there through and attached to the inlet and outlet closed end portions over and in alignment with the drilled holes (not shown) of the flattened copper tubing  17 . This allows fluid to be transferred between the inlet and outlet connectors  21  and  22  of  FIG. 4 , the inlet and outlet connectors  21 ′,  21 ″,  22 ′ and  22 ″ of  FIG. 7  and the inlet and outlet connectors  40 ,  41  and  42  of  FIG. 8  in a heat transfer relationship. 
         [0064]    Additionally, the plural alternating upstanding crest portions  15  has a pair of outside and inside inclined or angled portions  20   a  and  20   b  with an intermediate valley portion  19  interconnecting the inside angled portions  20   a  and  20   b  that extends substantially along the entire length of the crest portions  15 . Also, the crest portions  15  define alternating crest leg elements  20  of a shorter length dimension than the overall length of the upstanding crest portions  15 . Such alternating leg elements  20  forms a U-shape like portion of the continuous spiral shape with a pair of inside inclined or angled portions  20   a ′ and  20   b ′ that corresponds to the length dimension of the alternating crest leg elements  20 . Each of the alternating inside inclined or angled portions  20   a ′ and  20   b ′ is interconnected by a shorter valley portion  19 , which corresponds to the length dimensions of the inclined or angled connecting portions  20   a ′ and  20   b ′ and the shorter alternating crest leg elements  20 , which set forth the U-shape portion of the continuous spiral shape that conforms to the shape of the flattened tubing disposed in the undersurface channels or cavities  16 . 
         [0065]    Also, the 45 ton press folds an entire perimeter of the upper plate. The other one of the at least two elongated, generally rectangular heat absorbing thin metallic plates includes a lower substantially flat plate. Then the lower plate is mounted on a press (die) that folds and entire perimeter of the lower plate at a preferred 90 degree angle and ½″ height defining second peripheral edges. 
         [0066]    Also in  FIG. 1 , when the 45 ton press die apparatus is activated, it will fold an entire perimeter of the wider peripheral edge  12  of the upper plate at a 90 degree angle and ½″ height defining first peripheral edges for rigidity and stiffness. After this folding operation, the flattened copper tubing is positioned in the formed channels or cavities in an upside down position and the inlet and outlet connectors  21  and  22  as shown in  FIG. 4 , inlet and outlet connectors  21 ′,  21 ″,  22 ′ and  22 ″ as shown in  FIG. 7  and the inlet and outlet connectors  40 ,  41  and  42  as shown in  FIG. 8  are inserted through the punched holes  22   a  ( FIG. 4 ),  22   a ′ and  22   a ″ ( FIG. 7) and 35   a  ( FIG. 8 ) and welded to the top of the flattened copper tubing  17  ( FIGS. 1-3 ) and the flattened copper tubing  37  ( FIG. 8 ) over the drilled holes (not shown) of the flattened copper tubing  17 . Then the flattened copper tubing  17  that is now disposed within the channels or cavities  16  is sandwiched between the upper plate  11  and the lower plate  13  to attach the upper plate  11  and lower plate  13  together by mounting them into a folding apparatus where the ½″ folded peripheral edges  12  are folded over the peripheral edges  14  to form a single solar cell unit  10 . 
         [0067]    After the single solar cell unit has been formed, this newly formed solar cell unit  10  is then mounted on to another pressing die apparatus that presses the upper plate  11  and lower plate  13  peripheral edges  12  and  14  with an even and uniform pressure of about 80,000 P.S.I. This pressure is applied by a ram device where a male part of a die is mounted, so that when the male part of the die presses into a female part of the die, it forms a protuberance of about ¼″ in width and ⅛″ in height. After this operation, the folded and pressed corner edges  12 - 12   e  ( FIG. 6 ) defined by the wider peripheral edge  12  of the upper plate and the pressed corner edges  14 - 14   c  ( FIG. 6 ) defined by peripheral edge  14  of the lower plate  13  are then welded or soldered there between and at element  14   d  to establish a strong rigid and stiff connection around the entire perimeter of the newly formed solar cell unit  10 . 
