Fresnel lens angular segment manufacturing apparatus and method

[0001] This application is related to U.S. patent application Ser. No. 11/644,233 which was filed on Dec. 22, 2006, and to a Continuation-In-Part Application of that prior application which was filed on Jul. 11, 2007.

[0002] This invention is in the field of apparatuses and methods for manufacturing Fresnel lenses and in particular apparatuses and methods for extruding Fresnel lens angular segments from plastic.

[0003] Processes for extruding sheet plastic from raw plastic material such as ingots and pellets and the like are well known in the industry. Similarly, processes for extruding Fresnel lenses from plastic through the use of heat and roller equipment for the extrusion process and dies for impressing the facet grooves on the face of the lens are known in the industry.

[0004] The use of Fresnel lenses for solar collectors is also known in the industry. Economic, operational, and maintenance considerations dictate that the use of a larger collector for solar collection applications is desirable. When a Fresnel lens is to be used for a solar collector, this usually dictates that the solar collector cannot be constructed of a single lens. Also, in the manufacturing of the Fresnel lens, ordinarily a size limitation is dictated by the size of the rollers that are used for the production of the Fresnel lens. This then requires that a solar collector be constructed from a composite of Fresnel lens components. It is also found that the use of a generally circular shape for a Fresnel lens is desirable for solar collector applications. Because of facet groove orientation limitations and geometric sizing and shape limitations, the manufacturing of Fresnel lens components for a generally circular solar collector is problematic.

[0005] An object of the present invention is to provide an apparatus and a method for manufacturing Fresnel lens components for a generally circular solar collector that will provide for the matching of Fresnel lens facet grooves of the components with the desired overall pattern of the solar collector and will provide for economy in manufacturing, including the use of common size rollers and other common extrusion equipment and the minimization of material waste. For purposes of this application, the term “generally circular” shall be defined to include polygon shapes such as an octagonal or hexagonal shape which have sides which are roughly equidistant from the geometric center of the collector.

[0006] A preferred apparatus and method of the present invention utilizes a two roller extruder that is equipped with a blank roller and a die roller. The die roller is equipped with one or more pairs of peripheral lens dies. The lens dies provide, as the blank roller and the die roller rotate through one complete revolution, for the extrusion of one or more pairs of lens segments, each pair comprising a first lens segment and a second lens segment.

[0007] The die roller also has Fresnel facet dies for impressing Fresnel facet grooves in the first lens segment and the second lens segment in a pattern that provides for the Fresnel facet grooves to have a common center of curvature when the first lens segments and the second lens segments are positioned in a solar collector. The Fresnel facet dies also provide for an appropriate progression of the Fresnel grooving with distance from the common center of curvature so that solar energy incident to and passing the solar collector will be focused roughly to a common focal point or common focal field.

[0008] A power shaft or other means known to persons skilled in the art can be used to provide power to the blank roller shaft and the die roller shaft, with the blank roller and the die roller having a power link and preferably being driven at the same speed from the same power source.

[0009] A raw plastic sheet is fed to the rollers and successive pairs of the first lens segment and the second lens segment are discharged. The raw plastic sheet can be supplied from a roll of blank plastic sheeting or can be supplied from a raw sheet extruder using raw plastic pellets, ingots or the like. Depending upon the plastic being used, the desired thickness of the angular lens segments and other factors, the temperature of the raw plastic sheet will likely need to be controlled. The inventor of the present invention prefers to deploy the method of the present invention downstream of a raw sheet extruder which will normally discharge the raw sheet plastic in a pliable condition at an elevated temperature.

[0010] A continuous stream of successive pairs of angular lens segments, namely a first lens segment and a second lens segment, each pair being fitted together to form an angular lens segment for a solar collector can be produced using the method of the present invention. The method of the present invention also provides for eliminating or minimizing the waste of raw plastic material.

[0011] Generally longitudinal lens dies on the die roller impress the left edge and the right edge of each successive first lens segment and the left edge and the right edge of each successive second lens segment, the first right edge of each first lens segment being impressed proximal to the second right edge of an adjacent second lens segment, and the first left edge of each first lens segment being impressed proximal to the second left edge of an adjacent second lens segment. Optional end lens dies at the opposing die roller ends may also be used to impress the inner edges and the outer edges of each successive first lens segment and each successive second lens segment. Fresnel facet dies on the die roller impress Fresnel facet grooves on each successive first lens segment and each successive second lens segment. The Fresnel facet die pattern impresses a Fresnel facet groove pattern with facet grooves for each angular lens segment having a common center of curvature and progressive refraction, thus providing for focus of incident solar radiation on a common focal point or common focal zone.

