Heat transfer using flexible fluid conduit

Abstract

Heat transfer between a fluid-bearing flexible tube and a heat-conducting surface is improved by fixing a flexible heat-conducting sheath to the flexible tube and by compressive fixing that distorts the tube and deforms the sheath and/or the surface. The tube can be made of cross-linked polythene (PEX). The sheath can be spirally wound high-purity aluminum wire. The sheath enables efficient heat transfer between the outer surface of the tube and the heat-conducting surface. Applications include radiant heating and cooling. Tube layout can be customized and variable tube spacing is possible, for example by using a castellated layer to support the tube.

Claims

1. A sheathed flexible conduit configured for use in heat transfer applications requiring custom in-situ manual layout comprising: a flexible tube of plastic or plastic composite material arranged to conduct a heat transfer fluid, said tube having a uniform wall thickness and smooth inner and outer surfaces; a sheath of material with thermal conductivity greater than 15 W/m C. surrounding said outer surface of said flexible tube, said sheath contiguous with said outer surface of said flexible tube; said sheath being composed of a soft and malleable material that allows said sheath to be deformed in the course of said custom in-situ manual layout; said deformation being bending and spreading and thinning and conforming to an adjacent surface; said sheathed flexible conduit being arranged in a curved pattern and held in said curved pattern by fixing means; said sheathed flexible conduit having an outer surface fixed in thermally conductive contact with at least one contiguous heat-conducting surface having a thermal conductivity greater than 15 W/m C.; said thermally conductive contact being made under pressure by means of compressive fastening, whereby said flexible tube and said sheath distort against said contiguous heat-conducting surface and said sheath deforms against said contiguous heat-conducting surface by bending, spreading and thinning, so increasing heat transfer area and conforms to said contiguous heat-conducting surface, so reducing thermal contact resistance; said compressive fastening creating a thermal conductive path from all of the circumference of said flexible tube to said contiguous heat-conducting surface; said compressive fastening being formed in the course of said custom in-situ manual layout; said flexible tube having a longitudinal axis and said sheath comprising segments transverse to said longitudinal axis of said flexible tube and, when said sheathed flexible conduit is held straight, having spaces of uniform width between said segments of said sheath that are adjacent; said uniform spaces being completely filled with a flexible adhesive; said segments, in the absence of compressive deformation of said segments, having a uniform radial thickness and a uniform axial thickness; said sheathed flexible conduit being as flexible as said flexible tube alone at a coverage exceeding 95% of said exterior surface of said flexible tube by said sheath; said sheathed flexible conduit having a ratio of minimum bend radius to outer diameter of said flexible tube less than 10; said sheathed flexible conduit having a modulus of elasticity of 2 GPa or less.

2. The sheathed flexible conduit as claimed in claim 1 wherein said flexible tube has at least one layer of cross-linked, high-density polythene.

3. The sheathed flexible conduit as claimed in claim 1 wherein said sheath is a spiral strip enclosing said flexible tube and said adjacent segments are adjacent spirals of said spiral strip.

4. The sheathed flexible conduit as claimed in claim 1 wherein said sheath is a series of rings enclosing said flexible tube and each contiguous with said outer surface of said flexible tube and said adjacent segments are adjacent rings in said series of rings.

5. The sheathed flexible conduit as claimed in claim 1 wherein said sheath is composed of aluminum of at least 99.5% purity.

6. The sheathed flexible conduit as claimed in claim 1 wherein said heat transfer fluid is water.

7. The sheathed flexible conduit as claimed in claim 1 wherein said sheathed flexible conduit has a circular cross-section transverse to said longitudinal axis and said fixing means is a plurality of channels in a rigid surface where such channels have an inner radius matching the outer radius of said sheathed flexible conduit whereby said sheathed flexible conduit is gripped in said channels.

8. The sheathed flexible conduit as claimed in claim 1 wherein said fixing means is a deformable and heat-conducting layer fixed over a plurality of channels in a rigid surface and said deformable and heat-conducting layer is punctured along a center line of said channels, whereby by pressing said sheathed flexible conduit into said center line, said sheathed flexible conduit is gripped by bent edges of said deformable and heat-conducting layer and said gripping comprises said compressive fastening.

