U.S. patent application number 14/441362 was filed with the patent office on 2015-10-01 for formed reflector support arm.
The applicant listed for this patent is ABENGOA SOLAR, LLC. Invention is credited to Joseph Eisinger, Cory Hodgkins, Kerry Manning, Patrick Marcotte, Nathan Stegall.
Application Number | 20150276270 14/441362 |
Document ID | / |
Family ID | 50731616 |
Filed Date | 2015-10-01 |
United States Patent
Application |
20150276270 |
Kind Code |
A1 |
Manning; Kerry ; et
al. |
October 1, 2015 |
FORMED REFLECTOR SUPPORT ARM
Abstract
Reflector support arms for use in connection with parabolic
trough solar concentrators are provided. The reflector support arms
are constructed from multiple formed components. The use of
multiple formed components enables the provision of a precisely
constructed support arm. In addition, by using multiple components,
the support arm can be produced using smaller forming machines than
would otherwise be required.
Inventors: |
Manning; Kerry; (Lakewood,
CO) ; Marcotte; Patrick; (Lakewood, CO) ;
Eisinger; Joseph; (Lakewood, CO) ; Hodgkins;
Cory; (Lakewood, CO) ; Stegall; Nathan;
(Lakewood, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ABENGOA SOLAR, LLC |
Lakewood |
CO |
US |
|
|
Family ID: |
50731616 |
Appl. No.: |
14/441362 |
Filed: |
November 8, 2013 |
PCT Filed: |
November 8, 2013 |
PCT NO: |
PCT/US13/69302 |
371 Date: |
May 7, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61725719 |
Nov 13, 2012 |
|
|
|
Current U.S.
Class: |
359/850 ;
126/600; 126/694; 359/871 |
Current CPC
Class: |
Y02E 10/47 20130101;
F24S 50/20 20180501; Y02E 10/40 20130101; F24S 23/82 20180501; F24S
25/10 20180501; F24S 23/74 20180501 |
International
Class: |
F24J 2/10 20060101
F24J002/10; F24J 2/12 20060101 F24J002/12; F24J 2/38 20060101
F24J002/38 |
Claims
1. A support assembly of a solar concentrator mirror support
assembly, comprising: a first outer section having first end and a
second end, and a reflective element support surface; a second
outer section having first end and a second end, and a reflective
element support surface; a first inner section having first end and
a second end, and a reflective element support surface; a second
inner section having a first end and a second end, and a reflective
element support surface; wherein said second end of said first
outer section is associated with said second end of said second
outer section; wherein said first end of said first inner section
is interconnected to said first outer section at a point between
said first end and said second end of said first outer section;
wherein said first end of said second inner section is
interconnected to said second outer section at a point between said
first end and said second end of said second outer section; wherein
said second end of said first inner section is associated with said
second end of said second inner section; and wherein said
reflective element support of said first outer section, said first
inner section, second inner section, and said second outer section
support a plurality of reflective elements that are spaced in an
arcuate configuration.
2. The support assembly of claim 1, wherein said first inner
section and said second inner section are directly interconnected
and said first outer section and said second outer section are
interconnected by way of a central reflective element support
surface.
3. The support assembly of claim 1, wherein the reflective element
support surfaces of said first outer section, said first inner
section, second inner section, and said second outer section are
curved.
4. The support assembly of claim 3, wherein said plurality of
reflective elements comprise inner reflective elements that are
directly interconnected to said first inner section and said second
inner section; and wherein said plurality of reflective elements
comprise outer reflective elements that are directly interconnected
to said first outer section and said second outer section.
5. The support assembly of claim 1, wherein said reflective element
support surfaces of said first outer section and said second outer
section are straight and said reflective element support surface of
said first inner section and said second inner section are
curved.
6. The support assembly of claim 5, further comprising at least one
mirror interface feature associated with said first outer section
and at least one mirror interface feature associated with said
second outer section; wherein said plurality of reflective elements
comprise inner reflective elements that are directly interconnected
to said first inner section and said second inner section; and
wherein said plurality of reflective elements comprise outer
reflective elements that are interconnected to said at least one
mirror interface feature of said first outer section and said
second outer section.
