SOLAR REFLECTOR ASSEMBLY

FIELD OF THE INVENTION

[0001] The instant invention relates generally to the field of solar reflector assemblies,
and more particularly to a metal gore assembly and its manufacture.

BACKGROUND OF THE INVENTION

[0002] Concentrating Solar Power (CSP) systems utilize mirrors or other types of
reflective members to concentrate the sun's energy onto points or lines. A typical
CSP system uses a parabolic dish for supporting the mirrors. More specifically, the
mirrors are aligned and mounted on a strongback so as to provide an optical surface
that is configured for concentrating incident solar rays onto an energy convertor, such
as for instance a heat engine. In order to permit the mirrors to receive maximum
energy from the sun the parabolic dish-shaped array may be mounted to a structural
pylon, and coupled with a drive unit and controller assembly for tracking the
movement of the sun across the sky.
[0003] Several problems are known to be associated with prior art CSP systems that
are based on parabolic dish-shaped arrays. In particular, the array that is used for
concentrating the sun's energy is made from gore assemblies having parabolic
reflector elements secured to an A-surface thereof. Each gore assembly must have a
precisely defined shape across its entire A-surface, which may have a relatively large
surface area. Providing a precise shape over relatively large surface areas is
challenging from a manufacturing standpoint. Further, when the gore assemblies are
assembled together to form the dish-shaped array, the resulting structure must be
sufficiently rigid to be able to support the weight of the array and substantially prevent
deformation of the optical surface, even under conditions of extreme wind and snow
loading.
[0004] It would be desirable to provide a gore assembly and a method of making such
a gore assembly, which overcomes at least some of the above-mentioned limitations
of the prior art.
SUMMARY OF EMBODIMENTS OF THE INVENTION
[0005] In accordance with an aspect of the instant invention, a gore assembly made
from metal is provided. The gore is assembled from at least two individual metal
panels. The individual panels are manufactured by a stamping operation, for example.
During the manufacturing process, each individual panel is provided with a curvature
so as to reflect the solar beams captured by reflective members provided on an Asurface
of the panel onto a focal point that is specific to a solar beam collector. In
accordance with a further aspect of the invention, the B-surface of the panel is
provided with additional reinforcement members to provide sufficient structural
support and rigidity to the gore assembly in accordance with the invention.
[0006] In accordance with an aspect of an embodiment of the instant invention, there
is provided a gore assembly for focusing solar energy, comprising: at least two panels,
each panel having two radial edges and having a first surface defined between said
two radial edges for receiving a plurality of reflective elements thereon, each panel
having a second surface that is opposite the first surface and that is defined between
said two radial edges, and each panel having a flange provided along at least a portion
of each of said two radial edges, wherein, in an assembled condition, one of said two
radial edges of one of the at least two panels is abutted with one of said two radial
edges of the other one of the at least two panels, and wherein, in the assembled
condition, the flange along the one of said two radial edges of the one of the at least
two panels is aligned with the flange along the one of said two radial edges of the
other one of the at least two panels, the at least two panels fixedly secured one to the
other via the aligned flanges along the abutted radial edges thereof.
[0007] In accordance with an aspect of an embodiment of the instant invention, there
is provided a method of making a gore assembly, comprising: stamping sheet metal so
as to form at least two panels, each of the at least two panels having a first surface on
a first side thereof for receiving a plurality of reflective members thereon, and having
a second surface on a second side thereof that is opposite the first side, each of said at
least two panels comprising opposing radial edges, each opposing radial edge having a
flange defined along at least a portion thereof; stamping sheet metal for forming a
panel-reinforcement member; aligning the flange along one radial edge of one of the
at least two panels with the flange along one radial edge of the other of the at least two
panels; fastening the at least two panels one to the other along the aligned flanges of
the radial edges; and fastening the panel-reinforcement member to the second surfaces
of the at least two panels, such that the panel-reinforcement member spans the at least
two panels, for providing reinforcement to the gore assembly.
