Method of making solar heat collector

Abstract

A method for constructing a solar heat collector comprises applying a bit array to a sheet of reflective material to create a sheet of solar reflectors, each bit in the bit array creating a solar reflector having a known focal point; and mating the sheet of solar reflectors to a heat absorbing layer such that at least a portion of the heat absorbing layer passes through a focal point of at least some of the solar reflectors.

What is claimed is: 
     
         1 . A method for constructing a solar heat collector comprising:
 applying a bit array to a sheet of reflective material to create a sheet of solar reflectors, each bit in the bit array creating a solar reflector having a known focal point; and   mating the sheet of solar reflectors to a heat absorbing layer such that at least a portion of the heat absorbing layer passes through a focal point of at least some of the solar reflectors.   
     
     
         2 . The method of  claim 1 , wherein each bit in the bit array creates a hole centered in each reflector. 
     
     
         3 . The method of  claim 2 , wherein a first part of the heat absorbing layer is positioned adjacent to a non-sun-facing side of the sheet of reflective material; and
 a second part of the heat absorbing layer comprises tubing towers extending from the first part of the heat absorbing layer though the hole centered in each reflector to the focal point of at least some of the solar reflectors.   
     
     
         4 . The method of  claim 3 , wherein mating the sheet of solar reflectors to the heat absorbing layer comprises inserting the tubing towers of the heat absorbing layer into the hole centered in each of the solar reflectors, whereby the tubing towers extend orthogonally relative to the first part of the heat absorbing layer. 
     
     
         5 . The method of  claim 4 , wherein the first part of the heat absorbing layer comprises tubing positioned beneath the reflector; and further comprising embedding the tubing of the first part of the heat absorbing layer within a substrate. 
     
     
         6 . The method of  claim 5 , wherein the substrate is one of: a) a rubber; and b) foam. 
     
     
         7 . The method of  claim 1 , further comprising fixedly attaching the sheet of solar reflectors to the heat absorbing layer. 
     
     
         8 . The method of  claim 7 , wherein the sheet of solar reflectors is adhesively attached to the heat absorbing layer. 
     
     
         9 . The method of  claim 7 , wherein the sheet of solar reflectors is fused to the heat absorbing layer. 
     
     
         10 . The method of  claim 1 , wherein the heat absorbing layer comprises tubing and wherein mating the sheet of solar reflectors to the heat absorbing layer comprises mounting the tubing on a reflective side of the sheet of reflective material such that a portion of the tubing passes through a focal point of at least some of the solar reflectors. 
     
     
         11 . The method of  claim 1 , further comprising stamping or casting of the sheet of solar reflectors to thereby create additional reflective surface areas between each of the solar reflectors. 
     
     
         12 . A method comprising:
 applying a bit array to a sheet of reflective material to create a continuous reflective layer that defines a plurality of radially-symmetric solar reflectors, each having a focal point wherein each reflector redirects light impinging at any point along a surface of the reflector to the focal point;   positioning a heat absorbing layer at the focal point of at least some of the solar reflectors, and   providing passages for routing a heat absorbing fluid through the heat absorbing layer, through the focal points of at least some of the solar reflectors in series along a continuous path and through the focal points of at least some of the solar reflectors in parallel.   
     
     
         13 . The method of  claim 12 , further comprising affixing a portion of the heat absorbing layer to the sheet of reflective material. 
     
     
         14 . The method of  claim 13 , wherein the affixing comprises adhesively attaching at least a portion of the heat absorbing layer to the sheet of reflective material. 
     
     
         15 . The method of  claim 13 , wherein each bit in the bit array creates a hole centered in each reflector, and wherein a first part of the heat absorbing layer is positioned adjacent to a non-sun-facing side of the sheet of reflective material. 
     
     
         16 . The method of  claim 15 , wherein the step of providing passages includes inserting tubing towers extending from a first part of the heat absorbing layer though the hole centered in each reflector to the focal point of at least some of the solar reflectors. 
     
     
         17 . The method of  claim 12 , wherein the heat absorbing layer is positioned above the sheet of reflective material and wherein the step of providing passages further comprises mounting tubing on the reflective side of the sheet of reflective material such that a portion of the tubing passes through a focal point of at least some of the solar reflectors. 
     
     
         18 . The method of  claim 12 , further comprising stamping or casting of the sheet of solar reflectors to thereby create additional reflective surface areas between each of the solar reflectors.