7. The assembly of claim 6, wherein the first mirror interface is a
ceramic mirror pad.
8. The support assembly of claim 1, wherein said reflective element
support surfaces of said first outer section and said second outer
section are curved and said reflective element support surface of
said first inner section and said second inner section are
straight.
9. The support assembly of claim 8, further comprising at least one
mirror interface feature associated with said first inner section
and at least one mirror interface feature associated with said
second inner surface; wherein said plurality of reflective elements
comprise inner reflective elements that are interconnected to said
at least one mirror interface feature of said first inner section
and said second inner section; and wherein said plurality of
reflective elements comprise outer reflective elements that are
directly interconnected to said first outer section and said second
outer section.
10. The support assembly of claim 1, wherein said reflective
element support surface of said first outer section, said first
inner section, second inner section, and said second outer section
support are formed to the accuracy required to focus solar energy
reflected from said plurality of said reflective elements onto a
desired target.
11. The support assembly of claim 1, wherein said first outer
section, said first inner section, second inner section, and said
second outer section are formed from a single piece of
material.
12. The support assembly of claim 1, wherein said first outer
section and said second outer section are formed from a single
piece of material.
13. The support assembly of claim 1, wherein said first inner
section and said second inner section are formed from a single
piece of material.
14. The support assembly of claim 1, wherein said plurality of
reflective elements are mirrors that are directly bonded to said
first outer section, said first inner section, second inner
section, and said second outer section.
15. The support assembly of claim 1, wherein said plurality of
reflective elements are reflective composite members that are
directly bonded to said first outer section, said first inner
section, second inner section, and said second outer section.
16. A solar concentrator, comprising: a plurality of spaced support
assemblies, each comprising a first formed outer section having
first end and a second end, and a curved reflective element support
surface; a second formed outer section having first end and a
second end, and a curved reflective element support surface; a
first formed inner section having first end and a second end, and a
curved reflective element support surface; a second formed inner
section having a first end and a second end, and a curved
reflective element support surface; wherein said second end of said
first formed outer section is associated with said second end of
said second formed outer section; wherein said first end of said
first formed inner section is interconnected to said first formed
outer section at a point between said first end and said second
formed end of said first formed outer section; wherein said first
end of said second formed inner section is interconnected to said
second formed outer section at a point between said first end and
said second end of said second formed second outer section; wherein
said second formed end of said first formed inner section is
associated with said second end of said second formed inner
section; and wherein said reflective element support of said first
formed outer section, said first formed inner section, second
formed inner section, and said second formed outer section support
a plurality of reflective elements that are fixed in an arcuate
configuration, said plurality of reflective elements being directly
interconnected to said first formed outer section, said first
formed inner section, second formed inner section, and said second
formed outer section with the absence of mirror interface features;
central support structure associated with said second ends of said
first formed inner sections and said second formed inner section of
each said support assembles; and a receiver tube spaced above said
plurality of reflective elements, said receiver tube also
associated with a first pivot associated with a first end of said
solar concentrator and a second pivot associated with a second end
of said solar concentrator.
17. The support assembly of claim 16, wherein said reflective
element support surface of said first formed outer section, said
first formed inner section, second formed inner section, and said
second formed outer section support are formed to the accuracy
required to focus solar energy reflected from said plurality of
said reflective elements onto a said receiver tube.
18. The support assembly of claim 16, wherein said first formed
outer section, said first formed inner section, second formed inner
section, and said second formed outer section are formed from a
single piece of material.
19. The support assembly of claim 16, wherein said plurality of
reflective elements are mirrors that are directly bonded to said
first formed outer section, said first formed inner section, second
formed inner section, and said second formed outer section.
20. The support assembly of claim 16, wherein said plurality of
reflective elements are reflective composite members that are
directly bonded to said first formed outer section, said first
formed inner section, second formed inner section, and said second
formed outer section.
Description
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 61/725,719, filed Nov. 13, 2012, the entire
disclosure of which is incorporated by reference herein.
FIELD
[0002] Embodiments of the present invention are generally related
to a formed reflector support arm used in parabolic trough solar
concentrators.