[0008] In accordance with an aspect of an embodiment of the instant invention, there
is provided a gore assembly for focusing solar energy, comprising: N panels, N > 1,
each panel having two radial edges and having a first surface defined between said
two radial edges, the first surface for receiving a plurality of reflective elements
thereon, each panel having a second surface on a side thereof that is opposite the first
surface, and each panel having a flange defined along at least a portion of each of said
two radial edges, the N panels disposed in an edge-to-edge arrangement such that N-l
pairs of abutted radial edges are defined, and such that the flange along one radial
edge of each pair of abutted radial edges is aligned with the flange along the other
radial edge of the pair of abutted radial edges; and, a panel-reinforcement member
disposed in a mating relationship with the second surfaces of the N panels, the panelreinforcement
member spanning the N panels and comprising a plurality of flanges
extending away from the panel-reinforcement member and in a direction toward the
second surfaces of the N panels, the plurality of flanges arranged for being aligned
with the flanges of the N panels, wherein, in an assembled condition, some flanges of
the panel-reinforcement member are aligned with and mechanically coupled to the
aligned flanges along the pairs of abutted radial edges of the N panels, and other
flanges of the panel-reinforcement member are aligned with and mechanically coupled
to the flanges along outer, non-abutted radial edges of the edge-to-edge arrangement
of N panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Exemplary embodiments of the instant invention will now be described in
conjunction with the following drawings, wherein like numerals represent like
elements, and in which:
[0010] FIG. 1 shows the reflective surface of a solar array;
[0011] FIG. 2 shows the B-surface of the solar array presented in FIG. 1;
[0012] FIG. 3a shows a more detailed view of the A-surface of one of the gore
assemblies of the solar array presented in FIGS. 1 and 2;
[0013] FIG. 3b shows a more detailed view of the B-surface of one of the gore
assemblies of the solar array presented in FIGS. 1 and 2;
[0014] FIG. 4a shows a more detailed view of the A-surface of one of the panels of
the gore assembly presented in FIGS. 3a and 3b;
[0015] FIG. 4b shows a more detailed view of the B-surface of one of the panels of
the gore assembly presented in FIGS. 3a and 3b;
[0016] FIG. 5 shows an enlarged, detailed view of the various reinforcement members
depicted in FIG. 3b;
[0017] FIG. 6 is a side view illustrating the manner in which the individual
reinforcement members are fastened to each other and to the B-surface of the
individual panels of the gore assembly of the instant invention;
[0018] FIG. 7a is a perspective view illustrating the manner in which the individual
reinforcement members are fastened to each other and to the B-surface along one of
the outer radial edges of the individual panels of the gore assembly of the instant
invention;
[0019] FIG. 7b is a side view illustrating the manner in which the individual
reinforcement members are fastened to each other and to the B-surface along one of
the outer radial edges of the individual panels of the gore assembly of the instant
invention;
[0020] FIG. 8a shows the A-surface of a side-by-side arrangement of individual
panels;
[0021] FIG. 8b shows the arrangement of the individual reinforcement members one
relative to another;
[0022] FIG. 8c shows the reinforcement members of FIG. 8b secured to the A-surface
of the side-by-side arrangement of individual panels of FIG. 8a;
[0023] FIG. 9 shows slip planes along which the panels, reinforcement members and
attachment members are movable one relative to another;
[0024] FIG. 10 shows a chassis structure onto which the solar array of FIG. 1 is
mounted; and,
[0025] FIG. 11 shows the solar array of FIG. 1 mounted to the chassis structure shown
in FIG. 10.
DETAILED DESCRIPTION OF THE DRAWINGS
[0026] The following description is presented to enable a person skilled in the art to
make and use the invention, and is provided in the context of a particular application
and its requirements. Various modifications to the disclosed embodiments will be
readily apparent to those skilled in the art, and the general principles defined herein
may be applied to other embodiments and applications without departing from the
scope of the invention. Thus, the present invention is not intended to be limited to the
embodiments disclosed, but is to be accorded the widest scope consistent with the
principles and features disclosed herein.
