Patent Abstract:
A solar collector housing that is opened and closed without tools includes structure for accommodating temperature-related expansion and contraction of a polymer absorber housed within the collector. The housing includes a transparent cover, a frame for holding the transparent cover, and a base. The cover, frame and base collectively define a hollow interior within which the polymer absorber is positioned. A plurality of latches is secured to an exterior of the frame. The frame and base are pivotally connected to one another when the latches are open so that the collector housing can be opened. The housing cannot be opened when the latches are closed. A pair of variable gate closure components are positioned in slots formed in a second end of the collector and enable the polymer absorber to expand and contract without placing stress on the absorber tubes.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates, generally, to solar collectors. More particularly, it relates to solar collector housings that are easily opened and closed without tools. It also relates to solar collectors having polymer absorbers that expand and contract as temperatures rise and fall without placing stress on absorber tubes. 
     2. Description of the Prior Art 
     Conventional solar collectors include a cover and a base that are secured to one another by conventional fastening means including screws, nuts, rivets and the like. These fasteners perform well but require the use of tools. Opening and closing such housings cannot be accomplished quickly due to the large numbers of fastening members. 
     Thus there is a need for a solar collector housing that can be opened and closed quickly without the use of tools. 
     Unlike conventional metallic absorbers, polymer absorbers used in some solar collectors are subject to significant length changes due to thermal expansion and contraction. Over the course of a sunny day the absorber may experience temperature swings that may exceed 150° F., resulting in a change in length that may exceed an inch. 
     Prior art solar collectors mount both ends of the metallic absorber in a fixed position. The greater temperature-responsive expansion and contraction that polymer absorbers experience puts stress on the absorber tubes and eventually causes a leak or total failure. The art of solar collectors has long accepted this problem as being an inherent weakness of polymer absorbers and has responded to the problem by somehow allowing for the length change of polymer absorbers and the absorber tubes as needed. 
     Thus there is a need for an improved mounting means for a polymer absorber. The improved mounting means would accommodate the temperature-related expansion and contraction of a polymer absorber but would not make polymer absorber installation more difficult. 
     However, in view of the prior art considered as a whole at the time the present invention was made, it was not obvious to those of ordinary skill in the art that the use of conventional, tool-requiring fastening members to secure the cover to the base was unacceptable. Nor was it obvious that a better mounting means for the polymer absorber was needed. It follows that the solution to both unperceived problems was not obvious. 
     SUMMARY OF THE INVENTION 
     The long-standing but heretofore unfulfilled need for a solar collector housing that can be opened and closed manually, i.e., without tools, and which includes means for accommodating changes in length of the polymer absorber housed within the collector is now met by a new, useful, and non-obvious invention. 
     The novel solar collector includes a housing including a transparent cover, a frame for holding the transparent cover, and a base. The cover, frame and base collectively define a hollow interior within which a polymer absorber is positioned. 
     A plurality of latches is secured to an exterior of the frame about a perimeter of the frame. Each latch has an open configuration and a closed configuration. The frame and base may be separated from one another when the latches are in their respective open configurations and the frame and base may not be separated from one another when the latches are in their respective closed configurations. 
     The latches are opened and closed by hand, i.e., manually, so no tools are required to open and close the housing and the time required to open or close the housing is substantially less than the time required to do so when the housing is closed by conventional fastening members. 
     The frame has a square or rectangular structure formed by a pair of longitudinally extending, transversely spaced apart sidewalls and a pair of transversely disposed, longitudinally spaced apart end walls. The base has a mating structure formed by a pair of longitudinally extending, transversely spaced apart sidewalls and a pair of transversely disposed, longitudinally spaced apart end walls. 
     A first transversely disposed manifold having a hollow interior in open fluid communication with a first end of the absorber tubes is secured to a first end of a polymer absorber. A manifold pipe that is not in fluid communication with the heat transfer liquid fluid in the absorber tubes is integrally formed with each opposed end of the first manifold in axial alignment therewith and such manifold pipes enable pivotal mounting of the cover frame to the base. 