BACKGROUND
[0003] Parabolic trough solar concentrators utilize a fluid-filled
receiver tube that is positioned above sun-tracking reflectors that
focus solar energy onto the receiver tube. As development of
concentrating solar power plants continues, the size of the
focusing reflectors and associated installations has increased.
More specifically, one way to increase solar energy production is
to increase the size of the reflectors, receiving tubes, etc.,
which necessarily increases the size and weight of the associated
support structure. Commonly, reflector support structure is
comprised of a truss made of a number of welded components. Some
larger structures are comprised of stamped or otherwise formed
support members. As one of skill in the art will appreciate the
larger and more complex the support structure becomes, the greater
the associated fabrication costs. Accordingly, it is desirable to
provide reflector support assemblies that can be produced
inexpensively and that can accurately maintain a desired position
of relatively large reflectors under various conditions.
[0004] Again, typically truss support structures are used as they
provide sufficient strength and stiffness, while maintaining an
acceptable weight. Typical truss support systems are comprised of
individual support members that are formed from multiple pieces of
material, such as steel or aluminum that are welded or riveted
together. Brackets for connecting the reflectors, i.e., a series of
mirrors or other reflecting members to the support arms, and for
connecting the support arms to a central support structure, are
then added to the truss. Although truss designs can be used to
support reflectors of varying sizes, such designs can suffer from a
number of disadvantages. A primary disadvantage is that the truss
manufacturing process is relatively labor intensive and complex.
Also, such processes often result in a relatively large amount of
wasted material.
[0005] Another disadvantage is that the manufacturing process is
typically imprecise. More specifically, many solar collecting
assemblies are constructed by first laying down the reflectors on
an assembly support with the reflective side down. Next, plurality
of truss members are interconnected to the back side of the
reflectors, often with brackets or ceramic pads positioned between
the reflectors and the truss elements. Then the assembly is lifted
and rotated to orient the mirrors facing up. The pads that attach
the reflectors to the truss structure can then be modified to
ensure that the maximum amount of light gathered by the reflectors
is focused on receiving tube.
[0006] To address some of the disadvantages of truss-type support
arms, support arms formed from stamped metal have been proposed.
However, stamping large pieces requires a very high capital
investment, in the form of large presses. Also, there are limits to
the size of available presses, and a higher percentage of raw sheet
metal input is typically scrapped in the stamping of large
irregular-shaped parts. Accordingly, previous systems utilizing
stamped mirror support arms are not adequately cost-optimized.
SUMMARY
[0007] Embodiments of the present invention are directed to solving
these and other problems and disadvantages of the prior art. In
accordance with embodiments of the present invention, a solar
concentrator reflector support assembly is provided that utilizes
multiple support members, some of which are formed of a shape that
facilitates manufacture of a concentrator reflector assembly. In
particular, the contemplated support members that are attached to
the reflector elements, or mirrors are formed or shaped support
members. The reflector support members generally include a support
surface or interface that may possess a shape that corresponds with
the shape of the reflective element. Accordingly, at least a
portion of the support surface is curved. The support members also
include a backing surface that is spaced from the support surface.
An intermediate member extends between at least a portion of the
support surface and a portion of the backing surface. Each support
member can also include at least a first pad associated with the
mirror support surface, and an interconnection feature for
attaching the support member to other members of the structure. A
reflector support assembly in accordance with embodiments of the
present invention can also include an interconnection member that
has a first end that is fixed to the interconnection feature of a
first support member. A second end of the interconnection member is
fixed to either a central support structure or to a second support
member. Similar to the mirror support members, the interconnection
members can be formed from a single piece of material.
[0008] Methods in accordance with embodiments of the present
invention include forming support members that are not linear along
at least a first surface from an integral piece of material. The
first surface, or reflector support surface, can include one or
more reflector interface features. Some embodiments allow the
reflective members to directly interconnect to the curved surface.