[0027] FIG. 1 presents a view of the A-surface of a solar array 100, in accordance
with an embodiment of the instant invention. FIG. 2 presents a view of the B-surface
of the solar array 100. The A-surface and B-surface are alternatively referred to as a
first surface and a second surface, respectively. As is shown most clearly in FIG. 2,
the solar array 100 comprises a plurality of individual gore assemblies l0la-l0lf. In
the specific and non-limiting example that is depicted in FIGS. 1 and 2, the solar array
100 includes six gore assemblies. Optionally, a number of gore assemblies greater
than or less than six is provided.
[0028] FIGS. 3a and 3b present detailed views of a gore assembly according to an
embodiment of the instant invention. It is to be understood that although the gore
assembly 101a is shown explicitly in FIGS. 3a and 3b, the other gore assemblies
101b-f also have substantially the same arrangement. Referring now to FIG. 3a, the
A-surface of the gore assembly 101a is shown, to which surface reflective members
such as for instance mirrors, polished aluminum or other metals are bonded. The
reflective members are bonded to the A-surface using adhesives, such as for instance
pressure sensitive tapes or pressure sensitive adhesives. In the specific and nonlimiting
example that is depicted in FIG. 3a, the gore assembly 101a includes four
individual panels 302-305. The individual panels 302-305 are made from metal, such
as for instance steel, and are manufactured by a stamping operation. Optionally, fewer
or more panels are utilized to manufacture the gore assembly according to an
embodiment of the instant invention.
[0029] Referring now to FIGS. 4a and 4b, shown are more detailed views of the panel
302 of the gore assembly 101a, which is intended to serve as a representative example
of panels 302-305. FIG. 4a shows the A-surface 402 of panel 302, two radial edges
404 and 406, and circumferential edge 408, and FIG. 4b shows the B-surface 414 of
panel 302. The A-surface of panel 302 faces in a first direction, and the B-surface of
panel 302 faces in a second direction that is substantially opposite the first direction.
As is shown in FIGS. 4a and 4b, a flange 410 is formed along radial edge 404, a
flange 412 is formed along radial edge 406, and flanges 416 and 418 are formed along
circumferential edge 408. Each one of the flanges 410, 412, 416 and 418 protrudes in
the second direction, away from the A-surface and B-surface. In the specific and nonlimiting
example that is shown in FIGS. 4a and 4b, the flanges 410, 412, 416 and 418
are substantially normal to the B-surface. Flanges 410 and 412 extend along
substantially the entire length of radial edges 404 and 406, respectively. Each of the
flanges 410 and 412 is shown as a single flange with notch features disposed at
various locations along the length of the respective radial edges 404 and 406. The
radial edges 404 and 406 and the flanges 410 and 412 provided thereon are used to
secure the individual panels 302-305 together. This can be done, for example, by
aligning the flange 410 along the radial edge of one of the panels with the flange 412
along the radial edge 406 of an adjacent panel, and then spot welding along the
aligned flanges. The notch features of the flanges 410 and 412 are configured for
receiving panel reinforcement members, as will be described in greater detail in the
following sections. Optionally, each of the flanges 410 and 412 is provided as a
plurality of separate flanges, such as for instance would be the case when the notch
features extend all the way to the radial edges 404 and 406 respectively. That being
said, providing a continuous flange with relatively shallow notch features along
substantially the entire length of the radial edges 404 and 406 results in stiffer panels
for use in the gore assemblies l0la-f. Flanges 416 and 418 along circumferential
edge 408 are shown as two separate flanges in FIG. 4b, but of course optionally they
are formed as a single flange with a central notch defining a relatively narrowed
feature of the single flange. Forming the flanges 416 and 418 as a single flange with a
notch feature also results in stiffer panels for use in the gore assemblies l0la-f.
