Patent Abstract:
The solar collector-reflector system includes at least one modular solar panel arranged singly or in an array, each solar panel having a solar collector-reflector assembly, a driver for selective collection or reflection of solar energy, attachment assembly, mounting assembly, ducting and a controller for controlling the solar energy collection and reflection configuration based on the sensed differential temperature between the solar panel or array and a dwelling set temperature. The solar collector-reflector assembly has surfaces that either collect or reflect solar energy, and the solar collector-reflector system utilizes air-to-air heat transfer to provide additional heating to an existing ducting system in the dwelling or reflect solar flux from the roof, thereby reducing heating and cooling energy consumption and costs.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a continuation-in-part of my prior application Ser. No. 12/662,086, filed on Mar. 30, 2010 now abandoned, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/202,745, filed Mar. 31, 2009. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to solar energy devices, and more specifically, to a solar collector-reflector system that may be used as a means to regulate the temperature in a dwelling while also using the system as an additional heat source for household systems. 
     2. Description of the Related Art 
     Currently, feasible and cost-effective alternative energy sources are in high demand due to the costs of limited natural resources such as fossil fuels and coal, both to the consumer as well as the producer. The costs for maintaining energy consumption for heating and cooling a typical home is on the rise. Two of the existing solutions for this issue involve solar panels. While they may provide adequate additional energy resource, the first photovoltaic systems are expensive and inefficient, and invertors are required to convert DC to AC power. Another method is using ethylene glycol/water systems that require a separate liquid to air heat exchanger to transfer solar heat to the dwelling and/or hot water heating system. While adequate, installation is costly due to the additional hardware. 
     Thus, a solar collector reflector array system solving the aforementioned problems is desired. 
     SUMMARY OF THE INVENTION 
     The solar collector-reflector system includes at least one modular solar panel arranged singly or in an array, each solar panel having a solar collector-reflector assembly, a driver for selective collection or reflection of solar energy, attachment assembly, mounting assembly, ducting and a controller for controlling the solar energy collection and reflection configuration based on the sensed differential temperature between the solar panel or array and a dwelling set temperature. The solar collector-reflector assembly has surfaces that either collect or reflect solar energy, and the solar collector-reflector system utilizes air-to-air heat transfer to provide additional heating to an existing ducting system in the dwelling or reflect solar flux from the roof, thereby reducing heating and cooling energy consumption and costs. 
     These and other features of the present invention will become readily apparent upon further review of the following specification and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an environmental, perspective view of a solar collector-reflector system according to the present invention. 
         FIG. 2  is a top view of a modular solar panel of a solar collector-reflector system according to the present invention. 
         FIG. 3  is a side view of the modular solar panel of a solar collector-reflector system according to the present invention. 
         FIG. 4  is an enlarged partial side view of the modular solar panel of a solar collector-reflector system according to the present invention. 
         FIG. 5  is an enlarged partial side view in section of the modular solar panel according to the present invention, showing the driver for a solar collector-reflector system. 
         FIG. 6  is a perspective view of a solar collector-reflector tube of a solar collector reflector system according to the present invention. 
         FIG. 7  is a perspective view of an alternative embodiment of a solar collector-reflector assembly of a solar collector-reflector system according to the present invention. 
         FIG. 8  is a top view of a modular solar panel incorporating the alternative solar collector-reflector assembly of  FIG. 7 . 
         FIG. 9  is a side view of the alternative modular solar panel without the side frame member for a solar collector-reflector system according to the present invention. 
         FIG. 10  is a side view of the alternative modular solar panel frame for a solar collector-reflector system according to the present invention. 
         FIG. 11  is a partial diagrammatic view of a household heating/cooling system utilizing the solar collector-reflector system according to the present invention. 
         FIG. 12  is a section view of ducting (cooler air) from  FIG. 1  for a solar collector-reflector system according to the present invention. 
         FIG. 13  is a section view of ducting (heated air) from  FIG. 1  for a solar collector-reflector system according to the present invention. 
         FIG. 14  is a section view of a supplemental water tank from  FIG. 11  for a solar collector-reflector system according to the present invention. 
         FIG. 15  is a schematic diagram of a controller for a solar collector-reflector system according to the present invention. 
         FIG. 16A  is a perspective view of another alternative embodiment of a solar collector-reflector assembly of a solar collector-reflector system according to the present invention. 
         FIG. 16B  is a perspective view of still further alternative embodiment of a solar collector-reflector assembly of a solar collector-reflector system according to the present invention. 