[0012] Depending upon the diameter of the die roller and the desired dimensions of the angular lens segments, the orientation of a lens die may be changed to be oriented generally circumferential rather than generally longitudinal on the die roller, re-orienting the general layout of the first lens segment and the second lens segment on the die roller by ninety degrees. For that embodiment, the first inner edge and the second outer edge is impressed by a longitudinal lens dye and is proximal to the first outer edge and the second inner edge.

[0032] Referring first to FIG. 1, a preferred embodiment of the roller extruder 1 of the present invention having a blank roller 3 and a die roller 5 is shown. The die roller, for the preferred embodiment shown is equipped with two peripheral lens dies 7. Referring also to FIG. 2 and FIG. 3, the lens dies provide, as the blank roller and the die roller rotate through one complete revolution 9, for the extrusion of a lens wafer 305 having a pair of lens segments 211, comprising a first lens segment 213 and a second lens segment 215. The die roller also has Fresnel facet dies 75 for impressing, as the die roller is rotated through a complete rotation, Fresnel facet grooves 77 in the first lens segment and the second lens segment in a pattern that provide for the Fresnel facet grooves to have a common center of curvature 79 when the first lens segments and the second lens segments are positioned in a solar collector 45 as shown in FIG. 4. The Fresnel facet dies also provide for an appropriate progression of the Fresnel grooving with distance from the common center of curvature so that solar energy incident to and passing the solar collector will be focused roughly to a common focal point or common focal field.

[0033] Referring again to FIG. 1, the first lens die 113 and the second lens die 115 are angularly separated by a primary angular displacement 111 between the first lens die and the second lens die which increases linearly from the die junction 117, which is proximal to the first roller inner edge 123, to the first die end 119 and the second die end 121, which are proximal to the first roller outer edge 125. The first lens die and the second lens die may be joined or proximally joined at the die junction. The angular displacement between the first lens die at the first die end and the second lens die at the second die end for the preferred embodiment shown is approximately three hundred sixty degrees (360°). This is true whether the second lens die is generally horizontal as shown for the embodiment illustrated in FIG. 1 and FIG. 2 or the first lens die and the second lens die are both angularly displaced as shown for the alternative embodiment illustrated in FIG. 5 and FIG. 6.

[0034] Referring again to FIG. 1 and FIG. 2, a power shaft 83 can be used to provide power to the blank roller shaft 55 and the die roller shaft 59, with the blank roller and the die roller having a power link 57 and preferably being driven at the same speed from the same power source. Sprockets on the roller shaft and die roller shaft with chains or belts positively linking the rollers provides for the roller speed of the blank roller and the die roller to be equal. Other roller drive mechanisms for driving the rollers will be known to persons skilled in the art.

[0035] A pair of lower roller supports 63, 67 and a pair of upper roller supports 61, 65 maintain a desired roller clearance 79 between the blank roller periphery 73 and the die roller periphery 71, which determines the Fresnel lens thickness 81 of the finished lens output 49 which will be comprised of successive pairs of lens segments, a first lens segment 213 and a second lens segment 215. Shaft bearings 107 provide for the free rotation of the rollers on the support structure. The raw plastic sheet 47 is fed to the rollers upon a feed platform 51 and successive pairs of the first lens segment and the second lens segment as impressed in the lens wafer are discharged upon a discharge platform 53. Other roller support structures for supporting the rollers and maintaining the desired roller clearance between the blank roller periphery and the die roller periphery will be known to persons skilled in the art.

[0036] The raw plastic sheet can be supplied from a roll of blank plastic sheeting or can be supplied from a raw sheet extruder using raw plastic pellets, ingots or the like. Depending upon the plastic being used, the desired thickness of the angular lens segments and other factors, the temperature of the raw plastic sheet will likely need to be controlled. The inventor of the present invention prefers to deploy the method of the present invention downstream of a raw sheet extruder which will normally discharge the raw sheet plastic in a pliable condition at an elevated temperature. As noted above, the temperature of the raw sheet plastic that is optimum for the method of the present invention will depend on the plastic being used, the thickness of the plastic and other factors that will be unique to each installation.