     In an alternative embodiment, instead of providing a manifold pipe at the opposite ends of the first manifold, the first manifold is lengthened to that its opposite ends are outboard of the outermost absorber tubes. In this way, the outermost ends of the first manifold perform the same function as the manifold pipes. Accordingly, reference is hereinafter made to the outermost ends/manifold pipes of the first manifold. 
     An aperture is formed in a first end of each of the sidewalls of the frame and an aperture axially aligned therewith is formed in a first end of each of the sidewalls of the base, i.e., the apertures formed in the frame are in registration with the apertures formed in the base when the cover is in its closed position. The apertures pivotally receive the outermost ends/manifold pipes of the first manifold so that when the latches are in their respective open configurations, the collector is opened or closed by rotating the cover with respect to the frame about said outermost ends/manifold pipes. 
     Each latch has a flat base secured to the sidewalls of the frame and each latch has two primary mounting lugs extending from the flat base in normal relation thereto in lateral relation to one another on opposite sides of a vertical axis of symmetry of the flat base in equidistant relation to the vertical axis of the flat base. 
     An aperture is formed near a distal free end of each primary mounting lug. Each latch also has a second pair of mounting lugs extending from the flat base in normal relation to the flat base and in lateral relation to one another on opposite sides of and in equidistantly spaced relation to a vertical axis of symmetry of the flat base. 
     An aperture is also formed in the distal free end of each mounting lug of the second pair of mounting plugs. 
     A latch pull is pivotally connected at a first end to each mounting lug of the second pair of mounting lugs. The latch pull has a preselected length so that a second end of the latch pull abuts the flat base adjacent each primary mounting lug when the latch pull is pivoted from its open configuration to its closed configuration. 
     The latch pull has a thickness less than an extent of each primary mounting lug so that when the latch pull abuttingly engages the flat base, the apertures formed in the primary mounting lugs are adapted to receive a pin therethrough to prevent reverse pivoting of each latch pull. 
     A first end of the latch catch is pivotally mounted to an associated latch pull. The latch pull and latch catch are positioned in angular relation to one another when the latch catch is in its open configuration and when the latch pull is rotated from its open position to its closed position. 
     A second end of said latch catch engages and retains the base, thereby securing the cover to the base when the latch pull abuts the flat base of the latch. 
     A second transversely disposed manifold having a hollow interior in fluid communication with the absorber tubes is secured to a second end of the polymer absorber and a second manifold pipe is secured to the opposite ends of said second manifold. Like the manifold pipes at the first end of the polymer absorber, the manifold pipes at the second end of the polymer absorber are integrally formed with and in axial alignment with the second manifold but are not in fluid communication with the absorber tubes, i.e., the heat transfer liquid fluid in the absorber tubes does not flow into said manifold pipes. 
     However, it is also within the scope of this invention to use the opposite ends of the second manifold as manifold pipes and in such event the opposite ends of the second manifold extend outboard of the outermost absorber tubes. Accordingly, the respective opposite ends of the first and second manifolds are referred to as opposite ends/manifold pipes. In the claims that follow, reference to outermost ends shall be interpreted as including outermost ends of a manifold or to a manifold pipe attached to each outermost end. 
     A longitudinally-extending slot is formed in a second end of each of the sidewalls of said frame, there being a pair of transversely spaced apart slots in said second end of said frame. A longitudinally-extending slot is formed in a second end of each of the sidewalls of the base as well, there being a pair of transversely spaced apart slots in the second end of the base. 
     The respective pairs of slots formed in the frame and the base are in registration with one another. A variable gate closure component (VGC component) is positioned within both of the pairs of slots, there being two VGC components in transversely spaced apart relation to one another. The VGC components respectively receive the opposite ends/manifold pipes of the second manifold. 