         FIG. 17  is a top view of a further alternative modular solar panel that can incorporate the solar collector-reflector assemblies of  FIGS. 7 ,  16 A and  16 B. 
         FIG. 18A  is a side view in section of the modular solar panel of  FIG. 17 . 
         FIG. 18B  is an end view of the modular solar panel of  FIG. 17 . 
     
    
    
     Similar reference characters denote corresponding features consistently throughout the attached drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention relates to a solar collector-reflector system that selectively collects or reflects solar energy and uses air-to-air heat transfer to provide either additional heating or enhanced cooling resource to an existing household air conditioning system and thereby reduce energy costs. Referring to  FIGS. 1 and 2 , the solar collector-reflector system  10  includes a plurality of solar panels  20  arranged in an array on a roof of a household or dwelling and ducting  50 ,  51  to direct air through the array and the dwelling. Each modular solar panel  20  includes a solar panel housing  21  and a plurality of solar collector-reflector tubes  23  having end caps  22 . The solar panel housing  21  may be composed of aluminized Vinyl plastic or polished aluminum channel frame members. Polished aluminum or Vinyl cross braces  27  may be provided within the frame to support the Plexiglas cover  39  and prevent sagging of the same during the heating mode. To connect adjacent solar panels  20 , a coupling  30  is used to connect the shaft  29  to a corresponding shaft from the adjacent solar panel. Each coupling  30  includes pins  30 ′ slidably inserted into slot  29 ′ of the shaft  29 . These couplings  30  permit synchronized rotation of all the tubes  23  in the array of solar panels  20 . 
     To drive the tubes  23 , attention is directed to  FIGS. 3-5 . As shown in the Figures, coupling  30  engages a drive torque rod  38  that runs the full length of the solar panel frame. Spaced bearing support angles  35  include needle roller bearings  37  to support the torque rod  38  along its length. Each horizontal gang of solar panels can be powered by one gear motor drive in place of one of the end couplings  30 . Since each horizontal row of ganged solar panels are also coupled to the next abutting horizontal row of panels via couplings  30 , and since all tubes  23  also rotate within very low friction needle roller bearings  36  mounted within the bracket holding the shaft  29 , one gear motor provides enough torque to drive all panels simultaneously. A precision worm gear  34  drives gear  33  to rotate a tube  23  at one end of the solar panel via shaft  29 . Every shaft  29  in the bank of tubes  23  has a spur gear  32 . The spur gears  32  mesh all the tubes in the bank together, thereby providing equal and synchronized rotation of all the tubes  23 . Synchronized rotation may be accomplished by other means, such as a chain drive or pulley type system. However Nylon spur gears are inexpensive and provide a more positive and lighter weight function. The long channels include a plurality of openings  40 , which permit air to flow across and parallel to the tubes  23 , as well as through the tubes  23 , due to the holes  26  formed on each of the end caps  22 . 
     Each solar panel  20  includes an aluminum or Vinyl bottom  39 ′ embossed with integral ribs  28  to provide rigidity. A Styrofoam sheet  39 ″ may be provided beneath the bottom  39 ′ for thermal insulation. 
     Referring to  FIG. 6 , the solar collection-reflection tube  23  is an aluminum tube having two different surfaces. The reflection surface  24  is polished to reflect solar energy, i.e. reflecting mode, while the collection surface  25  may be black anodized to absorb the solar energy, i.e. heating mode. 
     Referring to  FIGS. 7-10 , these drawings disclose an alternative solar panel, which is lighter in weight. The solar collector-reflector assembly  100  includes an endless belt  102  preferably made of aluminized Mylar. The belt  102  rotates about rollers  104 . Half the length of belt  102  is provided with black solar collector corrugations  101  which are heat-sealed to the reflective portion of the belt  102 , i.e. the non-corrugated portion of the belt. Since Mylar has good thermal insulation characteristics, the surface temperature of the black portion will sustain higher temperatures when exposed to solar energy as compared to the aluminum tubes. One of the rollers  104  may be laterally spring loaded to maintain belt tension as well as compensating for thermal expansion. A drive mechanism may be attached to rod  103  through bearing  136  to thereby power the other roller  104  and the endless belt  102 . 
     Referring to FIGS.  1  and  11 - 14 , all solar panels  20  may be gang mounted as shown and bolted to a series of parallel I-beams  53 . Elastomeric gaskets  31  may be installed between each solar panel  20  to provide water and airtight seal. Each gasket is preferably made of extruded, silver pigmented Silicon rubber. An air inlet duct  50  includes longitudinal partition  81  and supplies airflow to the entire lower bank of solar panels. As shown in  FIG. 12 , the partition  81  separates the inlet duct  50  into two compartments. These dual compartments allow equalization of the air pressure drop through all the sloping rows of solar panels to thereby assure uniform heating in each sloping stack. Air outlet duct  51  includes a plurality of openings  54  for receiving the airflow up through all the panels. Both duets may be lined with thermal insulating Styrofoam  82 . The outer walls of the ducts are preferably made of polished aluminum or polished galvanized sheet metal. 