         [0068]    Next, the pressed and newly formed solar cell unit  10  is taken to a clincher machine where at least 16 circular depression like or pin-less like rivets  18 ,  18 ′ and  18 ″ are impressed along the valleys  19 ,  19 ′ and  19 ″ of the upper plate  11  and a corresponding aligned surface of the lower plate  13  with a dimension of ¾″ that will bring about a uniform clinching contact that will cause the upper plate  11  and the lower  13  to engage the flattened copper tubing  17  and  37  in a sandwich relationship. This will make the upper plate  11 , the lower plate  13  and the flattened copper tubing  17  and  37  an improved and complete single solar cell unit  10 . This clinching apparatus has a specially designed die that is able to fastened and press together the upper plate  11  and the lower  13  by forming the pin-less rivets  18 ,  18 ′ and  18 ″ as dimple-like depressions along the valleys  19 ,  19 ′ and  19 ″ of the upper plate  11  and the corresponding aligned surface of the lower plate  13 . Now, this operation completes the mechanical operation of the pressed and newly formed solar cell unit  10  by adding to it additional stiffness and rigidity to render a strong and unified final product. Then, inlet and outlet tubes  24  ( FIG. 7 ) are then connected to the inlet and outlet connectors  21  and  22  as shown in  FIG. 4 , inlet and outlet connectors  21 ′,  21 ″,  22 ′ and  22 ″ as shown in  FIG. 7  and the inlet and outlet connectors  40 ,  41  and  42  ( FIG. 8 ) to complete the fabrication of the newly formed solar cell unit  10 . 
         [0069]      FIG. 2  is a cut front sectional exploded view that shows the dimple-like depressions  18  along the valley portions  19  (not shown, see  FIG. 1 ) in the upper plate  11  and the corresponding aligned dimple-like depression  18   a  in a surface portion of the lower plate  13  created by the aforementioned pressing operation. Extending to the right of the dimple-like depressions  18  and  18   a  as shown is one of the alternating crest portions  20  with the inclined or angled portions  20   a  extending there from and the inclined or angled portion  20   b  of the one alternating crest portion  20  interconnects a first periphery edge raised protuberance  12  of the upper plate  11 . The first periphery edge raised protuberance  12  includes a pair angled or inclined leg portions  12   a  and  12   b , with angled leg portion  12   a  being connected to the alternating crest portion inclined portion  20   b  and the angled leg portion  12   b  being connected to an upper overlapping portion  12   c  and a lower overlapping portion  12   d . Extending inward of the lower overlapping portion  12   d  is a third raised protuberance  12   e , with angled leg portion  12   f  being connected to the lower overlapping portion  12   d  and the angled leg portion  12   g  being connected to an outward extending overlapping edge end portion  12   h , which is welded to an undersurface of the lower plate  13 . 
         [0070]    Lower plate  13  has a second periphery edge raised protuberance  14  disposed and nested between the first raised protuberance  12  and the third raised protuberance  12   e  of the upper plate  11 . Note that the second periphery edge raised protuberance  14  includes a pair of angled or inclined leg portions  14   a  and  14   b , with the angled leg portions  14   a  and  14   b  being pressed into an abutting engagement with mating surfaces of the cavity of the first raised protuberance  12 , with the lower surface of the lower plate  13  inward of the raised protuberances  12 ,  12   e  and  14  being pressed across and against the plural open channels or cavities  16  of the plural alternating crest portions  20  for enclosing the flattened copper tubing  17  therein. 
         [0071]    To rigidly secure the upper plate  11  and lower plate  13  together as a single cell unit, the third upstanding raised protuberance  12   e  is forcibly crimped or pressed into an underneath open cavity formed by the second raised protuberance  14  and the pair of angled or inclined leg portions  14   a  and  14   b , while at the same time forcing the pair of angled or inclined leg portions  12   f  and  12   g  into an abutting engagement with mating surfaces within the open cavity of the second raised protuberance  14 . 
         [0072]    An insulation material  21 , such as Styrofoam, is disposed below the lower plate  13  as shown. However, the insulation material  21  is in an engaging relationship with the lower plate  13  when the upper plate  11  and lower plate  13  are secured together as a single cell unit as previously discussed. 