     Each VGC component includes a flat, generally circular grommet having a flat formed in a top edge and a bottom edge, and having an aperture formed centrally thereof. The opposite ends/manifold pipes of the second manifold are disposed in engaged relation to an associated central aperture. 
     The VGC component includes an elongate frame having a generally oblong configuration. A plurality of parallel guide tracks is formed in an interior surface of the elongate VGC component frame. The plurality of guide tracks includes a center guide track that slideably receives the grommet. The grommet slides in its track in response to expansion or contraction of the polymer absorber. 
     A pair of interior guide tracks is formed in the interior surface on opposite, outboard sides of the center guide track and an interior panel is slideably received within both of the interior guide tracks. 
     Each interior panel of the pair of interior panels has a generally C-shaped structure and has flats formed in their respective top and bottom edges. The flats slideably engage their respective guide tracks and are displaced when the grommet is displaced. 
     The plurality of guide tracks further includes a pair of middle guide tracks formed in the interior surface of the VGC component frame on opposite, outboard sides of the interior guide tracks in parallel relation to the center tracks and to said interior tracks. 
     A pair of middle panels is slideably received within the middle guide tracks. Each middle panel of the pair of middle panels has a generally C-shaped structure and has flats formed in their respective top and bottom edges. The flats slideably engage their respective guide tracks and are displaced when the interior panels are displaced due to displacement of the grommet. 
     The plurality of guide tracks further includes a pair of exterior or outer guide tracks formed in the interior surface of the VGC component frame on opposite, outboard sides of the middle guide tracks. A pair of exterior or outer panels is slideably received within the exterior guide tracks. Each exterior panel of the pair of exterior panels has a generally C-shaped structure and has flats formed in their respective top and bottom edges. The flats slideably engage their respective guide tracks and are displaced when the middle panels are displaced. 
     It should therefore be understood that the grommet engages the interior panels so that said interior panels slide when the grommet slides, the interior panels engage the middle panels so that said middle panels slide when the interior panels slide, and said middle panels engage the exterior panels so that said exterior panels slide when the middle panels slide. Outside or ambient air therefore cannot enter into the slots occupied by the VGC component. The grommet of the VGC component moves conjointly with the polymer absorber as said polymer absorber lengthens and shortens, thereby eliminating stress on the absorber tubes. 
     An important object of the invention is to provide a solar collector housing that can be opened and closed quickly and easily by one person in the absence of tools. 
     A more specific object is to facilitate the opening and closing of the collector by providing manually-operated latches that are secured about the periphery of the frame that holds the transparent cover, which enable opening of the cover when in an open configuration and which secure the cover to the base when the collector is closed. 
     Another important object is to remove the stress from absorber tubes by attaching one end of the polymer absorber to a grommet that slides in a guide track in response to temperature-responsive expansions and contractions of the polymer absorber. 
     A closely related object is to provide panels that slide with the grommet so that ambient air cannot enter into the collector housing as the grommet slides. 
     These and other important objects, advantages, and features of the invention will become clear as this disclosure proceeds. 