[0030] Referring again to FIG. 3b, it can be seen that further panel reinforcement
members 307-309 are provided adjacent to the B-surfaces of the panels 302-305 of the
gore assembly 101a. The panel-reinforcement members 307-309 are also stamped
metal parts, such as stamped steel parts. The panel-reinforcement members 307-309
interface, i.e., they are slidingly received onto the flanges of the radial edges of panels
302-305, and are spot welded to said flanges so as to provide a gore assembly of
sufficient rigidity and stiffness to withstand forces acting upon the assembly. For
example, each panel 302-305 is stamped with a particular curvature so that the
reflective members mounted on the A-surface channel captured solar light onto a focal
point of a solar concentrator. Thus, a certain rigidity and stiffness of the gore
assembly is needed to maintain the predetermined shape or curvature of the panels in
the gore assembly, so as to achieve a good reflection of the solar light onto the focal
point of the solar collector, as depicted in FIG. 11. Prior to mounting the panel
reinforcement members 307-309 to panels 302-305, additional local attachment
brackets 310-315 optionally are mounted onto the panel reinforcement members 307-
309, in places where additional reinforcement is desired. These additional local
attachment brackets 310-3 5 are also stamped metal parts, and are spot-welded to the
reinforcement members 305-307. In accordance with the embodiment described
herein, spot welding is provided as one method of mounting and fixedly securing the
various reinforcement members. Alternatively, mechanical fasteners or adhesives can
be utilized to mount and fixedly secure the various reinforcement members and panels
of the gore assembly.
[0031] FIG. 5 shows a more detailed view of the various reinforcement members
depicted in FIG. 3b. For example, radial edges of the panels 304 and 305 are mated
with each other and are mechanically coupled, such as e.g., spot-welded, in locations
where the flanges are mutually aligned, as indicated by exemplary reference numerals
502 and 504. Furthermore, locations where multiple reinforcement members are
aligned can also be mechanically coupled, such as e.g., spot-welded, to provide
sufficient support to the assembled gore structure. For example, reference numeral
506 depicts a location where the flanges along the radial edges of the panels 304 and
305 meet with the panel reinforcement member 308 and with the local attachment
bracket 313. Reference numeral 508 indicates a mounting location for the panel arms
of the chassis structure to the gore assembly. This can be achieved by means of a
weld nut to bolt it to the panel arms shown in FIG. 10. However, other threaded or
alternative fasteners can be used instead for fastening the gore assembly to the panel
arm of the chassis.
[0032] Referring still to FIG. 5, shown are two C-channel brackets 510 and 512 which
are slipped onto the outer radial edges of the gore assembly, i.e., more precisely the
outer radial edges of panels 302 and 305. The C-channel brackets 510 and 512 add
further structural support and stiffness to the gore assembly. These brackets are
provided only on the outer edges of the gore assembly, and provide for a safe handling
of the gore assembly as sharp outer edges are covered. Furthermore brackets 510 and
512 also bridge the gaps along the outer edges between the panel reinforcement
members 307, 308, and 309.
[0033] FIGS. 6 and 7b are exploded side views showing how the individual
reinforcement members are fastened to each other and to the reinforcement surface of
the individual panels utilized in the gore assembly of the instant invention. In
particular, FIG. 6 shows a portion of the gore assembly along a pair of abutted radial
edges, such as for instance radial edge 404 along one side of panel 305 and radial edge
406 along an adjacent side of panel 304. FIG. 7b shows a portion of the gore
assembly along an outer one of the radial edges, such as for instance radial edge 406
along one side of panel 305. FIG. 7a is a perspective view showing how the
individual reinforcement members are fastened to each other and to the reinforcement
surface of the individual panels utilized in the gore assembly of the instant invention.
[0034] Referring to FIG. 6, the flange 412 along radial edge 406 of panel 304 is
aligned with and disposed behind the flange 410 along radial edge 404 of panel 305,
and so it is not visible in FIG. 6. Local attachment bracket 313 includes beads 600
and 601, which nest within notch features 603 between two raised portions of flange
410 of panel 305 and between two raised portions of the not illustrated flange 412 of
panel 304. Flanges 604 and 605 of the local attachment bracket 313 are aligned with
the two raised portions of the flange 410 along the radial edge 410 of the panel 305,
and with the two raised portions of the not illustrated flange 412 along radial edge 406
of panel 304. Similarly, the panel reinforcement member 308 includes beads 606 and
607, which nest within the beads 600 and 601 of the local attachment bracket 313.
Flanges 608 and 609 of the panel reinforcement member 308 are aligned with flanges
604 and 605, respectively, of the local attachment bracket 313, with the two raised
portions of the flange 410 along the radial edge 404 of the panel 305, and with the two
raised portions of the not illustrated flange 412 along radial edge 406 of panel 304.