         [0073]      FIG. 3  is a full cut front view of the cut sectional exploded view illustrated in  FIG. 2  with the upper plate  11  including a plurality of alternating crest portions  20  with the dimple-like depressions  18  along the valley portions  19  (not shown, see  FIG. 1 ) disposed there between and mating with the corresponding aligned dimple-like depression  18   a  in a surface portion of the lower plate  13 . The plurality of dimple-like depressions  18  are alternately joined to the inclined or angled portions  20   a  extending from one side thereof to an alternating crest portion  20  and the inclined or angled portion  20   b  extending from the other side thereof to another alternating crest portion  20 . The outer inclined or angled portions  20   a  and  20   b  adjacent the perimeter interconnects with the periphery edge raised protuberances  12  of the folded and overlapping edges of the upper plate  11  at opposite sides. Details of the folded periphery edge and raised protuberances  12  have been previously recited in the description of  FIG. 2  above. Note that the flattened copper tubing  17  is shown sandwiched between the upper inside surface of the upper plate  11  and the inside surface of the lower plate  11 . This sandwich relationship holds the flattened copper tubing  17  within the channels or cavities  16  in a tight engagement therein to prevent movement of the copper tubing  17 . 
         [0074]    Also in  FIG. 3 , an insulation material  21 , such as Styrofoam, is disposed below the lower plate  13  as shown. The insulation material  21  is shown in an engaging relationship with the lower plate  13  when the upper plate  11  and lower plate  13  are secured together as a single cell unit as previously discussed. 
         [0075]    The illustration shown in  FIG. 4  represents a top view of the solar cell unit  10 . This figure shows the periphery edges  12 , the plural imprinted or impressed continuous form of plural alternating upstanding crest portions  15  and  20 , dimple-like depressions or pin-less rivets  18 , valley portions  19  that receives the impressed dimple-like depressions or pin-less rivets  18  and the inclined or angled connecting portions  20   a ,  20   a ′,  20   b  and  20   b ′ on an upper surface that extends from alternating sides of the crest portions  15  and  20 . Further, the alternating crest portions  15  and  20  and valley portions  19  creates a continuous form of channels or cavities  16  on an under surface thereof (not shown, see  FIGS. 1-3 ). 
         [0076]    The undersurface channels or cavities  16  (not shown) are connected in a continuous form by the inclined and connecting portions  20   a ,  20   a ′,  20   b  and  20   b ′. The plural alternating upstanding crest portions  15  and  20  and the undersurface channels or cavities  16  (not shown) forms a continuous spiral shape for receiving the flattened copper tubing  17  not shown) with a pair of inlet and outlet holes The upper plate  11  is laid inside out and two holes (not shown) are punched there through near the perimeter to allow the similar inlet connector  21  and  22  and outlet connector  21  and  22  to be inserted there through and attached to an upper surface of the flattened copper tubing  17  (not shown) by welding, soldering or brazing. Note that a hole (not shown) is drilled through a top surface of the flattened copper tubing  17  that is positioned at least a ¼″ from a crimped end thereof that is silver soldered or brazed closed. To one of ordinary skill in the art, at the time the invention was made, the hole can be positioned at other distances from the closed crimped end of the flattened copper tubing  17 , if desired. 
         [0077]      FIG. 5  shows a cutaway isometric view of the folded and overlapping peripheral edge  12  corner of the upper plate  11  that is disposed in a slight spaced position from the bottom of lower plate  13  of the solar cell unit  10 , prior to the corner edges of the upper plate  11  and the lower plate  13  being pressed down and welded, soldered, brazed or epoxied together. 
         [0078]      FIG. 6  illustrates a cutaway 3-D isometric view of the pressed and soldered corner and folded and overlapping peripheral edge  12  seen from the bottom of lower plate  13  of the solar cell unit  10 . This view shows similar peripheral edge reference numbers as shown in  FIG. 2 . Note that  FIG. 6  shows a bottom oriented isometric 3-D affect and  FIG. 2  shows a front cut oriented view. The description of  FIG. 6  will be discussed in a similar manner as previously discussed in  FIG. 2  above, since it is merely turned upside down. 