     The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the disclosure set forth hereinafter and the scope of the invention will be indicated in the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed disclosure, taken in connection with the accompanying drawings, in which: 
         FIG. 1  is an exploded perspective view of the novel collector; 
         FIG. 2A  is a plan view of the cover; 
         FIG. 2B  is a front elevation view of the cover; 
         FIG. 2C  is an end elevation view of the cover; 
         FIG. 2D  is an enlarged view of the circled area of  FIG. 2A ; 
         FIG. 3A  is a perspective view of the novel frame latch; 
         FIG. 3B  is a side elevation view depicting the frame latch in an open configuration; 
         FIG. 3C  is a side elevation view depicting the frame latch in its closed configuration; 
         FIG. 4A  is an exploded perspective view of the novel VGC component; 
         FIG. 4B  is a perspective view of an assembled VGC component; 
         FIG. 4C  is a side elevation view of an assembled VGC component when the grommet is in its centered retracted position; 
         FIG. 4D  is a side elevation view of an assembled VGC component when the center of the grommet is in its fully extended position; 
         FIG. 4E  is a side elevation view of an assembled VGC component when the center of the grommet is in its fully retracted position; 
         FIG. 5A  is a side elevation view of the novel VGC component; 
         FIG. 5B  is a sectional view taken along  FIG. 5B-5B  in  FIG. 5A ; 
         FIG. 5C  is a sectional view taken along line  5 C- 5 C in  FIG. 5A ; and 
         FIG. 5D  is a plan view taken along line  5 D- 5 D in  FIG. 5A . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  is an exploded view of an illustrative embodiment of the novel structure, denoted as a whole by the reference numeral  10 . 
     Solar collector  10  has a conventional rectangular shape. Cover  12  of collector  10  includes glazed glass or other suitable transparent material  14  which is mounted in frame  16 . Base  18  is an aluminum skinned formed foam box which underlies cover  12  and is secured to said cover by a plurality of novel latches, collectively denoted  20 , which are secured to said frame  16 . As depicted, each end of frame  16  has a pair of the novel latches secured thereto, preferably disposed on opposite sides of the longitudinal axis of symmetry of frame  16  in equidistant relation thereto. Each side of frame  16  also has a pair of the novel latches, preferably disposed on opposite sides of the transverse axis of symmetry of frame  16  in equidistant relation thereto. 
     Polymer absorber  22  is positioned in an interior space that is formed by connecting cover  12  to base  18 . A first transversely disposed manifold  24  is secured to a first end of polymer absorber  12 . Manifold pipe  26  is secured to the opposite ends of the first manifold in axial alignment therewith, it being understood that one manifold pipe is obscured in said Figure. In the alternative, first manifold  24  is lengthened so that its opposite ends extend beyond, i.e., outboard of the outermost absorber tubes in the polymer absorber and said opposite ends perform the same functions as manifold pipes  26 . 
     Opening  18   a  is formed in cover frame  16  and in base  18  at a leading end thereof as depicted in  FIGS. 1 and 2B  and said opening pivotally receives a first end of outermost end/manifold pipe  26 . The pivotal connection is secured by grommet  28 . A second opening  18   a  is formed in base  18  in transversely opposed relation to the depicted opening  18   a  in  FIG. 1  and is obscured by cover  12 . That second opening pivotally receives the opposite end of outermost end/manifold pipe  26  and a second grommet secures that connection. 
     Second manifold  30  is mounted to the opposite end of polymer absorber  22  and it has the same structure as first manifold  24 , i.e., it may have a manifold pipe  32  secured to its opposite ends or it may be lengthened so that its opposite ends extend outboard of the outermost absorber tubes so that said opposite ends perform the same function as such manifold pipes. 
     Elongate slots  34 ,  34  are formed in base  18  near its trailing end. Each opposite end/manifold pipe of second manifold  30  is engaged by a novel device referred to herein as a variable gate closure or VGC component  36 . 
       FIGS. 2A, 2B and 2C  provide plan, side, and end views of cover  12 .  FIG. 2D  is an enlarged view of the circled corner in  FIG. 2A . It discloses that the outer border of frame  16  has a box-like frame  16   a  and the inner border  16   b  thereof has two vertically spaced apart projections that receive glazed glass or other suitable transparent material  14  between them. Each projection has glaze-engaging teeth formed in it to enhance its grip on the outer edge or border of said glazed glass  14 . 