The dotted line 506 corresponds to the point in FIG. 5 where the flanges along the
radial edges of the panels 304 and 305 meet with the panel reinforcement member 308
and the local attachment bracket 313.
[0035] Referring now to FIG. 7b, C-channel bracket 510 slips over a portion of the
flange 412 along radial edge 406 of panel 305. Flange 700 along one edge of panelreinforcement
member 608 fits over the C-channel bracket 510 and the raised portions
of flange 412. The flange 700 of the panel-reinforcement member 608 is
mechanically coupled to the flange 412 of panel 305, such as by spot-welding. The
overlapping flange 700 and C-channel bracket 510 provide a smooth handling surface
along the outside edge 406 of the gore assembly. The dotted line 702 corresponds to a
point where the flange 700 of the panel-reinforcement member 608 is mechanically
coupled to the flange 412 of panel 305.
[0036] FIGS. 8a-c show selected stages during the manufacture of a gore assembly
according to an embodiment of the instant invention. As is illustrated in FIG. 8a, four
individual panels 302-305 are aligned in an edge-to-edge fashion, such that the flanges
along the radial edge of one panel mate with the flanges along an abutted radial edge
of a next panel. The panels 302-305 are mechanically coupled together, such as for
instance by spot welding along the mated flanges, so to form the illustrated edge-toedge
assembly of panels identified as Part "1." In the illustrated embodiment, Part "1"
is made using four common parts, panels 302-305. Optionally, fewer or more than
four panels are used to make the Part " 1." Being made up of four common parts
permits communization/reduction in variants of reflective panels that are applied to
the A-surface.
[0037] Referring now to FIG. 8b, the panel-reinforcement members 307-309 are
identified collectively as Part "2," and the local attachment brackets 310-315 are
identified collectively as Part "3." Part "3" provides the attachment hardware as well
as structural support for localized areas. Since Part "3" can be located by fixture when
mated to Part "2," attachment location variation is reduced. After being located by
fixture, Part "3" is spot welded to part "2."
[0038] Referring now to FIG. 8c, finally the pre-assembled Parts "2" and "3" are spot
welded to the B-surface of Part "1," resulting in the complete gore assembly 101a.
The process is repeated for each of the remaining gore assemblies l0lb-f, and the
resulting gore assemblies l0la-f are assembled together to form the solar array 100.
Optionally, more than or fewer than six gore assemblies are used to produce the solar
array 100.
[0039] In an alternative embodiment, the Part "3" brackets are located and
mechanically coupled to the B-surface of Part "1," such as for instance by spot
welding. Subsequently, the Part "2" panel reinforcement members are located and
mechanically coupled to the pre-assembled Parts "1" and "3," such as for instance by
spot welding.
[0040] In a further alternative embodiment, the Part "3" brackets are omitted and the
Part "2" panel reinforcement members are located and mechanically coupled to the
Part "1" preassembled panels.
[0041] Referring now to FIG. 9, shown is the completed gore assembly 101a. The
inset in FIG. 9 shows enlarged detail along the radial edge 406 of panel 305. It should
be noted that the downturned side flanges of the individual panels, which are aligned
with and spot-welded to Part "1," support slip-plane adjustment between Part "1" and
part "2" during assembly. As is shown in the inset, slip plane adjustment along the
direction "S" is supported between the optically important A-surfaces of the panels
and the preassembled parts "1" and "2." There is no distortion to the A-surface of the
panels because attachment to a base mounting structure is achieved using non-critical
features/surfaces of Part "1" and Part "2." Overall the design slip planes between the
panels and the preassembled parts "1" and "2" allows for detail part variation, but
minimizes variation in the assembly for both optical performance and attachment to
the structure.