     To utilize the heating and reflecting capabilities of the solar collector-reflector system  10 , external return duct  52  is connected to the existing return duct  64  to the furnace  60 . Three valves  57 ,  59 ,  63  are provided into the existing duct. These valves are automatically cycled by a modified house thermostat. During the summer months, when air conditioning is utilized, valve  57  is motor operated into the closed position, rotating the vane into the vertical position while valve  63  is motor driven to the open position also sealing off duet  64  (as shown by dashed line) from the furnace  60 . Normal operation of the furnace fan  61  draws house air in through valve opening  63 , goes through the existing air conditioning heat exchanger in the furnace cabinet, and is distributed to all the rooms in the house via existing ducting  62 . Also, during the summer months, potable water may be heated using the roof mounted solar panel array via the auxiliary tank  76 . A modified thermostat located on the standard (existing) hot water heater  77  will automatically close the vane door of the motorized valve  59  (shown dashed) and energize the hot water tank fan  58  and the small low power centrifugal pump  72  which will circulate the water between the two tanks  76 ,  77 . This action may also be controlled by sensing the temperature of the uppermost solar array duct whereby the temperature in the duct is higher than the low set point temperature of the water heater&#39;s thermostat. During the winter months, valves  57  and  59  will be open and valve  63  will be closed (as shown in solid line). House return air to the solar array system will flow through valve  59 . This area, i.e. the basement, is normally the coldest part of the dwelling. The ducting leading from the window  56  to valve  57  and to the hot water heater will be thermally insulated, as well as the plumbing lines  75 ,  75 ′ and the line above plumbing line  75  running between the two water tanks/heaters  76 ,  77 . The cold-water inlet line  70  enters the auxiliary heater tank  76 . From there, heated water will enter the standard heater tank  77 . Check valve  71  only permits water flow from the standard tank heater  77  to the auxiliary tank heater  76 . The existing pressure relief valve  73  protects both tanks. 
     Referring to  FIG. 15 , this drawing schematically shows the controller  90  for synchronized rotation of the solar collector-reflector system  10  and the tubes  23 . Switch  91  is a DPDT (Double Pole Double Throw) switch automatically cycled by the modified house thermostat. If the thermostat is set to the ‘heat’ position and the temperature sensor in the array indicates or senses a higher temperature than the set point temperature, power from the power supply is directed to the gear motor(s)  96  to rotate all array tubes  23  to the ‘black side up’ position. A cam wheel  92  located on the master powered solar panel has a cam stud  93 , which rotates on the array tube&#39;s longitudinal axis. When the stud  93  engages a microswitch  94 , power to the gear motor  96  is turned off and all array tubes will have rotated 180° with their black surfaces facing skyward. If the tubes are already in the ‘black surface up’ position, switch  94  is in the open circuit condition and the gear motor(s) is/are not energized. Both switches  94  and  95  are wired normally closed. If the thermostat is set in the ‘cool’ position, switch  91  is toggled to reverse polarity thereby supplying power to operate the gear motor(s)  96  in the opposite direction until the stud  93  engages microswitch  95 . At this point all array tubes will have their reflective surfaces facing skyward. In order to minimize the heat gain of a roof that is already shingled, it is recommended that all areas of the roof not covered by array panels be clad with reflective aluminum sheet or polished galvanized sheet metal. For new building construction, polished cladding should be installed in lieu of colored shingles. Homes that already have galvanized metal sheet roofs should be painted with reflective silver, or at least white. They may also be polished in place. 
     The solar collector reflector system  10  includes further alternative embodiments of a solar collector-reflector assembly for increased efficiency and thermo dynamic heat transfer. As shown in  FIG. 16A , one further alternative solar collector-reflector assembly  200  includes an endless belt  202  trained and rotatable about rollers  204 . Similar to the previously described solar collector-reflector assembly  100 , the belt  202  is preferably constructed from aluminized Mylar for the excellent thermal insulation and reflective properties thereof. In this embodiment, about one-half the length of the belt  202  can be provided with a plurality of hemispherical balls or protrusions  201 , while the remainder retains the reflective surface. The hemispherical balls  201  are preferably blackened in a similar manner described above to form a collection surface. Since a sphere has a maximum surface area compared to any other simple shape, the plurality of hemispherical balls  201  provide maximum surface area exposure to solar rays during operation thereby maximizing solar energy absorption and increasing efficiency. Additionally, the bumpy surface of the plurality of hemispherical balls  201  creates turbulent air flow. The solar collector-reflector assembly  200  operates in the same manner as the solar collector-reflector assembly  100 . 