9. The sheathed flexible conduit as claimed in claim 1 wherein said fixing means is a rigid surface comprising a uniformly spaced array of castellations, channels being between said castellations, and the width of said channels matching a portion of the outer circumference of said sheathed flexible conduit, whereby said sheathed flexible conduit is gripped in said channels and projects above said castellations enabling thermally conductive contact between said sheath and said heat-conducting surface adjacent to said castellations; said thermal conductive contact being maintained by said means of compressive fastening, pressing said sheath and said adjacent heat-conducting surface together.

10. The sheathed flexible conduit as claimed in claim 1 wherein said fixing means is an array of omega-shaped clips attached to a rigid substrate and arranged so that said flexible sheathed conduit is gripped by said omega-shaped clips and projects above said omega-shaped clips, whereby said heat-conducting surface is pressed upon said sheath by said means of compressive fastening.

11. The sheathed flexible conduit as claimed in claim 1 wherein said heat-conducting surface has a deformable heat-conducting facing adjacent to said sheath and said sheath and said heat-conducting surface are held together by said means of compressive fastening, whereby said tube and said sheath distort against said heat-conducting surface and said heat-conducting facing deforms by spreading and thinning against said sheath, so increasing heat transfer area and reducing thermal contact resistance.

12. The sheathed flexible conduit as claimed in claim 9 wherein said means of compressive fastening is an adhesive layer between said heat-conducting surface and said castellations.

13. The sheathed flexible conduit as claimed in claim 9 wherein said means of compressive fastening is an array of threaded fasteners connecting said heat-conducting surface to said castellations.

14. A method of installing a heat transfer apparatus comprising: manually laying out in-situ a sheathed flexible conduit comprising: a flexible tube of plastic or plastic composite material arranged to conduct a heat transfer fluid, said tube having a uniform wall thickness and smooth inner and outer surfaces; a sheath of material with thermal conductivity greater than 15 W/m C. surrounding said outer surface of said flexible tube, said sheath contiguous with said outer surface of said flexible tube; said sheath being composed of a soft and malleable material that allows said sheath to be deformed in the course of said custom in-situ manual layout; said deformation being bending and spreading and thinning and conforming to an adjacent surface; said flexible tube having a longitudinal axis and said sheath comprising segments transverse to said longitudinal axis of said flexible tube and, when said sheathed flexible conduit is held straight, having spaces of uniform width between said segments of said sheath that are adjacent; said uniform spaces being completely filled with a flexible adhesive; said segments, in the absence of compressive deformation of said segments, having a uniform radial thickness and a uniform axial thickness; said sheathed flexible conduit having a ratio of minimum bend radius to outer diameter of said flexible tube less than 10; said sheathed flexible conduit having a modulus of elasticity of 2 GPa or less; arranging said sheathed flexible conduit in a curved pattern; holding said sheathed flexible conduit in said curved pattern by fixing means; fixing an outer surface of said sheathed flexible conduit in thermally conductive contact with at least one contiguous heat-conducting surface having a thermal conductivity greater than 15 W/m C.; providing, by means of said sheath, a thermal conductive path from all of the circumference of said flexible tube to said contiguous heat-conducting surface; said thermally conductive contact being made under pressure by means of compressive fastening, whereby said flexible tube and said sheath distort against said contiguous heat-conducting surface and said sheath deforms against said contiguous heat-conducting surface by bending, spreading and thinning so increasing heat transfer area and by conforming to said contiguous heat-conducting surface, so reducing thermal contact resistance; creating by said compressive fastening a thermal conductive path from all of the circumference of said flexible tube to said contiguous heat-conducting surface.

Description

DETAILED DESCRIPTION

Summary of Figures

(1) The figures shown are schematic and not to scale.

(2) FIG. 1a: flexible tube sheathed by a spiral strip.

(3) FIG. 1b: flexible tube sheathed by a series of rings.

(4) FIG. 1c: detail of bonding agent applied to the sheath.

(5) FIG. 2a: flexible sheathed tube inside an omega-shaped channel in a conducting surface.

(6) FIG. 2b: thermal bypass formed by the sheath.

(7) FIG. 3a: sheathed tube with malleable sheath in non-compressive contact with a conducting surface.

(8) FIG. 3b: sheathed tube with malleable sheath in compressive contact with a conducting surface.

(9) FIG. 4a: sheathed tube in non-compressive contact with a conducting surface with malleable layer.

(10) FIG. 4b: sheathed tube in compressive contact with a conducting surface with malleable layer.

(11) FIG. 5a: sheathed tube in an omega-shaped clip with adhesive base.

(12) FIG. 5b: sheathed tube in an omega-shaped clip with barbed base.