[0042] Fig. 10 shows a chassis structure 1000 for supporting solar array 100. The
chassis structure 1000 includes a central hub 1002, to which a plurality of panel arms
1004-1015 is mounted. The panel arms 1004-1015 are used as a mounting frame for
the gore assemblies l0la-lOlf. In accordance with the embodiment presented in
FIGS. 1-3, each gore assembly l0la-l0lf is mounted to two panel arms. A mounting
bracket 1017 is fastened to the central hub 1002, to which a boom arm 1019 is
mounted for supporting a solar beam collector 1021 to capture the solar radiation
focused thereon by the solar array 100, and to convert said solar radiation into
electricity.
[0043] Turning now to FIG. 11, solar array 100 is shown mounted onto the chassis
structure 1000 presented in FIG. 10. Slot 1001 provides a clearance to a mounting
pole (not shown) to allow articulation of the solar array 100 between a stowing
position and a sun tracking position.
[0044] The following provides a brief description for an assembly of a gore structure
in accordance with an embodiment of the instant invention. Two or more individual
panels are stamped from sheet metal to meet a particular optical shape. Furthermore,
panel-reinforcement members and local attachment brackets are also stamped
individually from sheet metal. The local attachment brackets are then spot welded to
desired reinforcement locations on the panel-reinforcement members. The two or
more stamped panels are then loaded into a fixture to align them with each other along
their radial edges. The two or more panels are then joined to each other by spot
welding along the flanges of abutted radial edges of the two or more panels. Once the
two or more panels are joined together, the panel-reinforcement members are slipped
onto the flanges of the panels, and then the flanges of the panel reinforcement
members are spot welded to the flanges of the panels.
[0045] If desired, all components can receive a Zn-coating prior to the forming and
assembly operation, so as to provide rust protection to the assembled gore structure.
[0046] In accordance with an embodiment of the instant invention, the curvature of
the gore assembly, which is necessary to reflect the solar beams onto a solar beam
collector, is better controlled when the gore assembly is manufactured from two or
more individual panels. Furthermore, manufacturing a gore assembly using two or
more individual panels provides for a more optimal material utilization of the stamped
metal sheets that are used in the manufacturing of the panels. The flanges that are
provided along the radial edges between the two or more panels provide better
reinforcement than a one-piece panel structure, resulting in increased ability to
withstand wind loading and snow loadings in addition to other general environmental
loads. For example, wind speeds in excess of 90 mph can pose substantial
environmental forces that a solar array must be able to withstand.
[0047] Furthermore, a gore assembly manufactured from metal parts can be produced
with faster cycle times than conventional plastic sheet molded structures. A gore
assembly according to an embodiment of the instant invention can also be
manufactured in high volumes, has a very good thermal stability, a repeatable smooth
surface and is recyclable.
[0048] It should be appreciated that the foregoing description is illustrative in nature
and that the present invention includes modifications, changes, and equivalents
thereof, without departure from the scope of the invention.
CLAIMS
What is claimed is:
1. A gore assembly for focusing solar energy, comprising:
at least two panels, each panel having two radial edges and a first surface
defined between said two radial edges for receiving a plurality of reflective elements
thereon, each panel having a second surface that is opposite the first surface and that
is defined between said two radial edges, and each panel having a flange provided
along at least a portion of each of said two radial edges,
wherein, in an assembled condition, one of said two radial edges of one of the
at least two panels is abutted with one of said two radial edges of the other one of the
at least two panels, and
wherein, in the assembled condition, the flange along the one of said two
radial edges of the one of the at least two panels is aligned with the flange along the
one of said two radial edges of the other one of the at least two panels, the at least two
panels fixedly secured one to the other via the aligned flanges along the abutted radial
edges thereof.
2. The gore assembly according to claim 1, wherein the first surface comprises a
plurality of reflective members disposed thereon.
3. The gore assembly according to claim 1 or 2, comprising a panel-reinforcement
member disposed adjacent to the second surfaces of the at least two panels, the panelreinforcement
member spanning the at least two panels and comprising a plurality of
flanges extending away from the panel-reinforcement member and in a direction
toward the second surfaces of the at least two panels, the plurality of flanges arranged
for being aligned with the flanges along the radial edges of the at least two panels.
4. The gore assembly according to claim 3, wherein the flanges of the panelreinforcement
members are mechanically coupled to the flanges along the radial edges
of the at least two panels.