[0037] Referring again to FIG. 3, two successive pairs of angular lens segments 211, each pair consisting of a first lens segment 213 and a second lens segment 215, are shown. The angular lens segments may be fitted together to form a solar collector 45 as shown in FIG. 4. FIG. 3 illustrates the continuous stream of angular lens segments 211 that can be produced using the method of the present invention. The first lens segment 213 has a first inner edge 231 with a first inner generally circumferential dimension 283, a first outer edge 227 with a first outer generally circumferential dimension 285, a first left edge 237 with a first left dimension 287 and a first right edge 239 with a first right dimension 289. The second lens segment 215 has a second inner edge 225 with a second inner generally circumferential dimension 291, a second outer edge 229 with a second outer generally circumferential dimension 293, a second left edge 235 with a second left dimension 295, and a second right edge 233 with a second right dimension 297. The first lens segment has a first radial dimension 299 from the first inner edge to the first outer edge, the second lens segment having a second radial dimension 301 from the second inner edge to the second outer edge. For the preferred embodiment shown, the dimensions of the first lens segment 213 and the second lens segment 215 are equal or approximately equal. The first inner generally circumferential dimension 283 and the second inner generally circumferential dimension 291 will preferably be only as large as is necessary to accommodate the central hub 303 of the solar collector 45. Depending on the Fresnel facet die pattern on the die roller, the Fresnel facet groove pattern may provide for the first lens segments and the second lens segments to be arranged for a solar collector 45 as shown in FIG. 4 with the first right edge 239 proximal to the second left edge 235 and the second right edge 233 being proximal to the first left edge 237. Alternatively, again depending on the Fresnel facet die pattern on the die roller, the first lens segment and the second lens segment may be arranged for a solar collector as shown in FIG. 4a with the first right edge 239 proximal to the second right edge 233 and the second left edge 235 being proximal to the first left edge 237 of an adjacent pair of lens segments.

[0038] For the embodiment shown, the generally longitudinal lens dies 7 on the die roller impress the left edge and the right edge of each successive first lens segment and the left edge and the right edge of each successive second lens segment, the first right edge of each first lens segment being impressed proximal to the second right edge of an adjacent second lens segment, and the first left edge of each first lens segment being impressed proximal to the second left edge of an adjacent second lens segment. Fresnel facet dies 75 on the die roller impress Fresnel facet grooves 77 on each successive first lens segment and each successive second lens segment, the Fresnel facet die pattern impresses a Fresnel facet groove pattern with facet grooves for each angular lens segment having a common center of curvature and progressive refraction, thus providing for focus of incident solar radiation on a common focal point or common focal zone.

[0039] Optional end lens dies 69 at the opposing die roller ends 103 may be used to impress the inner edges and the outer edges of each successive first lens segment and each successive second lens segment. However, the inventor prefers not to utilize end lens dies on the die roller. This allows the inner edges and outer edges of the lens wafer to extend beyond the desired finish inner edges and outer edges of the lens segments, thereby accommodating variations in the thickness of the raw plastic sheet, and allowing the lens segments to be trimmed, after extrusion, at the desired inner edges and desired outer edges. This reduces the probability of lens segments not fully extending to the desired finish inner edge and the desired finish outer edge, which requires the rejection of the lens segments.

[0040] Depending upon the diameter of the die roller and the desired dimensions of the angular lens segments, the orientation of the lens die which impresses the first left edge 237 and the second left edge 235 may be changed to be oriented generally circumferential rather than generally longitudinal on the die roller, re-orienting the general layout of the first lens segment and the second lens segment on the die roller by ninety degrees. For that embodiment, the first inner edge 231 and the second outer edge 229 would be impressed by a longitudinal lens dye 7 and would be proximal to the first outer edge 227 and the second inner edge 225.

[0041] Referring now to FIG. 7, two successive pairs of Fresnel lens segments manufactured through use of the alternative preferred embodiment of the roller extruder shown in FIG. 5 are shown. FIG. 8 illustrates a plan view of a hexagonal shaped solar collector utilizing Fresnel lens angular segments comprised of the Fresnel lens segments of FIG. 7 manufactured through use of the alternative preferred embodiment of the roller extruder of FIG. 5.

[0042] A further alternative embodiment of the two roller extruder of the present invention, that is used for an alternative embodiment of the method of the present invention, consists of a first die roller 239 and a second die roller 241 as shown in FIG. 18, the first die roller being substantially similar to the die roller described above and shown in FIGS. 1-2 and FIGS. 5-6, having at least two generally longitudinal peripheral lens dies and peripheral first Fresnel facet dies 243. However, for this alternative embodiment, the second die roller 241 also has peripheral second Fresnel facet dies 245. The second peripheral Fresnel facet dies of the second die roller may match the first Fresnel facet dies, with the pattern of the matching second Fresnel facet dies being a mirror image of the pattern of the first Fresnel facet dies, with the patterns of the Fresnel facet dies and the synchronization of the first die roller and the second die roller providing for matching of first Fresnel facet grooves 127 on the front segment surface 129 and second Fresnel facet grooves 131 on the rear segment surface 133 of each lens segment 213, 215 as shown in FIG. 9. Similarly the cross-sections and other dimensions of the first Fresnel facet dies and the second Fresnel facet dies may be generally the same, providing for the cross-section 135 of first Fresnel facet grooves and the cross-section 137 of the second Fresnel facet grooves to be the same, as shown in FIG. 9. The effect of impressing matching Fresnel facet grooves on both surfaces of the lens segments is that the focal length of the lens is approximately one-half of the focal length of a comparable lens with Fresnel facet grooves impressed on one surface only.