(13) FIG. 5c: sheathed tube in an omega-shaped clip with screw-in base.

(14) FIG. 6a: sheathed tube over a u-shaped channel with slotted conducting layer.

(15) FIG. 6b: sheathed tube in u-shaped channel held by bent conducting layer.

(16) FIG. 7a: serpentine tube layout for radiant heat transfer.

(17) FIG. 7b: layers of radiant heat transfer system.

(18) FIG. 8a: serpentine tube layout using a castellated surface.

(19) FIG. 8b: layers of radiant heat transfer system using a castellated surface.

(20) FIG. 9a: roof-mounted panels and layout for solar heating.

(21) FIG. 9b: layers of solar heating system.

DETAILED DESCRIPTION

(22) FIG. 1a: Flexible Tube Sheathed by a Spiral Strip.

(23) FIG. 1a is a side view of a sheathed tube (10) comprising a flexible fluid-bearing tube (11) with a flexible heat-conducting sheath that is a spiral strip (12), tightly wrapped round the tube (11). The spiral strip (12) can be a wire or a tape and is made of heat conducting material. The material has a thermal conductivity greater than 15 W/m C. and is preferably easily deformed (ie malleable and ductile). In an example, a suitable deformable heat-conducting material is high purity aluminum. The spirals (12) of the sheath are separated by uniform gaps (13) that permit bending of the sheathed tube (10).

(24) FIG. 1b: Flexible Tube Sheathed by a Series of Rings.

(25) FIG. 1a is a side view of a sheathed tube (10) comprising a flexible fluid-bearing tube (11) with a flexible heat-conducting sheath that is a series of rings (14) tightly wrapped round the tube (11). The rings (14) can be wire or strip or tape and are made of heat conducting material. The material has a thermal conductivity greater than 15 W/m C. and is preferably easily deformed (ie malleable and ductile). In an example, a suitable deformable heat-conducting material is high purity aluminum. The rings (14) are separated by uniform gaps (15) that permit bending of the sheathed tube (10).

(26) FIG. 1c: Detail of Bonding Agent Applied to the Sheath.

(27) FIG. 1c is a cross-section in side view of one wall of the sheathed tube (10). Pressed against the fluid-bearing tube (11) is a series of spiral wires (12) separated by uniform gaps (13). Fixed in the gaps (13) is a layer of flexible adhesive (16). The adhesive (16) can be applied as follows: The spiral wire (12) is wound tightly around the tube (11). The adhesive (16) is painted on to the spiral (12) and then wiped off, using a motion at right angles to the spiral (12), so leaving adhesive in the gaps (13)

(28) FIG. 2a: Flexible Sheathed Tube Inside an Omega-Shaped Channel in a Conducting Surface.

(29) FIG. 2a shows the cross-section of a flexible sheathed tube (10) installed in the omega-shaped channel (20) of a heat diffusing/collecting plate (21). The sheathed tube (10) comprises a flexible, fluid-bearing tube (11) with a flexible, heat-conducting outer sheath (22). The sheath (22) is tightly fitted to the outer surface of the tube (11) and fixed to the tube (11) using a layer of flexible adhesive (not shown). The sheath (22) provides a thermal path between the entire outer surface of the tube (11) and the plate (21).

(30) Thermal contact resistance between sheath (22) and channel (20) is reduced by: Ensuring a tight fit of tube (11) and sheath (22) in the channel (20). A tight fit is enabled by using a sheath (22) of deformable material. For example, high purity aluminum and graphite foil are both easily deformed. Using a sheath (22) of deformable material and so enabling the outer surface of the sheath (22) to conform to the inner surface of the channel (20). Using a sheath (22) of high thermal conductivity and so providing a thermal bypass around air gaps between the sheath (22) and the inner surface of the channel (20).

(31) An array (not shown) of plates (21) with channels (20) can support a desired curved pattern of flexible sheathed tube (10).

(32) FIG. 2b: Thermal Bypass Formed by the Sheath.

(33) FIG. 2b shows a cross-section of the interface between a portion of the sheath (22) and an adjacent portion of a heat-conducting surface (23) such as the inner surface of the groove (20: see FIG. 2a). Good thermal contact between sheath (22) and surface (23) is shown at two zones (24) with an air gap (25) in between the zones (24). The sheath (22) provides a thermal bypass around the gap (25)

(34) FIG. 3a: Sheathed Tube with Malleable Sheath in Non-Compressive Contact with a Conducting Surface.

