Richard Guy Rhodes

US Patent:

6487768, Dec 3, 2002

Filed:

Apr 16, 2001

Appl. No.:

09/836056

Inventors:

Richard O. Rhodes - San Francisco CA

Assignee:

Fafco Incorporated - Chico CA

International Classification:

B23P 1526

US Classification:

295648, 29 33 K, 29 33 G, 29 33 T, 29890047, 29890045, 29726, 29782, 165162

Abstract:

Improved plastic heat exchanger production systems are described. The production systems are arranged to extrude plastic tubing, cut the tubing into segments of desired length and convey the tubing to a plurality of aligned tube inserters. Clip strips are feed through the tube inserters which sequentially automatically insert tube segments into the clip strips. The clip strips are then cut at desired lengths to provide tubing panels of a desired size or sizes. In a preferred system, header pipes are attached to the respective ends of the cut tubing panels to provide completed heat exchanger panels. When desired, heat exchangers having laterally offset tubes may be created by cutting one or more middle clip strips into spacer segments and rotating the spacer segments to laterally offset at least some of the tubes. In another aspect of the invention, improved tube inserters suitable for inserting plastic tubing into a plastic clip strip are described.

US Patent:

6581273, Jun 24, 2003

Filed:

Feb 4, 2000

Appl. No.:

09/498312

Inventors:

Richard O. Rhodes - San Francisco CA

Assignee:

Fafco Inc. - Redwood City CA

International Classification:

B23P 1526

US Classification:

297265, 29726, 29 33 G, 29 33 T

Abstract:

A weaving apparatus used to separate the tubes of a heat exchanger so that spacers that hold the tubes apart can be inserted between the tubes to increase thermal efficiency. The weaving apparatus includes a frame assembly and a weaving mechanism contained within the frame assembly. The weaving mechanism includes an alignment plate to align the tubes and separation plates to separate the tubes after they have been aligned. The weaving apparatus thus automates the step of separating the tubes of the heat exchanger so that the spacer can ready inserted between the tubes.

US Patent:

6709616, Mar 23, 2004

Filed:

May 8, 2001

Appl. No.:

09/851623

Inventors:

Richard O. Rhodes - San Francisco CA

Assignee:

FAFCO, Incorporated - Chico CA

International Classification:

B29C 4700

US Classification:

264145, 264167

Abstract:

Methods and apparatus for forming continuous lengths of material with non-uniform cross-sections are disclosed. In accordance with one aspect of the present invention, a method for forming a continuous length of material that is of a substantially non-constant cross-section includes providing the material to a single shaping wheel. The material is in a first state, and the single shaping wheel includes a template that is arranged to form a three-dimensional shape using the material. The method also includes shaping the material to form an extended strip from the material, as well as at least one three-dimensional shape in the extended strip. The extended strip and the three-dimensional shape being formed using substantially only the single shaping wheel. In one embodiment, the method includes cooling the extended strip by cooling the material from a molten state to a solid state.

US Patent:

6722358, Apr 20, 2004

Filed:

Nov 30, 2001

Appl. No.:

10/001224

Inventors:

Richard O. Rhodes - San Francisco CA

Assignee:

Fafco, Incorporated - Chico CA

International Classification:

F24J 224

US Classification:

126655, 126675, 126663, 126709, 126704

Abstract:

The present invention relates to an integral solar energy collector storage systems. Generally, an integral collector storage system includes a tank system, a plurality of heat exchange tubes with at least some of the heat exchange tubes arranged within the tank system, a first glazing layer positioned over the tank system and a base plate positioned under the tank system. In one aspect of the invention, the tank system, the first glazing layer an the base plate each include protrusions and a clip is provided to hold the layers together. In another aspect of the invention, the first glazing layer and the base plate are ribbed to provide structural support. This arrangement is particularly useful when these components are formed from plastic. In yet another aspect of the invention, the tank system has a plurality of interconnected tank chambers formed from tubes. In this aspect, a supply header pipe and a fluid return header pipe are provided at a first end of the tank system.