     Another further alternative solar collector-reflector assembly  300  based on the same principles of the assembly  200  is shown in  FIG. 16B . The solar collector-reflector assembly  300  includes an endless belt  302  trained and rotatable about rollers  304 . The belt  302  is preferably constructed from aluminized Mylar. In this embodiment, about one-half the length of the belt  302  can be provided with a plurality vertical fibers or protrusions  301 , while the remainder retains the reflective surface. The fibers  301  are preferably blackened and constructed from materials such as various types of fabrics, polymers, lightweight metal and/or combinations thereof. Maximum surface area exposure can be obtained by user defined variance in size, shape and layout density of the fibers  301  on the belt  302 . Moreover, the fibers  301  create turbulent air flow as the media flows over them. In all other respects, the solar collector-reflector assembly  300  operates in the same manner above with the other solar collector-reflector assemblies. 
       FIGS. 17-18B  disclose an alternative solar panel  420 . In this embodiment, the solar panel  420  can accommodate any of the solar collector-reflector assemblies described above. The solar panel  420  includes a housing  421  defined by oppositely disposed side frame members  422  and oppositely disposed end frame members  424 . As mentioned previously, at least one of the rollers  104 ,  204 ,  304  must be tensioned in order to maintain properly trained alignment of the respective belts  102 ,  202 ,  302  and to compensate for thermal expansion thereof. In that regard, the solar panel  420  includes a belt tension mechanism or assembly  401 . The belt tension mechanism  401  includes a pair of brackets  402  that are each disposed near the ends of one of the frame members  424 . The shaft or rod  103  of one of the rollers, e.g., roller  304 , is mounted through an elongate slot  406  in each frame member  422 . A biasing means, such as a spring  404 , is connected to a respective end of the shaft  103  and the bracket  402 . Thus, the elongate slots  406  permit limited movement of the roller  104 ,  204 ,  302  for tensioning the belt  102 ,  202 ,  302  via the spring  404 . Various tension springs can be used to facilitate tensioning of the belt  102 ,  202 ,  302 , such as leaf springs, coil springs, and the like. It is noted that positive tension setting means, such as a tension bolt interconnecting a biased connection between the shaft end and the bracket, can also be used so that a desired tension can be set by tightening or loosening the bolt. However, the variance in thermal expansion and contraction of the belt can be relatively large during operation, and a preset tension may cause the belt to exceed its elastic limit and undesirably deform. Hence, careful consideration must be exercised when using such tension setting mechanisms. 
     The solar panel  420  also includes features for more efficient thermal transfer. As shown in  FIGS. 18A and 18B , each end frame member  424  includes at least one circulation opening  440 . Unlike the openings  40 ,  140 , the openings  440  are narrow and disposed on the upper half of the frame member  424  so that air will circulate along the length and top surface of the belt  102 ,  202 ,  302 . This configuration maximizes heat transfer by concentrating air flow on the hottest area of the belt and minimizing heat loss through the cooler underside of the belt. Some or all the interior surface of the housing  421  can be reflective or mirrored to reflect solar rays onto the black surface when the sun is at an acute angle to the solar panel  420 . In addition, it is preferable that the solar panel  420  and the various solar collector-reflector assemblies  100 ,  200 ,  300  be constructed from lightweight yet strong materials that conform to building codes and structural load parameters. 
     It is noted that the solar collector reflector system encompasses a variety of alternatives. For example, the blackened surfaces of the tube  23  and the belt  102  may include a plurality of raised surfaces to increase the area of solar energy absorption. As shown in  FIG. 6 , the collection surface  25  may include black tinsel strips and/or tufts  25 ′ along the length of the tube  23  to effectively increase the blackened surface area. Similarly, the blackened corrugations  101  may also include black tinsel strips and/or tufts  101 ′. While the raised surfaces have been disclosed as strips, other shapes such as rounded or geometric shaped protrusions in a variety of patterns may also be viable to increase surface area. In light of this configuration, the raised surfaces help create turbulence in the airflow which increases the heat transfer coefficient in addition to increasing the rate of heat absorption due to the larger area. 
     It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.

Technology Classification (CPC): 8