(35) FIG. 3a shows a cross-section of a flexible fluid-bearing tube (11) with sheath (22) in contact with a rigid planar insulating surface (30) and a rigid planar heat-conducting surface (31). The contact is non-compressive so that the contact area between sheath (22) and conducting surface (31) is small. The thermal contact resistance is significant.

(36) FIG. 3b: Sheathed Tube with Malleable Sheath in Compressive Contact with a Conducting Surface.

(37) FIG. 3b shows a cross-section of a flexible fluid-bearing tube (11) with flexible heat-conducting sheath (22) in contact with a rigid planar insulating surface (30) and a rigid planar heat-conducting surface (31). The contact is compressive and in this instance, the sheath (22) is made of malleable material. The tube (11) and sheath (22) distort and the sheath (22) deforms, so that the contact area is increased; also the thermal contact resistance is reduced.

(38) Compressive contact can be achieved by a variety of means (not shown) that pull or push the rigid planar surfaces (30, 31) towards each other and hold these surfaces (30,31) in position.

(39) In an instance of the present invention, the contact between sheath (22) and heat-conducting surface (31) is sufficiently compressive to cause distortion of the tube (11) and deformation of the sheath (22), whereby overall thermal resistance is reduced.

(40) FIG. 4a: Sheathed Tube in Non-Compressive Contact with a Conducting Surface with Malleable Layer.

(41) FIG. 4a shows a cross-section of a flexible fluid-bearing tube (11) with sheath (22) in contact with a rigid planar insulating surface (30) and a rigid planar heat-conducting surface comprising two layers: a rigid layer (40) and a malleable layer (41). The contact is non-compressive so that the contact area is small. The thermal contact resistance is significant.

(42) FIG. 4b: Sheathed Tube in Compressive Contact with a Conducting Surface with Malleable Layer.

(43) FIG. 4b shows a cross-section of a flexible fluid-bearing tube (11) with sheath (22) in contact with a rigid planar insulating surface (30) and a rigid planar heat-conducting surface comprising two layers: a rigid layer (40) and a malleable layer (41). The contact is compressive. The tube (11) and sheath (22) distort and the malleable layer (41) deforms, so that the contact area is increased; also the thermal contact resistance is reduced.

(44) In an instance of the present invention, the contact between sheath (22) and heat-conducting surface is sufficiently compressive to cause distortion of the tube (11) and deformation of a malleable layer (41) in the heat-conducting surface (30), whereby overall thermal resistance is reduced.

(45) FIG. 5a: Sheathed Tube in Omega-Shaped Clip with Adhesive Base.

(46) FIG. 5a shows a cross-section of a flexible fluid-bearing tube (11) with flexible heat-conducting sheath (22). The sheath (22) is held in an omega-shaped channel formed by a clip (50) fixed to a flat base (51). A portion (52) of the tube (11) and the sheath (22) projects above the clip (50). The flat base (51) is attached to a rigid substrate (53) by an adhesive layer (54). The substrate (53) can be an insulating layer. For convenience, the adhesive layer (54) is a peel-off contact adhesive.

(47) FIG. 5b: Sheathed Tube in Omega-Shaped Clip with Barbed Base.

(48) FIG. 5b shows a cross-section of a flexible fluid-bearing tube (11) with flexible heat-conducting sheath (22). The sheath (22) is held in an omega-shaped channel formed by a clip (50) fixed to a base with barbs (55). A portion (52) of the tube (11) and the sheath (22) projects above the clip (50). The barbs (55) are inserted into a rigid substrate (53).

(49) FIG. 5c: Sheathed Tube in Omega-Shaped Clip with Screw-in Base.

(50) FIG. 5c shows a cross-section of a flexible fluid-bearing tube (11) with flexible heat-conducting sheath (22). The sheath (22) is held in an omega-shaped channel formed by a clip (50) fixed to a base with a screw (56). A portion (52) of the tube (11) and the sheath (22) projects above the clip (50). The screw (56) is inserted into a rigid substrate (53).

(51) In an instance of the present invention, clips (50) as described in FIGS. 5a, 5b and 5c can be fixed on a suitable rigid substrate (53) so as to support a sheathed tube in a desired curved pattern.

(52) The clips (50) shown in FIGS. 5a, 5b, 5c can be made of a moldable polymer such as polypropylene.