         [0079]    Looking from the bottom of the lower plate  13 , the first periphery edge raised protuberance  12  includes a pair of angled or inclined leg portions  12   a  and  12   b , with angled leg portion  12   a  that is connected to the alternating crest portion inclined portions  20   a  and  20   b  (not shown) and the angled leg portion  12   b  being connected to an upper overlapping portion  12   c  and a lower overlapping portion  12   d . Extending inward of the lower overlapping portion  12   d  is a third raised protuberance  12   e , with angled leg portion  12   f  being connected to the lower overlapping portion  12   d  and the angled leg portion  12   g  being connected to an outward extending overlapping edge end portion  12   h , which is welded, brazed or soldered to an undersurface of the lower plate  13 . 
         [0080]    Lower plate  13  has a second periphery edge raised protuberance  14  disposed and nested between the first raised protuberance  12  and the third raised protuberance  12   e  of the upper plate  11 . Note that the second periphery edge raised protuberance  14  includes a pair of angled or inclined leg portions  14   a  and  14   b , with the angled leg portions  14   a  and  14   b  being pressed into an abutting engagement with mating surfaces of the cavity of the first raised protuberance  12 , with the lower surface of the lower plate  13  inward of the raised protuberances  12 ,  12   e  and  14  being pressed across and against the plural open channels or cavities  16  (not shown) of the plural alternating crest portions  20  (not shown) for enclosing the flattened copper tubing  17  (not shown) therein. To rigidly secure the upper plate  11  and lower plate  13  together as a single cell unit, the third upstanding raised protuberance  12   e  is forcibly crimped or pressed into an underneath open cavity formed by the second raised protuberance  14  and the pair of angled or inclined leg portions  14   a  and  14   b , while at the same time forcing the pair of angled or inclined leg portions  12   f  and  12   g  into an abutting engagement with mating surfaces within the open cavity of the second raised protuberance  14 . 
         [0081]    The four corner edges defined by the raised protuberances  12 ,  12   e  and  14 , inclined or angled leg portions  12   a ,  12   b ,  12   f ,  12   g ,  14   a  and  14   b  and the under surface overlapping outward and inward edge portions  12   d  and  12   h  are pressed and welded, soldered, brazed or epoxied there between to further add strength and rigidity to the formed solar cell unit  10 . Also,  12   h  is welded, soldered or brazed to the lower plate  13  at  14   d  to further strengthen the peripheral edge  12  and the solar cell unit  10 . If desired, other types of securing means could be utilized, such as, adhesives or other types of bonding means. 
         [0082]    As illustrated in  FIG. 7 , an isometric top view of the solar cell device as a dual module unit that includes a pair of formed solar cell units  11 ′ and  11 ″. These units are identical to solar cell unit  10  in  FIGS. 1-6  and the reference numerals are identical except that they have a ‘and” added to them. This dual module arrangement further includes a four-piece extruded aluminum frame  27  and  28 , 3 copper tube members  24  bent at an angle of 45 degrees, a pair of corner openings  26  disposed within one of the frame pieces  27  or  28  to allow one end of the copper tube members to pass there through, at least a pair of 3 frame securing screw through channels, and a plurality of frame and solar unit hold-down clamping members  24   a.    
         [0083]    It is preferred that the dual solar cell units have an overall dimension of 32″ in height, 47″ in width and 2¼″ in thickness. This size is important because any contractor may use regular construction supply material yielding minimum waste. The size is also easily handled by one person during installation. 
         [0084]    The four-piece frame  27  and  28  is assembled around the pair of solar cell units  11 ′ and  11 ″. A pair of frame pieces  27  is positioned perpendicular to a pair of frame pieces  28  forming an enclosed structure. At least one of the pair of frame pieces  27  or  28  has at least three substantially spaced-apart screw through channels therein that receives complimentary screws for securing the frame pieces  27  and  28  together as a housing unit. For example, the at least three spaced-apart screw channels are disposed along an interior surface of at least one of the pair of frame pieces  27  or  28  that extends substantially along its entire length. These screw channels are in alignment with the screws  29  as shown in  FIG. 7  for holding the frame pieces  27  and  28  together. Note that  FIG. 7  depicts the screws  29  being positioned along the corner ends of frame pieces  27 , so that the screws  29  can be inserted on opposite corners of both frames  27  through the spaced-apart screw channels that would be disposed along an interior surface of frame pieces  28 . 