       FIG. 3A  depicts a latch  20  in perspective view. Flat base  40  is secured to sidewalls  16  of cover  12 . Two (2) mounting lugs, collectively denoted  42 , extend from base  40  in normal relation thereto in lateral relation to one another on opposite sides of a vertical axis of symmetry of said latch  20 , in equidistant relation to said vertical axis. An aperture  44  is formed near the distal free end of each mounting lug. Each mounting lug is flat and has a vertical axis parallel to the vertical axis of symmetry of latch  20 . As used herein, terms such as “vertical” and “horizontal” refer to a solar collector  10  disposed in a horizontal plane on a flat roof so that sidewalls  16  thereof are in a vertical plane. 
     Two (2) further mounting lugs are collectively denoted  46  although only one (1) of them can be seen in  FIGS. 3A-C . Lugs  46  are also flat and they also extend from flat base  40  in normal relation to said flat base in lateral relation to one another on opposite sides of and in equidistantly spaced relation to a vertical axis of symmetry of said flat base, but they are preferably spaced further from one another than are mounting lugs  42 ,  42 . An aperture  48  (depicted in  FIGS. 3A and 3B  but labeled only in  FIG. 3B  to avoid cluttering the drawings) is formed in the distal free end of each mounting lug  46 . 
     A latch pull  50  is pivotally connected at a first end by a pivot pin to each mounting lug  46  as at  52  on the outboard side thereof. Latch pull  50  is formed of a rigid material and its length is preselected so that second end  54  thereof abuts flat base  40  on the outboard side of each mounting lug  42 ,  42  when latch pull is pivoted about pivot pin  52  from its  FIG. 3A  or  FIG. 3B  position to its  FIG. 3C  position. 
     Latch pull  50  has a thickness less than the extent of each mounting lug  42 ,  42  so that when said latch pull  50  abuttingly engages flat base  40 , apertures  44 ,  44  formed in said mounting lugs are clear. A clevis pin, not depicted, or other suitable locking means is then inserted through each aperture  44 ,  44 , preventing reverse pivoting of each latch pull  50 . 
     Latch catch  56  is also formed of a rigid material and has a lateral extent slightly greater than the lateral spacing between mounting lugs  46 ,  46  so that its opposite end are positioned outboard of said mounting lugs  46 ,  46 . A first end  56   a  of latch catch  56  is pivotally mounted as at  58  to each latch pull  50 ,  50  about midway between ends  52  and  54  of said latch pull. Latch pull  50  and latch catch  56  are positioned roughly normal to one another when latch catch  56  is in its open configuration as depicted in  FIGS. 3A and 3B . When latch pull  50  is rotated from its open position of  FIGS. 3A and 3B  to its closed position of  FIG. 3C , latch pull  50  and latch catch  56  remain in their respective, mutually normal positions. 
     After latch pull  50  abuts flat base  16  and a clevis pin or the like is inserted into each aperture  44  to prevent reverse rotation, latch catch  56  is then rotated from its open configuration of  FIGS. 3A and 3B  into its closed positon of  FIG. 3C . Second end  56   b  of latch catch  56  then engages and retains base/aluminum skinned formed foam box  18 , thereby securing said base  18  to cover  12 . This enables the locking procedure of all six (6) latches  20  to be performed by one (1) installer in just a few moments. Collectors of differing sizes may have more or fewer latches but in all cases the novel locking procedure is much faster than the locking procedures of the prior art. 
     Projection  54   a  at the upper end  54  of latch pull  50  provides a finger-engageable part that facilitates opening of latch  20  when the undepicted locking pin/clevis pin is removed. Such pin is not removed until after second end  56   b  of latch catch  56  is rotated away from its engagement with base  18 . 
     Variable gate closure or VGC component  36  is depicted in  FIGS. 4A-4E  and in  FIGS. 5A-5D . In view of the temperature-related changes in length that a polymer absorber undergoes, a first end of the absorber needs to have a fixed position while a second end needs freedom to move longitudinally. VGC component  36  moves with the second end of the polymer absorber while keeping the inside of the collector enclosure isolated from outside air. 