(53) In each case, the sheath (22) projects above the clips (50) so that a conducting surface (not shown) can be pressed down on the sheath (22). The clips (50) cannot support a significant load so that other load-bearing means (not shown) are required. For example, castellations can be used (see FIGS. 8a, 8b).

(54) Clips are widely used to pin down flexible tube in radiant heating but the conventional clips differ from those shown in FIGS. 5a, 5b, 5c: Self-adhesive P-clips have a snap-in fit from the side rather than the top. Self-adhesive PEX grip rails have upper retaining barbs and the tube when inserted in the rail is completely below the level of the barbs. Barbed PEX clips have a hoop shape ie the clip passes over the tube and acts as a staple. PEX screw clips and so-called Quips (for attaching PEX tube to a wire grid) have upper retaining barbs so that the tube when inserted in the clip is completely below the level of the barbs.

(55) FIG. 6a: Sheathed Tube Over u-Shaped Channel with Slotted Conducting Layer.

(56) FIG. 6a shows a cross-section of a flexible fluid-bearing tube (11) with flexible heat-conducting sheath (22). Below the tube (11) with sheath (22) is shown in cross-section a deformable heat-conducting layer (60) fixed to a rigid planar substrate (61). The conducting layer (60) covers a u-shaped channel (62) in the substrate (61). Penetrating the conducting layer (60) is a slit (63) that is centred over the u-shaped channel (62) and runs parallel with the channel (62).

(57) FIG. 6b: Sheathed Tube in u-Shaped Channel Held by a Bent Conducting Layer.

(58) FIG. 6b shows a cross-section of a flexible fluid-bearing tube (11) with flexible heat-conducting sheath (22) after the tube (11) with sheath (22) has been pressed down on the slit (63: see FIG. 6a) above the u-shaped channel (62). On each side of the channel (62) the heat-conducting layer (60) has been bent back.

(59) As a result of the mechanical resistance to bending of the conducting layer (60), the sheath (22) is held firmly in the channel (62) and the thermal contact resistance between sheath (22) and conducting layer (60) is low.

(60) An array of panels (not shown) with u-shaped channels (62) and an attached conducting layer (60) with slits (63) can support a desired curved pattern of sheathed tube (10).

(61) The slit (63) can be substituted by another form of puncturing of the conducting layer (60): for example, a line of closely spaced perforations (not shown).

(62) FIG. 7a: Serpentine Tube Layout for Radiant Heat Transfer.

(63) FIG. 7a shows in plan view an example of a simple serpentine layout of a flexible fluid-bearing sheathed tube (10) for radiant under-floor heating. The tube (10) conducts hot heat transfer fluid from a manifold (70) to a zone requiring higher heat transfer rates (71) such as a zone adjacent to a large exterior window. This zone (71) requires closer spacing of the sheathed tube (10). The tube (10) continues with wider spacing and returns to the manifold (70). The direction of fluid flow (76) is shown by arrows. In an example, the heat transfer fluid is water.

(64) Means of fixing the sheathed tube (10) in a desired layout are not shown but are described under FIGS. 2, 5, 6 and 8.

(65) FIG. 7b: Layers of Radiant Heat Transfer System.

(66) FIG. 7b shows in cross-section the possible layers of a radiant under-floor heating system. The lowest layer is a rigid planar substrate (73) that can be a subfloor. Fixed to the substrate (73) is an insulating layer (74). Fixed to the insulating layer is the sheathed tube (10) laid out in a curved pattern. Fixed to the top of the sheathed tube (10) is a rigid planar heat-conducting surface (75).

(67) Other layers (not shown) can be placed on the conducting surface (75): such layers can include ceramic tile, engineered wood plank, carpet and so on.

(68) Means of fixing the sheathed tube (10) in a desired layout are not shown but are described under FIGS. 2, 5, 6 and 8.

(69) FIG. 8a: Serpentine Tube Layout Using a Castellated Surface.

(70) FIG. 8a shows in plan view a flexible sheathed tube (10) in an example of a serpentine layout on a rigid planar castellated surface (80). The castellations (81) are rigid protrusions arranged in a uniform grid. By weaving the tube (10) between castellations (81) the tube (10) can be fixed in a desired curving pattern.

(71) The geometry of the castellated surface (80) enables the sheathed tube (10) to be securely gripped and at the same time, a portion of the sheathed tube (10) projects above the castellations (81).

(72) FIG. 8b: Layers of Radiant Heat Transfer System Using a Castellated Surface.