         [0085]    The middle screw channel has a three-fold purpose, which will be discussed later during the description of  FIG. 8  below. With this being said the four piece frame  27  and  28  is assembled by the top, middle and bottom screws  29  at each joining corner (12 total screws). 
         [0086]    Prior to securing the four piece frame around the dual solar cell units  11 ′ and  11 ″, a 45 degree angled copper tube member  24  having one end  23  soldered to the inlet and outlet connectors  21 ′,  22 ′ and  21 ″ and  22 ″ with the other end  25  being inserted through the corner openings  26  in one of the frames  28  at the corner ends as illustrated in  FIG. 7 . The assumption is that the top connectors  21 ′ and  22 ′ that cooperate with opening  26  is labeled as the inlet connector attached to a fluid medium source and the bottom connectors  21 ′ and  22 ″ of solar cell unit  11 ′ is labeled as the outlet connector. 
         [0087]    Then another 45 degree angled member  24  is disposed between the dual solar cell units  11 ′ and  11 ″ and soldered at both ends  23  with one end of  23  being connected to the outlet connector  21 ′ and  22 ′ of solar cell unit  11 ′ with the other end  23  being connected to the inlet connector  22 ″ of solar cell unit  11 ″ and the bottom connector  22 ″ of solar cell unit  11 ″ that is associated with opening  26  is labeled as the outlet connector and connected to a heat utilization device (not shown). If desired, this arrangement can be reversed and the above inlet and outlet connectors will be just the opposite. 
         [0088]    In  FIG. 7 , the peripheral folded and overlapped edges  12  as shown in  FIGS. 1-4  have at least three spaced-apart hold-down clamps  24   a  on the front and back sides of the frame elements  28  of the dual solar cell units  11 ′ and  11 ″ for clamping down the dual solar cell units  11 ′ and  11 ″ within the module housing unit defined by frame members  27  and  28 . Note that the at least three spaced-apart hold-down clamps  24   a  on the front side are not shown. Additionally, at least a single hold-down clamp  24   a  is disposed at an intermediate location for clamping down the peripheral folded and overlapped edges  12  relative to the sides defined by frame members  27  and at an intermediate location along the adjacent interior sides of the solar cell units  11 ′ and  11 ″ within the module housing unit defined by the frame members  27  and  28 . 
         [0089]    Referring now to  FIG. 8 , a complete module of the preferred embodiment of the dual solar cell module as shown in  FIG. 7 , which shows a specially shaped design extruded aluminum frame of a specified length comprising four-piece pre-cut aluminum frame members  44  with at least three (3) screw channels  45  formed along an interior surface adjacent the corner edges thereof. For example, the at least three (3) screw channels  45  are formed substantially along the entire length of all of the four-piece frame members  44  (similar to elements  27  and  28  of  FIG. 7 ) at upper, intermediate and lower locations thereon. Note that each corner edge of all of the frame members  44  (not shown, but similar to elements  27  and  28  of  FIG. 7 ) have at least three (3) drilled screw holes  29  therein as shown in  FIG. 7  that will align with the at least three (3) screw channels  45 . 
         [0090]    This will allow screws (not shown) to be inserted through screw holes  29  at the four corner edges of the frame members  44  and into the screw channels  45  to secure the four-piece frame members  44  together to define the dual solar cell module housing unit  30 . All of the specially designed frame members  44  further includes at least three (3) supporting ledges, an upper ledge  46   a  at an upper section that includes the screw hole  46   b , an intermediate ledge  49  at an intermediate section  47  and a base, foot or bottom ledge  48  projected inward from an interior surface thereof. These ledges  46   a ,  48  and  49  are designed such that the upper ledge  46   a  is shorter than the intermediate ledge  49  and the intermediate ledge is shorter than the base or bottom ledge  48 . This allows other solar cell module elements to be placed therein without experiencing interference with other elements. 