     As best understood in the exploded perspective view of  FIG. 4A  and in the assembled perspective view of  FIG. 4B , VGC component  36  includes grommet  60  which is flat and generally circular but with a flat formed in its top edge  60   a  and its bottom edge  60   b , and which has aperture  60   c  formed centrally thereof. Aperture  60   c  engages the opposite ends/manifold pipes  32  of second manifold  30  when novel collector housing  10  is fully assembled. 
     In this preferred embodiment, seven (7) grooves or guide tracks are formed on the inner surface of each part of confronting frame parts  62   a ,  62   b . Center guide track  64  is slightly narrower than the other guide tracks and slideably receives grommet  60  when said parts  62   a ,  62   b  abut one another as depicted In  FIGS. 4A and 4B . 
     Grommet  60  is flanked by and engages a pair of interior panels  66   a ,  66   b  which are slideably received within interior guide tracks  66   c ,  66   d , respectively, when VGC component  36  is fully assembled. 
     Interior panels  66   a ,  66   b  are flanked by and engage a pair of middle panels  68   a ,  68   b  which are slideably received within middle guide tracks  68   c ,  68   d , respectively, when VGC component  36  is fully assembled. 
     Middle panels  68   a ,  68   b  are flanked by and engage a pair of outer panels  70   a ,  70   b  which are slideably received within outer guide tracks  70   c ,  70   d , respectively, when VGC component  36  is fully assembled. 
     The interior, middle and outer panels are generally C-shaped and have flats formed in their respective top and bottom edges, just as in grommet  60 . The flats are not numbered to avoid clutter. They slideably engage their respective guide tracks when grommet  60  slides in central guide track  64 . 
     Each grommet  60  is free to slide in its central guide track  64  when an installer places the outermost ends/manifold pipes  32 ,  32  of second manifold  30  in apertures  60   c ,  60   c  while installing polymer absorber  22 . 
       FIG. 4C  depicts the central position of grommet  60  where it is centered in VGC component  36 , i.e., when the polymer absorber is in a position of repose, i.e., neither extended nor contracted. 
       FIG. 4D  depicts the fully extended position of grommet  60  where it has slid in its guide track towards the second end of collector  10  due to temperature-related expansion of the polymer absorber. 
       FIG. 4E  depicts the fully retracted position of grommet  60  where it has slid in its guide track towards the first end of collector  10  due to temperature-related contraction of the polymer absorber. 
     In the preferred embodiment, grommet  60  can slide about three-quarters of an inch in either direction from its central position but other distances are within the scope of this invention, i.e., differing polymer absorbers may have differing ranges between full extension and full retraction. 
       FIGS. 5A-D  depict the same parts disclosed in connection with the disclosure of  FIGS. 4A-E .  FIGS. 5A-D  depict VGA component structure  36  when grommet  60  is slightly to the right of the center of said VGA component, said center being where parts  62   a ,  62   b  meet. The respective positions of the interior, middle, and exterior panels are depicted in  FIG. 5A  but those positions are best understood when comparing  FIG. 5A  with  FIGS. 5B-D . For example, middle panel  68   a  is obscured in  FIG. 5A  by exterior panel  70   a  as depicted in  FIG. 5C . 
     It should therefore be understood that grommet  60  engages interior panels  66   a ,  66   b  so that said interior panels slide when the grommet slides, the interior panels engage middle panels  68   a ,  68   b  so that said middle panels slide when the interior panels slide, and said middle panels engage exterior panels  70   a ,  70   b  so that said exterior panels slide when the middle panels slide. Outside or ambient air therefore cannot enter into the slots occupied by VGC component  36 . Grommet  60  moves conjointly with the polymer absorber as said polymer absorber lengthens and shortens, thereby eliminating stress on the absorber tubes. 
     It will thus be seen that the objects set forth above, and those made apparent from the foregoing disclosure, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing disclosure or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein disclosed, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.

Technology Classification (CPC): 5