(73) FIG. 8b shows in cross-section the possible layers of a radiant heat transfer system using a castellated surface (80). The first layer is a rigid substrate (82). For example, in the case of an under-floor heating or cooling system, the substrate (82) can be a subfloor. In the case of a wall-mounted heat transfer system, the substrate (82) can be wall-panels. In the case of a ceiling-mounted heat transfer system the substrate (82) can be panels on a suspended frame.

(74) Fixed to the substrate (82) by an adhesive layer (83) is a layer with a castellated surface (80) that can comprise rigid insulation into which a uniform grid of castellations (81) is molded. In an example, the castellated layer (80) is rigid polyurethane foam. The castellations (81) have flat tops and concave faces and provide channels (84) that can retain the sheathed tube (10) in a desired curved pattern. The dimensions of the channels (84) ensure that a portion of the sheathed tube (10) projects above the castellations (81). Shown above the castellated layer (80) is a rigid heat-conducting layer (85) that is pressed against an adhesive layer (86) on the flat tops of the castellations (81). When the conducting layer (85) is pressed against the adhesive layer (86) in the direction shown (87), the conducting layer (85) is in compressive contact with the sheathed tube (10), meaning that the sheathed tube (10) distorts and the sheath (22: see FIG. 3b) deforms sufficiently to significantly reduce thermal resistance between the heat transfer fluid carried in the sheathed tube (10) and the conducting layer (85).

(75) The adhesive layer (86) can be peel-off contact adhesive.

(76) Instead of, or in addition to, the adhesive layer (86), bolts or screws (not shown) can be used to fix the conducting layer (85) to the castellated surface (84) with compressive contact between the conducting layer (85) and the sheathed tube (10).

(77) FIG. 9a: Roof-Mounted Panels and Layout for Solar Heating.

(78) This figure gives a plan view of a hipped roof (90) and an array of solar panels of standard size (91). Indicated by a dotted line is an example of an underlying simple serpentine of sheathed tube (10). Water or water with anti-freeze agent, or other heat-transfer fluid, is circulated through the serpentine.

(79) By using panels of moderate size that are installed one by one: One-man installation is made possible. The geometry of the roof can be matched. Sufficiently small panels (91) allow a system to be built round dormer windows and chimneys.

(80) FIG. 9b: Layers of Solar Heating System.

(81) This figure shows a cross-section of a portion of the system shown in FIG. 9a.

(82) The top layer of each panel (91) is a transparent sheet (92) that is, for example, glass or acrylic. This sheet (92) is separated from a planar, rigid, heat-conducting surface (93) by an air gap (94). The top layer (95) of the conducting surface (93) is coloured black to aid absorption of heat. In an example, the conducting surface (93) is aluminum plate and the top layer (95) is anodized.

(83) The transparent layer (92) and conducting layer (93) of each panel (91) are held together along the edges by a rectangular frame (not shown). The frames can be linked, for example, by tongue and groove edges (not shown) so that panels (91) can be linked into a continuous array.

(84) The underside of the conducting surface (93) is fixed by a layer of adhesive (96) to the flat tops of castellations (97) in a castellated surface (98). The conducting surface is in compressive contact with sheathed tube (10): shown here with deformation of the sheath (22). Conveniently, the adhesive (96) can be peel-off contact adhesive. The sheathed tube (10) is held in channels (99) between the castellations (97). The castellated surface (98) is fastened to an insulating layer (910) by a layer of adhesive (911).

(85) A method for fixing the panels (91) to a roof (90) in a customized layout of flexible sheathed tube (10) is as follows: Install fixing devices (not shown) on the roof (90): for example, using hooks that run under tiles and that can be fixed to the interior roof beams. Mount external rails on the hooks. Attach rigid panels with an insulating layer (910) to the rails (not shown). The panels can have castellated surfaces (98) attached to or molded into the insulating layer (910). Snap flexible sheathed tube (10) into the channels (99) in the castellated surface (98) in the desired pattern. The sheathed tube (10) projects slightly above the castellations (97). Peel off the protective layer (not shown) on the flat tops of the castellations (97) to expose a contact adhesive layer (96). Install the solar panels (91) by pressing down the rigid conducting surface (93) on the adhesive layer (96), so that the conducting surface (93) is in compressive contact with the sheathed tube (10). Place flexible water-proof grout between panels. Attach water-proof side strips to the outer edges of the array of panels. (These finishing steps are not shown). The result is a sealed, customized solar heat collector.