5. The gore assembly according to claim 3, wherein the flanges of the panelreinforcement
members are mechanically coupled to the flanges along the radial edges
of the at least two panels by one of an adhesive, spot welding, riveting and metal and
gas welding.
6. The gore assembly according to any one of claims 3 to 5, wherein each one of the
at least two panels comprises a circumferential edge joining the two radial edges, there
being a flange provided along the circumferential edge, and wherein said flange
provided along the circumferential edge of each one of the at least two panels is
fastened to flanges of the panel-reinforcement member.
7. The gore assembly according to claim 6, wherein, for each panel of the at least two
panels, the two radial edges diverge one from the other between a first end of the
panel and a second end of the panel that is opposite the first end, and wherein the
circumferential edge joins the two radial edges at the second end of the panel.
8. The gore assembly according to any one of claims 3 to 7, comprising a plurality of
attachment brackets provided on predetermined locations of the panel-reinforcement
member.
9. The gore assembly according to any one of claims 3 to 8, comprising slip planes
between the at least two panels and the panel reinforcement member for allowing
detail part variation and minimizing a variation in an assembly of the gore assembly.
10. The gore assembly according to claim 8, comprising slip planes between the at
least two panels, the panel reinforcement member and the plurality of attachment
brackets for allowing detail part variation and minimizing a variation in an assembly
of the gore assembly.
11. The gore assembly according to any one of claims 8 to 10, wherein the plurality
of attachment brackets comprises a fastening structure for fastening the gore assembly
to a chassis.
12. The gore assembly according to any one of claims 3 to 11, comprising at least one
C-shaped bracket disposed along an outer, non-abutted radial edge of each one of the
at least two panels.
13. The gore assembly according to any one of claims 1 to 12, wherein, in the
assembled condition, the first surface of each one of the at least two panels is oriented
facing in substantially a same direction.
1 . The gore assembly according to any one of claims 1 to 13, wherein the first
surface faces in a first direction and the second surface faces in a second direction that
is substantially opposite the first direction, and wherein said flanges along the radial
edges of each of said at least two panels extend along the direction away from the
second surface.
15. The gore assembly according to claim 13, wherein said flanges along the radial
edges of each of said at least two panels are substantially normal to the second surface
of a respective one of the at least two panels.
16. The gore assembly according to any one of claims 1 to 15, wherein the at least
two panels are made from metal.
17. The gore assembly according to claim 16, wherein the metal is one of steel,
aluminum and an alloy thereof.
18. The gore assembly according to any one of claims 3 to 12, wherein the plurality
of panel reinforcement members are made from metal.
19. The gore assembly according to claim 18, wherein the metal is steel.
20. The gore assembly according to any one of claims 8 to 12, wherein the plurality
of attachment brackets is made from metal.
2 1. A method of making a gore assembly, comprising:
stamping sheet metal so as to form at least two panels, each of the at least two
panels having a first surface on a first side thereof for receiving a plurality of
reflective members thereon, and having a second surface on a second side thereof that
is opposite the first side, each of said at least two panels comprising opposing radial
edges, each opposing radial edge having a flange defined along at least a portion
thereof;
stamping sheet metal for forming a panel-reinforcement member;
aligning the flange along one radial edge of one of the at least two panels with
the flange along one radial edge of the other of the at least two panels;
fastening the at least two panels one to the other along the aligned flanges of
the radial edges; and
fastening the panel-reinforcement member to the second surfaces of the at least
two panels, such that the panel-reinforcement member spans the at least two panels,
for providing reinforcement to the gore assembly.
22. The method according to claim 21, comprising prior to fastening the panelreinforcement
member to the second surfaces of the at least two panels:
stamping sheet metal for forming a plurality of attachment brackets; and,
fastening the plurality of attachment brackets to the panel-reinforcement
member.
23. The method according to claim 2 1 or 22, wherein the panel-reinforcement
member is mated with the flanges along the radial edges of the at least two panels.
24. The method according to any one of claims 2 to 23, wherein the panelreinforcement
member is spot-welded to the flanges along the radial edges of the at
least two panels.