         [0091]    As shown in  FIG. 8 , the upper screw channel  45  is formed on an undersurface of ledge  46   a  adjacent an end thereof, the intermediate screw channel  45  is formed on and extend from an interior surface of the front and back frame members  44  contiguous to and above the intermediate ledge  49  and the lower screw channel  45  is formed on an interior upper surface of the bottom ledge  48 , which is spaced at a location close to but spaced from the end thereof. As previously mentioned, the intermediate screw channel  45  has a three-fold purpose, the first being to receive securing screws through corner screw holes  29  ( FIG. 7 ) to secure the frame about the single solar cell unit  11 ′,  11 ″ and  30 , the second being the utilization only of the screw channel  45  for holding the frame members  44  together when assembling them and third, the screw channel  45  is used as rest support for the single solar cell unit peripheral edges  12  and  32 . 
         [0092]    Further in accordance to  FIG. 8 , solar module housing unit  30  is represented by a cut sectional front side view of dual solar cell units  11 ′ and  11 ″, but is represented by different reference numerals, which will now be described in greater details. The solar cell units  11 ′ and  11 ″ is represented by a corrugated upper plate  31  with inclined or angled portions  31   a  and  31   b , a top crest portion  35  with a peripheral edge of a specified dimension, a lower plate  33  with a peripheral edge that is less than the dimension of the upper plate member  31   a  to allow the peripheral edge of the upper plate  31  to be crimped and folded over the peripheral edge of the lower plate  33  to provide rigidity and strength to the solar cell units  11 ′ and  11 ″, an opening  35   a  that is drilled through the crest portion  35  near the crimped silver soldered closed end (not shown) of the flattened copper tubing member  37  that receives the inlet and out connectors  40 ,  41 ,  42  and  42   a  there through and soldered or welded or brazed to a top portion of the flattened copper tubing member  37  over a hole (not shown) formed in the flattened copper tubing member  37  adjacent the crimped closed end to allow the fluid medium to pass between the fluid inlet and outlet connectors  40 , 41 ,  42  and  42   a . Element  42   a  is an opening within the angled copper tubing  42  that receives the fluid medium through the flattened copper tubing member  37  on the left side and discharges heat exchanged fluid from the flattened copper tubing member  37  on the right side as illustrated in  FIG. 8 . 
         [0093]    As shown, the flattened copper tubing  37 , which takes on a spiral shape is received in a spiral like cavity or channel  36  defined in an undersurface of the crest portion  35 . Also, the module housing unit  30  further includes back support plates  39  (for the solar cell units  11 ′ and  11 ″) that is supported on the bottom ledge  48  that supports and receive an insulation material  38 , such as Styrofoam, thereon, which extends outward in close proximity to the screw channel  45  on the bottom ledge  48 . 
         [0094]    Additionally, the corrugated upper plate  31  with the inclined or angled portions  31   a  and  31   b , the top crest portion  35 , the lower plate  33  and a first inward portion of the folded and overlapped peripheral edge  32  is positioned to rest on the insulation material  38 . A second outward portion of the peripheral edge  32  rests on the intermediate ledge  49  and spaced from the intermediate screw channel  45 . The dual solar cell unit defined by the upper plate  31  with the inclined or angled portions  31   a  and  31   b , the top crest portion  35 , the lower plate  33  and the folded and overlapped peripheral edge  32  is clamped down within the dual solar cell module housing unit  30  by a plurality of hold-down clamps  50  by screw  51  and washer  52  device. The screw  51  is screwed through the hold-down clamps  50  and through screw holes  49   a  in the intermediate ledge  49  to compress the peripheral edge  32  between the intermediate ledges  49  and the hold-down clamps  51  for adjusting and establishing the necessary compression force thereto. Also, this adjustable compression force will simultaneously press the above defined dual solar cell units into abutting engagement with the insulation materials  38 . A screw head of screw  51  rests upon the washer  52  that rests upon an upper surface of the hold-down clamps  50 . Also, the hold-down clamps  50  have a first end that rests upon the intermediate screw channel member  45  and a second end that rests upon the peripheral edge  32 . 
