Low Cost High-Accuracy Compound Parabolic Concentrator System—A Manufacturing Methodology

Abstract One of the problems of designing a solar compound parabolic concentrator (CPC) is related to its manufacturing shape accuracy. The complexity of curving and holding the CPC profile in place is indeed a challenging issue, especially because there are no standardized molds and the process is typically handmade. It is very easy to provoke misalignment on the CPC surface and in consequence, divert the solar incident rays, affecting significantly the optical efficiency of the system. This work presents a novel, inexpensive methodology to manufacture a CPC with accuracy by using basic tools. The design starts with the acquisition of a pair of medium-density fiberboard wooden templates of the CPC profile that are used later to make a Styrofoam CPC mold and then cut with a hot-wire technique. A high-reflectance anodized aluminum sheet is curved to approximate the CPC shape and is then coupled with the temporary Styrofoam mold. The last part consists of the elaboration of a housing system to contain the parts. This is consolidated by a polyurethane resin that expands and fills all enclosure cavities, offering stiffness and stability. A photogrammetry analysis was implemented for the validation of the surface shape accuracy. The results from the optical analysis show that this technique achieved a high degree of accuracy and homogeneity on the CPC surface shape.