25. The method according to any one of claims 2 1 to 24, wherein the sheet metal is
coated with zinc for providing protection against rust.
26. A gore assembly for focusing solar energy, comprising:
N panels, N > 1, each panel having two radial edges and having a first surface
defined between said two radial edges, the first surface for receiving a plurality of
reflective elements thereon, each panel having a second surface on a side thereof that
is opposite the first surface, and each panel having a flange defined along at least a
portion of each of said two radial edges, the N panels disposed in an edge-to-edge
arrangement such that N-1 pairs of abutted radial edges are defined, and such that the
flange along one radial edge of each pair of abutted radial edges is aligned with the
flange along the other radial edge of the pair of abutted radial edges; and,
a panel-reinforcement member disposed in a mating relationship with the
second surfaces of the N panels, the panel-reinforcement member spanning the N
panels and comprising a plurality of flanges extending away from the panelreinforcement
member and in a direction toward the second surfaces of the N panels,
the plurality of flanges arranged for being aligned with the flanges of the N panels,
wherein, in an assembled condition, some flanges of the panel-reinforcement
member are aligned with and mechanically coupled to the aligned flanges along the
pairs of abutted radial edges of the N panels, and other flanges of the panelreinforcement
member are aligned with and mechanically coupled to the flanges along
outer, non-abutted radial edges of the edge-to-edge arrangement of N panels.
27. The gore assembly according to claim 26, wherein the flanges of the panelreinforcement
member are mechanically coupled to the flanges of the edge-to-edge
arrangement of N panels by one of an adhesive, spot welding, riveting and metal inert
gas welding.
28. The gore assembly according to claim 26 or 27, wherein the panel reinforcement
member comprise a plurality of panel reinforcement members.
29. The gore assembly according to claim 28, wherein the panel reinforcement
members of the plurality of panel reinforcement members are spaced apart one from
the other in a direction along the length of the radial edges of the N panels.
30. The gore assembly according to claim 28 or 29, wherein each one of the N panels
comprises a circumferential edge joining the two radial edges, there being a flange
provided along at least a portion of the circumferential edge, and wherein said flange
provided along the at least a portion of the circumferential edge of each one of the N
panels is mechanically coupled to flanges of one of the plurality of panelreinforcement
members that is disposed adjacent the circumferential edge of the N
panels.
31. The gore assembly according to claim 30, wherein, for each panel of the N panels,
the two radial edges diverge one from the other between a first end of the panel and a
second end of the panel that is opposite the first end, and wherein the circumferential
edge joins the two radial edges at the second end of the panel.
32. The gore assembly according to any one of claims 26 to 31, comprising a plurality
of attachment brackets provided on predetermined locations of the panelreinforcement
member.
33. The gore assembly according to claim 32, wherein, prior to being assembled, the
N panels, the panel-reinforcement member and the plurality of attachment brackets are
moveable one relative to the other within a plane, for allowing detail part variation
and minimizing a variation in an assembly of the gore assembly.
34. The gore assembly according to claim 32 or 33, wherein the plurality of
attachment brackets comprises a fastening structure for fastening the gore assembly to
a chassis.
35. The gore assembly according to any one of claims 26 to 34, comprising at least
one C-shaped bracket disposed along each outer, non-abutted radial edge of the edgeto-
edge arrangement of N panels.
36. The gore assembly according to any one of claims 26 to 35, wherein, in the
assembled condition, the first surface of each one of the N panels are oriented facing
in substantially a same direction.
37. The gore assembly according to any one of claims 26 to 36, wherein said flanges
along the radial edges of each of said N panels extend in a direction that is away from
and substantially normal to the second surface of a respective one of the N panels.
38. The gore assembly according to any one of claims 26 to 37, wherein the N panels
are made from metal.
39. The gore assembly according to claim 38, wherein the metal is one of steel,
aluminum and an alloy thereof.
40. The gore assembly according to any one of claims 26 to 37, wherein the plurality
of panel reinforcement members are made from metal.
41. The gore assembly according to claim 40, wherein the metal is steel.
42. The gore assembly according to any one of claims 32 to 34, wherein the plurality
of attachment brackets is made from metal.