[0043] However, the spacing and dimensions of the second Fresnel facet dies do not necessarily have to be the same as the first Fresnel facet dies. It is merely essential that the second Fresnel facet dies impress Fresnel facet grooves on the rear segment surface of each successive first lens segment and each successive second lens segment, which will provide a groove pattern for each angular lens segment having a common center of curvature, which center of curvature is directly opposite the center of curvature on the opposing front surface of the angular lens segment, and will provide for progressive refraction, thus providing for focus of incident solar radiation on a common focal point or common focal zone. First Fresnel facet grooves 127 and second Fresnel facet grooves 131 having a differing cross-section are illustrated in FIG. 10.

[0044] The embodiment of the die roller 5 shown in FIG. 1-2 and the embodiment shown in FIG. 5-6 are all illustrated with a first lens die 113 and a second lens die 115 that have a triangular cross section and have a die protrusion 149 which protrudes from the die roller. However, the first lens die and the second lens die may have a number of other cross-sections, some of the other preferred cross-sections being illustrated in FIGS. 11-13.

[0045] FIG. 11 illustrates a lens die 7 that is a lens groove 151 with a trapezoidal cross-section. Groove embodiments of the lens die such as this provide for thickening of the edges of the lens segments. The trapezoidal cross-section facilitates the separation of the lens segments from the die roller. Referring to FIGS. 12-13, other alternative cross-sections of a lens die 7 incorporating lens grooves 151 are shown. The lens groove of FIG. 11 requires the subsequent division of the first lens segment from the second lens segment by cutting or otherwise dividing the first left edge 37 from the second right edge 33 and the first right edge 39 from the second left edge 35. The lens dies of FIG. 12 and FIG. 13 on the other hand incorporate lens grooves 151 and a lens groove protrusion 153 which provide for the division of the first lens segment from the second lens segment, while providing for thickened edges of the lens segments. Other embodiments of the lens dies, whether or not incorporating die protrusions, lens grooves, lens groove protrusions, or other cross-sections, in view of the foregoing will be known to persons skilled in the art.

[0046] For embodiments incorporating end lens dies 69, the lens die cross-sections illustrated in FIGS. 2 and 5, and in FIGS. 11-13, as well as other embodiments known to persons skilled in the art in view of the foregoing, may be used for the end lens dies as well.

[0047] Also, embodiments for the configuration of the peripheral lens dies varying between the configuration shown in FIG. 1 and the configuration shown in FIG. 5, in view of the foregoing, will be known to persons skilled in the art.

[0048] Referring again to FIGS. 2 and 6, horizontal feed of the raw plastic 47 is shown for the embodiments of FIGS. 2 and 6. However, referring to FIG. 14, vertical feed of the raw plastic 47 may be used for other embodiments. Similarly, while horizontal takeoff of the finished lens output 49 may be used as shown for the embodiments of FIGS. 2 and 6, if the raw plastic is fed vertically to the extruder, vertical takeoff of the finished lens output from the pinch point 143 may be used as shown in FIG. 14, or horizontal takeoff of the finished lens output from the die roller bottom 147 of the die roller 5, as shown in FIG. 15, or from the bottom of the blank roller.

[0049] Referring to FIG. 16, alternative embodiments of the roller extruder 1 of the present invention may incorporate three rollers, a die roller 5, a blank roller 3, and a third roller 155. For the embodiment shown, the die roller and the blank roller are as shown in FIG. 1 or FIG. 5. The third roller may be a blank roller or may be a die roller having second Fresnel facet dies, thereby providing for impressing second Fresnel facet grooves 131 on the rear segment surface 133 of each lens segment as shown in FIG. 9 and FIG. 10. If the third roller is to be used to impress second Fresnel facet grooves, it will ordinarily be necessary to provide heat to the third roller, as the lens segments are ordinarily allowed to cool on the first roller as the lens segments progress from the first pinch point 143 between the first roller and the second roller to the second pinch point 145 between the first roller and the third roller.

[0050] Referring to FIG. 17, the blank roller 3 or the die roller 5, for a two roller alternative, or the blank roller, the die roller, or the third roller for a three roller alternative, may have a safety ring 139, preferably affixed to the roller near the inner edge or the outer edge of the roller. Alternative embodiments may incorporate a pair of safety rings, one safety ring preferably being affixed near the inner edge and the other near the outer edge of one of the rollers. The safety ring maintains a minimum roller clearance 141 between the rollers, thereby preventing damage from roller contact in the course of normal use.

[0051] Other embodiments and other variations and modifications of the embodiments described above will be obvious to a person skilled in the art. Therefore, the foregoing is intended to be merely illustrative of the invention and the invention is limited only by the following claims and the doctrine of equivalents.