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SolarInterested

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Reply with quote  #1 
A few links to get this started:

http://en.wikipedia.org/wiki/Coroplast
http://www.iwilltry.org/b/projects/build-a-simple-solar-water-heater/
http://www.iwilltry.org/b/john-hearty-solar-water-heater/

and some from the Yahoo group

Construction details of Scott's coroplast absorber and connector construction.
http://groups.yahoo.com/group/SimplySolar/photos/album/1626274866/pic/list

Coroplast collector using goop by Kenneth W
http://groups.yahoo.com/group/SimplySolar/photos/album/56580480/pic/list
http://tech.groups.yahoo.com/group/SimplySolar/message/21574

 CoroplastAdhesiveStatus.rtf     
 CoroplastTestList.rtf    


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Both temperature rise and airflow are integral to comparing hot air collectors

SolarInterested

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These are the photos with comments for the Coroplast Collector by Kenneth W. Some of the Yahoo group posts regarding this project are found beginning at   http://tech.groups.yahoo.com/group/SimplySolar/message/21574
 
3/4 cpvc headers before cutting the slot with the clean extra glue by the elbow removed




Cut the slot in the header so that is fit loosely on to the coroplast and sand thoroughly. When sawing join two headers to gather make the job easier.




Cutting the coroplast to size with 1 inch taper. 4 inch is cut off (1 inch for insulation and 1 inch for header on both ends ) Cut 1/2 off side making the width 47 1/2.




Scrubbing with ammonia




Torch treating the coroplast with a home made flame spreader. THIS IS A MUST to get the glue to stick. Pass the torch back and forth like painting until you see the coroplast just starting to deform (about 10 passes) This is followed with a alcohol wipe cleaning




Goop Glue in chalking tube from Mills Fleetfarm. the marine has UV protection in it. Any Goop glue will work. One tube will do two collectors but I would have a extra small tube on hand just in case you run short if doing 2 collectors.





The coroplast with the header glued on to it. Be sure to have both end the same so that the same coroplast tubes is glued shut on both ends.




3/4 deep saw cut in side insulation 3/4 from the front on the collector for the coroplast to fit into and taper cut insulation 1"; to 0 for the absorber to rest on.




Corner Detail This shows the 1 inch to 0 support shim and the slot cut in the side insulation to hold the coroplast.




10 foot stud track 8 1/2 foot straight with bend 11 1/2 inch bend on the ends. and the 30 1/2 inch spacer with 3 inch joints on ends.




finished collector




Corner and joint detail





finished coroplast collector with stud track frame






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Both temperature rise and airflow are integral to comparing hot air collectors
SolarInterested

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Reply with quote  #3 
Continuing on with more photos with comments for the Coroplast Collector by Kenneth W.


Portable Stand Testing stand made triangle of 6 foot 2x4s and a sheet of OSB




End view of portable stand




Inside testings set up This is a temporary inside setup with pump(behind the radiator) fan, radiator and expansion tank(5 gallon bucket)





Inside testings set up
Another view of the temporary inside set up


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Both temperature rise and airflow are integral to comparing hot air collectors
SolarInterested

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Continuing on with the last photos with comments for the Coroplast Collector by Kenneth W. after the collector was accidently stagnated. Note that it was at a 30 degree angle and glazed with twinwall polycarbonate.

Quote:
 I have no ideal how hot it got. The pump got unplugged in the middle of summer with the collector set at 30 degrees. If One is to use twinwall polycarbonate on a coroplast collector it would be advisable to find a way to vent it if the pump fails.


http://tech.groups.yahoo.com/group/SimplySolar/message/28177



Coroplast after stagnation




shrinkage pulling glue open



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Both temperature rise and airflow are integral to comparing hot air collectors
Scott Davis

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Reply with quote  #5 
A subject near and dear to my heart!  Coroplast has so many positives, but I could not quite get a good seal and based on your pictures, stagnation is definitely a concern too!
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gbwillson

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Reply with quote  #6 
I just noticed that Home Depot sells sheets of coroplast online. Shipping is free to your local HD, and the reviews were good. Only problem is you have to buy 10 sheets. The cost for 10 sheets is $110. That's only $11 per sheet. That's less than 1/3rd the cost of twinwall. I need 4-5 sheets if anyone wants to split an order. I'm building an Air to Air exchanger. Might try a heater too.

Greg, MN

Link to the HD website:

http://www.homedepot.com/p/Unbranded-48-in-x-96-in-White-Cap-Corrugated-Plastic-Cardboard-10-Pack-WC4896-10/202489118#.UlRVPxah_y8
Garage_Hermit

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Reply with quote  #7 
Funny, I was just playing around with this stuff, this arvo, I had some builders in lately, and they used it as protection for my floors, and I axed them to let me have it after they'd done !

It is black, 3 mm thick, I have 2 x sheets, they are 2m x 80 cms, think I'll mock up an air collector (at last...) for my garage door !

G_H

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sundug

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Reply with quote  #8 
I have been buying 4mm black coroplast at local sign companies for $15 a sheet. Doug

 

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Scott Davis

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Reply with quote  #9 
I got mine from a sign shop too for $15 for  4' X 8'.  They were even kind enough to drop them off as they had a job nearby!

If only I could have gotten a good seal.  They sure did a great job of heating up the fluid circulating through, but two tiny leaks thwarted that plan.

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Silverback

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Reply with quote  #10 
I like the idea. Can someone point me at some performance data for one of these?
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