Moreover, the support surface can be formed with the accuracy
required to focus the mirrors or reflectors on the receiver tube or
other target. Alternatively, or in addition, mirror pads may be
associated with the first surface. An interconnection feature may
be formed on a second surface of the support member. In accordance
with at least some embodiments of the present invention, the
interface features, the mirror pads, and/or the interconnection
features are formed simultaneously with the formation of the
associated support member. Moreover, the interface features, the
mirror pads, and/or interconnection features may be integral to the
associated mirror support member. Forming the support members can
include stamping the members from sheet stock, roll-forming,
bending, stretch forming, or by other known mechanical or hydraulic
bending and forming processes. The formation of a mirror support
assembly can include interconnecting first and second support
members via the interconnecting member that, like the mirror
support members themselves, is curved along at least first, second,
and third surfaces. In accordance with at least some embodiments,
the interconnecting member can include a mirror pad and an
interconnection feature.
[0009] It is yet another aspect of the present invention to provide
a support assembly of a solar concentrator mirror support assembly,
comprising: a first outer section having first end and a second
end, and a reflective element support surface; a second outer
section having first end and a second end, and a reflective element
support surface; a first inner section having first end and a
second end, and a reflective element support surface; a second
inner section having a first end and a second end, and a reflective
element support surface; wherein the second end of the first outer
section is associated with the second end of the second outer
section; wherein the first end of the first inner section is
interconnected to the first outer section at a point between the
first end and the second end of the first outer section; wherein
the first end of the second inner section is interconnected to the
second outer section at a point between the first end and the
second end of the second outer section; wherein the second end of
the first inner section is associated with the second end of the
second inner section; and wherein the reflective element support of
the first outer section, the first inner section, second inner
section, and the second outer section support a plurality of
reflective elements that are spaced in an arcuate
configuration.
[0010] It is still yet another aspect of the present invention to
provide a solar concentrator, comprising: a plurality of spaced
support assemblies, each comprising a first formed outer section
having first end and a second end, and a curved reflective element
support surface; a second formed outer section having first end and
a second end, and a curved reflective element support surface; a
first formed inner section having first end and a second end, and a
curved reflective element support surface; a second formed inner
section having a first end and a second end, and a curved
reflective element support surface; wherein the second end of the
first formed outer section is associated with the second end of the
second formed outer section; wherein the first end of the first
formed inner section is interconnected to the first formed outer
section at a point between the first end and the second formed end
of the first formed outer section; wherein the first end of the
second formed inner section is interconnected to the second formed
outer section at a point between the first end and the second end
of the second formed second outer section; wherein the second
formed end of the first formed inner section is associated with the
second end of the second formed inner section; and wherein the
reflective element support of the first formed outer section, the
first formed inner section, second formed inner section, and the
second formed outer section support a plurality of reflective
elements that are spaced in an arcuate configuration, the plurality
of reflective elements being directly interconnected to the first
formed outer section, the first formed inner section, second formed
inner section, and the second formed outer section with the absence
of mirror interface features; central support structure associated
with the second ends of the first formed inner sections and the
second formed inner section of each the support assembles; and a
receiver tube spaced above the plurality of reflective elements,
the receiver tube also associated with a first pivot associated
with a first end of the solar concentrator and a second pivot
associated with a second end of the solar concentrator.
[0011] The Summary of the Invention is neither intended nor should
it be construed as being representative of the full extent and
scope of the present invention. Moreover, references made herein to
"the present invention" or aspects thereof should be understood to
mean certain embodiments of the present invention and should not
necessarily be construed as limiting all embodiments to a
particular description. The present invention is set forth in
various levels of detail in the Summary of the Invention as well as
in the attached drawings and the Detailed Description of the
Invention and no limitation as to the scope of the present
invention is intended by either the inclusion or non-inclusion of
elements, components, etc. in this Summary of the Invention.
Additional aspects of the present invention will become more
readily apparent from the Detail Description, particularly when
taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate embodiments of
the invention and together with the general description of the
invention given above and the detailed description of the drawings
given below, serve to explain the principles of these
inventions.