US Patent:

7328509, Feb 12, 2008

Filed:

Apr 8, 2003

Appl. No.:

10/410669

Inventors:

Richard O. Rhodes - San Francisco CA, US

Assignee:

FAFCO Incorporated - Chico CA

International Classification:

B21D 53/06
B21P 15/26

US Classification:

29890045, 29890047, 297265, 29726

Abstract:

A weaving apparatus used to separate the tubes of a heat exchanger so that spacers that hold the tubes apart can be inserted between the tubes to increase thermal efficiency. The weaving apparatus includes a frame assembly and a weaving mechanism contained within the frame assembly. The weaving mechanism includes an alignment plate to align the tubes and separation plates to separate the tubes after they have been aligned. The weaving apparatus thus automates the step of separating the tubes of the heat exchanger so that the spacer can ready inserted between the tubes.

US Patent:

8161963, Apr 24, 2012

Filed:

Feb 19, 2009

Appl. No.:

12/389150

Inventors:

Richard O. Rhodes - San Francisco CA, US

International Classification:

F24J 2/04

US Classification:

126641, 126640, 126669

Abstract:

A solar collector is provided that is formed from relatively thin polymer sheet(s). The sheet(s) are welded together to integrally define a storage tank, a plurality of fluid flow channel (e. g. risers), and other desired features within the collector. The storage tank is located at a first end of the panel and a heat exchanger is provided within the storage tank. The heat exchanger is arranged to transfer heat from the storage tank to a target fluid (such as water) that is to be heated or preheated by the collector. The collector is arranged so that when it is installed, the collector may be positioned with the storage tank located generally above the fluid flow channels. The storage tank and the fluid flow channels are arranged such that when the collector is installed and filled with a working fluid, a thermosiphon effect will cause the collection of hot water within the storage tank.

US Patent:

8573285, Nov 5, 2013

Filed:

Mar 24, 2011

Appl. No.:

13/071322

Inventors:

Richard O. Rhodes - San Francisco CA, US

International Classification:

F28F 19/04
F28F 9/16

US Classification:

165 79, 165133, 165158, 165173, 165178

Abstract:

A variety of methods of forming polymer manifolds and the resulting manifold structures are described. The described manifolds are well suited for use in heat exchangers and a variety of other applications. In one aspect a polymer manifold includes a multiplicity of tubes having first ends that are received by a manifold housing. A polymer film is secured to the manifold housing and to the ends of each of the tubes. The film is arranged to seal the housing while leaving the openings of the tubes exposed to thereby create a manifold. In some embodiments, a potting material is used to reinforce the film. In a method aspect, a manifold may be formed by positioning first ends of the tubes in a manifold housing and welding a polymer film to the manifold housing and to distal tips of the tubes. Openings for the tubes are then formed in the film by directing heat towards the film which melts or vaporizes the film in the regions of the tube openings. A liquid coolant or potting material is placed inside of the chamber within the manifold housing that is sealed by the film during the heating to help prevent the heat from damaging the seals between the film and the tube tips or the film in the interstitial spaces between the tubes.

US Patent:

20070137639, Jun 21, 2007

Filed:

Dec 16, 2005

Appl. No.:

11/303573

Inventors:

Richard Rhodes - San Francisco CA, US

International Classification:

F24J 2/46

US Classification:

126570000

Abstract:

A solar collector is provided that is formed from relatively thin polymer sheet(s). The sheet(s) are welded together to integrally define a storage tank, a plurality of fluid flow channel (e.g. risers), and other desired features within the collector. The storage tank is located at a first end of the panel and a heat exchanger is provided within the storage tank. The heat exchanger is arranged to transfer heat from the storage tank to a target fluid (such as water) that is to be heated or preheated by the collector. The collector is arranged so that when it is installed, the collector may be positioned with the storage tank located generally above the fluid flow channels. The storage tank and the fluid flow channels are arranged such that when the collector is installed and filled with a working fluid, a thermosiphon effect will cause the collection of hot water within the storage tank.