> A circular polyurethane foam (36 mm diameter and 25 mm thickness) was used as the floating thermal insulation. An insulating ring (36 mm external diameter, 31 mm internal diameter, and 6 mm height) made of polystyrene foam was attached on top of the floating thermal insulation. Black paint (245198, Rust-Oleum) was uniformly sprayed on the top of the thermal insulation layer, creating a 31 mm diameter area for solar absorption. Five 2.5 mm diameter macrochannels were drilled through the thermal insulation using waterjet. One of five macrochannels was in the center of the floating thermal insulation, while the other four were in four vertices of a square, 9 mm away from the central macrochannel. A circular copper plate (36 mm diameter) was used as the balancing weight, which was attached to the bottom of the floating thermal insulation. Similar to the floating thermal insulation, five 2.5 mm diameter macrochannels were also machined through the copper plate using waterjet. The total weight of the copper plate was 23.4 g to enable the neutral buoyancy of the entire structure. The convection cover comprised two glass slides (45 mm diameter and 2 mm thickness) and an air gap (5 mm thickness). The solar absorber for the contactless mode was a double-sided black-painted aluminum plate, attaching to the back side of the convection cover.
The $4 estimate comes from replacing copper with something cheaper.
Paper link: https://www.nature.com/articles/s41467-022-28457-8
Here is the design of prototype:
> A circular polyurethane foam (36 mm diameter and 25 mm thickness) was used as the floating thermal insulation. An insulating ring (36 mm external diameter, 31 mm internal diameter, and 6 mm height) made of polystyrene foam was attached on top of the floating thermal insulation. Black paint (245198, Rust-Oleum) was uniformly sprayed on the top of the thermal insulation layer, creating a 31 mm diameter area for solar absorption. Five 2.5 mm diameter macrochannels were drilled through the thermal insulation using waterjet. One of five macrochannels was in the center of the floating thermal insulation, while the other four were in four vertices of a square, 9 mm away from the central macrochannel. A circular copper plate (36 mm diameter) was used as the balancing weight, which was attached to the bottom of the floating thermal insulation. Similar to the floating thermal insulation, five 2.5 mm diameter macrochannels were also machined through the copper plate using waterjet. The total weight of the copper plate was 23.4 g to enable the neutral buoyancy of the entire structure. The convection cover comprised two glass slides (45 mm diameter and 2 mm thickness) and an air gap (5 mm thickness). The solar absorber for the contactless mode was a double-sided black-painted aluminum plate, attaching to the back side of the convection cover.
The $4 estimate comes from replacing copper with something cheaper.