[0013] FIG. 1 is a top perspective view of a parabolic trough solar
concentrator structure of the prior art;
[0014] FIG. 2 is a bottom perspective view;
[0015] FIG. 3 is a side elevation view of a solar concentrator
reflector support assembly in accordance with embodiments of the
present invention;
[0016] FIG. 4 is a side elevation view of a solar concentrator
reflector support assembly in accordance with other embodiments of
the present invention;
[0017] FIG. 5 is a side elevation view of a solar concentrator
reflector support assembly in accordance with other embodiments of
the present invention;
[0018] FIG. 6 is a side elevation view of a solar concentrator
reflector support assembly in accordance with other embodiments of
the present invention;
[0019] FIG. 7 is a side elevation view of a solar concentrator
reflector support assembly in accordance with other embodiments of
the present invention;
[0020] FIG. 8 is a side elevation view of a solar concentrator
reflector support assembly in accordance with other embodiments of
the present invention; and
[0021] FIG. 9 is a flowchart depicting aspects of a method for
forming a solar concentrator reflector support assembly in
accordance with embodiments of the present invention.
[0022] To assist in the understanding of one embodiment of the
present invention the following list of components and associated
numbering found in the drawings is provided herein:
TABLE-US-00001 # Component 2 Parabolic trough solar concentrator
assembly 10 Parabolic mirror 14 Mirror segment 18 Mirror support
assembly 22 Support arms 26 Central support structure 30 Pivot 34
Receiver tube 38 Outer lateral edge 142 Mirror support member 144
Mirror support surface 154 Interconnection point 156 Secondary
support member 160 End interconnection point 162 Mirror interface
features 242 Mirror support member 244 Mirror support surface 248
Outer section 250 Inner section 254 Interconnection point 260 End
interconnection point 264 End interconnection point 342 Mirror
support member 344 Mirror support surface 348 Outer section 350
Inner section 354 Interconnection feature 360 End interconnection
feature 356 Interconnection feature 362 End interconnection feature
442 Mirror support member 444 Mirror support surface 448 Outer
section 450 Inner section 462 End interconnection feature 500
Mirror support assembly 542 Mirror support member 544 Mirror
support surface 548 Outer section 549 Central mirror support 600
Mirror support assembly 644 Mirror support surface 648 Truss 650
Truss members 654 Interconnection features
[0023] It should be understood that the drawings are not
necessarily to scale. In certain instances, details that are not
necessary for an understanding of the invention or that render
other details difficult to perceive may have been omitted. It
should be understood, of course, that the invention is not
necessarily limited to the particular embodiments illustrated
herein.
DETAILED DESCRIPTION
[0024] FIGS. 1 and 2 are perspective views of a parabolic trough
solar concentrator assembly or structure 2 of the prior art. In
general, the solar concentrator assembly 2 includes a parabolic
mirror or reflective element 10. The parabolic mirror can be
comprised of a plurality of mirror segments 14. The parabolic
mirror 10 is supported by a mirror support structure or assembly 18
that includes a plurality of formed support arms 22, and a central
support structure 26. The mirror support assembly 18 is
interconnected to a fixed support structure (not shown) by a pivot
30. By tilting the mirror 10 about the pivot 30, radiation from the
sun is directed towards a solar or receiver tube 34 containing a
heat transfer fluid.
[0025] As shown in FIG. 2, the formed reflector support arms 22 are
located at predefined intervals along the length of the mirror 110.
The support arms 22 may also support a number of mirror segments
14. Each formed support arms 22 generally extend to or near outer
lateral edges 38 of the mirror 10. Such structures are also
described in U.S. Patent Application Publication No. 2012/0217209,
which is incorporated by reference in its entirety herein.
[0026] FIGS. 3-7 are elevation views of support arms employed by
embodiments of the present invention. Here, the formed support arm
assemblies 122 are generally comprised of one or more mirror
support members 142 having a curved mirror support surface 144. The
mirror support members 142 of this embodiment are manufactured
using a precision forming process that provides the curvature
necessary to accommodate reflective elements that are capable of
focusing solar energy onto the desired target without the need for
post-fabrication modifications. Accordingly, in some embodiments,
pads or other interconnection members that are traditionally used
to interconnect the mirror to the support surface 144 may be
omitted, which reduces fabrication time and cost. Further, one
embodiment of the support surface is previously curved to receive a
compliant, composite reflective member or reflective members that
are concave along their length as discussed in WIPO Publication No.