         [0095]    It can be seen from  FIG. 8  that the upper ledge  46   a  serves as a rest member for supporting a cover glass  54  thereon. The cover glass has at least a ⅛″ thickness and is held in place by at least a preformed one-piece 90 degree aluminum angular molding having a thickness that is at least 0.070″. In addition, the cover glass  54  has a back cover that will be made from either galvanized or aluminum sheet metal or a composite material, if desired. The upper ledge  46   a  has a sealing caulking type or compound that is applied thereto, so that the cover glass  54  will be secured and made weather resistant by the combination of the sealing caulking type or compound and the downward pressure applied to the four-piece frame members  44  and the at least one-piece 90 degree angular molding  46 . This at least one-piece 90 degree angular molding  46  includes an upper rim portion  53  that engages and extends along an upper surface of a peripheral end portion of the cover glass  54  and a downward perpendicular leg portion of the at least one-piece angular molding  46  that projects around the upper portion of the upper part of the frame members  44 . 
         [0096]    The at least one-piece angular molding  46  is secured to the upper portion of the upper part of the frame members  44  by at least 8 sheet metal screws  55  that extends through drilled holes (not shown) in the angular molding  46  and through the screw holes  46   b  of the frame members  44  at a lateral side thereof to tightly secure the cover glass  54  against the ledges  46   a  of the frame members  44 . Note that the sheet metal screws are disposed at a spaced distance below the upper screw channel  45  to obviate any interference therewith. 
         [0097]    Finally, the dual module frame members  44  are wire brushed to a polished finish. Then the inlet and outlet connectors are capped at the end portions  25  of the 45 degree angular copper tube member  24  and the dual solar module housing unit  30  is now ready for shipment. 
         [0098]      FIGS. 9A and 9B  are similar in that represent an exploded sectional view of the left and right sides of the folded and overlapped peripheral edges  32 . Since each are the same the following description will apply to both  FIGS. 9A and 9B . 
         [0099]    In  FIGS. 9A and 9B , the upper plate  31  includes a first periphery edge raised protuberance  32  includes a pair angled or inclined leg portions  32   a  and  32   b , with angled leg portion  32   a  being connected to an alternating crest inclined portion  20   b  and the angled leg portion  32   b  being connected to an upper overlapping portion  32   c  and a lower overlapping portion  32   d . Extending inward of the lower overlapping portion  32   d  is a third raised protuberance  32   e , with angled leg portion  32   f  being connected to the lower overlapping portion  32   d  and the angled leg portion  32   g  being connected to an outward extending overlapping edge end portion  32   h , which is welded to an undersurface of the lower plate  33 . 
         [0100]    Lower plate  33  has a second periphery edge raised protuberance  34  disposed and nested between the first raised protuberance  32  and the third raised protuberance  32   e  of the upper plate  31 . Note that the second periphery edge raised protuberance  34  includes a pair of angled or inclined leg portions  34   a  and  34   b , with the angled leg portions  34   a  and  34   b  being pressed into an abutting engagement with mating surfaces of the cavity of the first raised protuberance  32 , with the lower surface of the lower plate  33  inward of the raised protuberances  32 ,  32   e  and  34  being pressed across and against the plural open channels or cavities  36  of the plural alternating crest portions  35  for enclosing the flattened copper tubing  37  therein. 
         [0101]    To rigidly secure the upper plate  31  and lower plate  33  together as a single cell unit, the third upstanding raised protuberance  32   e  is forcibly crimped or pressed into an underneath open cavity formed by the second raised protuberance  34  and the pair of angled or inclined leg portions  34   a  and  34   b , while at the same time forcing the pair of angled or inclined leg portions  32   f  and  32   g  into an abutting engagement with mating surfaces within the open cavity of the second raised protuberance  34 . 
         [0102]    While the foregoing written description of the invention enables one of ordinary skill in the art to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.