2012/145513, which is incorporated in its entirety herein. In these
examples, the mirror segments are directly bonded to the mirror
support surface 144. The mirror support member 142 includes an
interconnection point 154 or feature that receives a secondary
support member 156, which is interconnected to additional support
structure associated with the parabolic mirror assembly. In
addition, the mirror support member 142 includes an end
interconnection point 164 or feature for interconnection to a
corresponding and oppositely disposed mirror support member.
Alternatively, the end interconnection point 160 interfaces with a
centralized support member that interconnects corresponding mirror
support members.
[0027] In addition, the mirror support member 142 may include a
plurality of mirror interface features 162 that may be integrated
or attached to the mirror support service 144. For example, some
embodiments the present invention use ceramic pads that are
fastened to the mirror support surface 144. The ceramic pads in
turn receive a rear surface of the reflective element. As will be
described below, in other embodiments, the mirror interface
features are omitted and the rear surface of the mirror is directly
interconnected or bonded to the mirror support surface 144.
[0028] As shown in FIG. 4, for example, the mirror support member
142 can be further divided to include an outer section 248 and an
inner section 250. The outer section 248 is interconnected to the
inner section 250 at point 254. This allows for adjustments between
the outer section 248 and inner section 250 which provides the
curved necessary to accommodate the curvature of the mirror. The
inner section 250 also has an end interconnection point 260 that is
adapted to interface with a similar point or interconnection
feature on a corresponding inner section 250 of the opposite side
of the arm support structure (not shown). Similarly, the outer
section 248 includes a connection point and end interconnection
point 264 for interconnection to other support structure associated
with the parabolic mirror assembly (not shown).
[0029] In accordance with embodiments of the present disclosure,
the mirror support member 242 is a formed component. Further, the
outer section 248 and/or the inner section 250 may be formed. As
used herein, "formed" means that the component is provided with at
least some aspects of its final configuration during a forming
step, as opposed to an assembly step. Examples of forming include
pressing, roll forming, bending, hydro-forming, stamping, and the
like. Moreover, the interconnection point or features and the
mirror interface features (if applicable) can be formed when the
forming of the mirror support members is performed.
[0030] FIG. 5 is a view in elevation of one half of a formed mirror
support arm 342 in accordance with other embodiments of the present
disclosure, which is half of a formed reflector support arm
assembly. The support arm 342 includes an outer section 348 and an
inner section 350. The inner section 350 includes a precision
formed mirror support surface 344, an interconnection feature 354,
a second interconnection feature 356 and an end interconnection
feature 360. The interconnection features of the inner section 350
are coincident with interconnection features of the outer section
248. The outer section 248 also includes a precision-formed mirror
support surface 344, and an end interconnection feature 360. The
end interconnection features 360 and 362 provide for the
interconnection of the half of the formed reflector support arm
assembly to a central support structure. The mirror support
surfaces 344 cooperate to provide support for a corresponding half
of the mirror from or near the outer edge of the mirror to the area
corresponding to the central trough or area 380. In addition, one
or both of the mirror support member sections can comprise formed
components as described above. For example, the outer section 348
may comprise a structural material in a stock format, while the
inner section 360 may comprise a formed component, in which case
the mirror support surface 344 provided by the outer section 348
may be straight, while the mirror support surface 344 of the inner
section 350 may be curved. Thus, the outer section 348 may be
provided with a mirror interface feature 362.
[0031] FIG. 6 is one half of a formed reflector support arm
assembly in accordance with other embodiments of the present
invention. In particular, a mirror support arm 442 with an outer
section 448 is provided in combination with an inner section 450.
Each of the mirror support member sections may be provided with
interconnection features as described above, to provide an
interconnection point between the inner and outer sections. In
addition, the sections may each be provided with end
interconnection features as described above, for interconnecting
the respective sections to a central support structure. At least
some or all of the sections may comprise formed components as
described above. For example, the outer section 448 may comprise a
formed component with a curved mirror support structure 444, while
the inner section 250 may comprise a straight mirror support
surface 444. In addition, one or both of the sections may include a
mirror interface feature 462.
[0032] FIG. 7 is a view of a mirror support arm assembly 500 in
accordance with still other embodiments of the present invention.
The reflector support arm assembly 500 includes a mirror support
member 542 formed from a plurality of mirror support member
sections. More particularly, first and second outer mirror support
member sections 548a and 548b and a central mirror support member
section 549 are provided. Each of the mirror support member
sections includes a precision formed mirror support surface 544.
Moreover, the mirror support surfaces 544 can be curved. Each of
the included mirror support member sections include various
interconnection features as described above. For example,
interconnection features provide for the interconnection between
the first outer mirror support member 548a and the central mirror
support member 549. Similarly, interconnection features provide for
the interconnection of the second outer mirror support member 548b
to the central mirror support member 549. Some or all of the mirror
support members 542 can also include interconnection features 20
that provide for the interconnection of the reflector support arm
assembly 500 to a central support structure.
[0033] FIG. 8 depicts one half of a formed reflector support arm
600 in accordance with still other embodiments of the present
invention. In particular, the support arm 600 includes a curved,
precision-formed mirror support surface 644. The mirror support
surface 644 is supported by a truss 648 formed from multiple
interconnected members 650. The interconnected truss members 650
need not be precision formed. In addition, at least some of the
truss members 650 may be interconnected to interconnection features
654 formed as part of the mirror support surface 644.
[0034] With reference now to FIG. 9, aspects of a method for
providing a mirror support assembly in accordance with embodiments
of the present disclosure are illustrated. More particularly, at
step 704, components of a reflector support arm assembly are
formed. For example, one or more mirror support member sections
and/or interconnection members included in a mirror support arm
assembly may be formed from a sheet metal blank. Forming can
include pressing, hydro forming, roll forming, bending, stamping,
and the like. In accordance with other embodiments, the mirror
support member sections and/or interconnection members may be
composite structures formed from laying up and adhering material.
In addition, forming can include creating curves, ridges, or other
three-dimensional features, to increase the rigidity of the
component being formed in a selected direction. Forming can also
include the creation of mirror support surfaces, interconnection
features and/or mirror interface features as described above.
Moreover, the forming of rigidity enhancing features, mirror
support surfaces, interconnection features, and/or mirror interface
features can be performed simultaneously. In accordance with still
other embodiments, forming includes creating rigidity enhancing
features, interconnection features, and/or mirror interface
features simultaneously. In accordance with still other
embodiments, forming can include cutting to remove material that
extends beyond a desired profile of the component as formed, and/or
the removal of areas inside of the periphery of the component being
formed. Such removal can be accomplished by, for example, a die
cutting step. Moreover, a die cutting step can be performed
simultaneously with a formation of rigidity enhancing features,
mirror support surfaces, interconnection features, and/or mirror
interface features.
[0035] At step 708, the mirror support member sections and any
included interconnection members of the mirror support arm assembly
are joined to one another. For example, the various components can
be aligned with one another, such that complimentary
interconnection features are positioned adjacent one another.
Mechanical fasteners, such as bolts and nuts, adhesives, rivets,
and/or welding and clinching can then be applied to fix the
components of the mirror support arm assembly to one another.
[0036] At step 712, the mirror support arm assembly can be
interconnected to a central support structure. As can be
appreciated by one of skill in the art after consideration of the
present disclosure, where the mirror support arm is provided in
halves, the components of the two halves can be interconnected to
one another, and the assembled half of the reflective support arm
assembly can then be joined to a central support structure.
[0037] At step 716, a determination can be made as to whether a
mirror support structure is complete. If additional mirror support
arms are required, the process can return to step 704. Once the
mirror support structure is complete, the mirror elements 118 can
be joined to the mirror support arms (step 720). The process can
then end.
[0038] As can be appreciated by one of skill in the art after
consideration of the present disclosure, mirror support arms are
provided that can be manufactured using a forming step or steps.
Moreover, such processes allow the mirror support arms to be
manufactured with high precision. In addition, the mirror support
arms can be designed such that mirrors with relatively large areas,
and thereby requiring correspondingly large mirror support arms can
be assembled using mirror support member sections and/or
interconnection members that are smaller than would otherwise be
required. Therefore, the construction of relatively large modules
can be performed relatively economically.
[0039] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting. The use of "including,"
"comprising," or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items.
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