Abstract:
An inductive energy converter includes a non-magnetic housing, at least one magnet and at least one induction coil disposed within the housing, and at least one spring coupled to the magnet or induction coil. Thus, the spring and the magnet or induction coil form a spring-mass system that oscillates relative to the housing when the housing is subjected to movement. The other of the magnet and induction coil does not move relative to the housing. In an alternative embodiment, human movement results in the depression of a push plate that is coupled to a wheel that causes a ring magnet to rotate relative to one or more induction coils or vice-versa. In either case, the movement of the magnet relative to the coil results in a voltage being induced on the coil according to Faraday&#39;s law.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    a. Field of the Invention 
         [0002]    The instant disclosure relates to energy converters. More specifically, the present disclosure relates to an electromechanical induction generator for converting mechanical energy into electrical energy. 
         [0003]    b. Background Art 
         [0004]    An energy converter is a device that transforms motion, such as human body movement, into electrical energy. This electrical energy can then be stored or used for other purposes. Typically, energy converters fall into one of three categories: piezoelectric, capacitive, and inductive. 
         [0005]    Piezoelectric materials generate a voltage when they are stressed along a preferred direction. Thus, mechanical energy can be converted to electrical energy through the use of a dielectric elastomer generator. The dielectric elastomer is susceptible to various modes of failure, however, including electrical breakdown, electro-mechanical instability, loss of tension, and rupture by over-stretching. These modes of failure define a cycle of maximum energy that can be converted. 
         [0006]    Capacitive devices are disadvantageous because they require an auxiliary electrical supply. The available electric power density to capacitive devices is also limited. 
         [0007]    Inductive devices use Faraday&#39;s law of induction, that electrical energy is generated when a time-varying magnetic flux links to a closed loop coil. The simplified governing equation for induction voltage, which will be familiar to those of ordinary skill, is 
         [0000]    
       
         
           
             
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         [0000]    Thus, the output voltage generated by the induction in the coil is proportional to the number of turns in the coil n, the rate of change in magnetic flux density that links through the coil 
         [0000]    
       
         
           
             
               
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         [0000]    and the cross-sectional area of the coil A. Flux density B changes perpendicular to the coil&#39;s cross-sectional plane. In order to increase the output voltage, the product nA needs to be increased, which is directly related to the physical size of the induction coil&#39;s diameter. Thus, the output is related to the overall size of the induction coils and the time-varying magnetic flux that links to the coil. 
         [0008]    Research shows that a flexible polyimide membrane of 2 mm diameter with an attached magnet produces a maximum power of 0.3 microwatts at 4.4 kHz. See C. Sherwood and R. B. Yates, “Development of an Electromagnetic Microgenerator”, Electronics Letters, v. 13, p. 1883, (1997). Amirtharajah and Chandrakasan estimate the maximum power output of small inductive harvesters at 400 microwatts at 500 kHz, and estimate that the power density that can be achieved by inductive harvesters is limited to 0.5 milliwatts/cm 3 . See R. Amirtharajah and A. Chandrakasan, “Self-powered Signal Processing Using Vibration-Based Power Generation”, IEEE Journal of Solid State Circuits, v. 33, n. 5, pp. 687-695 (1998). 
         [0009]    The electromagnetic approaches are the best candidates for energy harvesting generators, producing a maximum of 2 watts for two steps per second. Electronically, the magnetic unit is far easier to work with. See P. Niu, P. Chapman, and R. Riemer, “Evaluation of Motions and Actuation Methods for Biomedical Energy Harvesting”, 2004 35 th  Annual IEEE Power Electronics Specialist Conference, pp. 2100-2106. The theoretical maximum power density of the electromagnetic unit is rated highest (400 mW per cubic centimeter), and it does not require a high voltage circuit or smart materials like piezoelectric materials. See D. Jia and J. Liu, “Human power-based energy harvesting strategies for mobile electronic devices”, Frontier Energy Power Engineering, China 2009, 3 (1), pp. 27-46. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    It is an object of the present invention to provide an energy converter that is capable of converting the byproduct of mechanical energy into electrical energy. 
         [0011]    It is another object of the present invention to provide an energy converter that produces an increased power output relative to extant energy converters. 
         [0012]    It is a further object of the present invention to provide an energy converter that exhibits an increased power density. 
         [0013]    It is still another object of the present invention to provide an energy converter that produces an increased power output relative to extant energy converters while remaining lightweight, compact, and of sufficiently small size that it can be easily worn, carried, and/or installed within small containers, including, but not limited to, the heel of a shoe. 
         [0014]    Disclosed herein is an inductive energy converter that includes a housing having a longitudinal axis and including an inner shell and an outer shell. The inner shell defines a travel channel substantially parallel to the longitudinal axis of the housing and the inner shell and outer shell define at least one annular chamber therebetween. At least one magnet is disposed within the travel channel, oriented such that its magnetic poles lie along an axis substantially parallel to the longitudinal axis of the housing. At least one induction coil is disposed within the at least one annular chamber, oriented with its cross-sectional area (i.e., the cross-section of the coil, not of the wire that makes up the coil) substantially perpendicular to the longitudinal axis of the housing. At least one spring is coupled to the at least one magnet and the housing such that, when the at least one magnet is set in motion via movement of the housing, the at least one magnet oscillates within the travel channel, through an interior region of the at least one induction coil, and substantially in a direction parallel to the longitudinal axis of the housing. 
         [0015]    Preferably, the housing comprises a non-magnetic material. Thus, in some aspects of the invention, the inductive energy converter is devoid of ferromagnetic materials used to guide magnetic flux. 
         [0016]    It is also desirable for the housing to be relatively small, such as less than about one inch tall and/or less than about two inches in diameter. This permits the inductive energy converter to be installed in small spaces, such as within the heel of a shoe. 
         [0017]    Typically, the at least one magnet comprises two magnets. These two magnets may be part of a spring-mass system that includes comprises a flexure spring positioned between the two magnets. Alternatively, the two magnets may be part of a spring-mass system that includes two flexure springs, one of the two flexure springs positioned at a first end of the housing and another of the two flexure springs positioned at a second, opposite end of the housing. 
         [0018]    To harvest energy, the at least one induction coil can be coupled to an electrical conductor passing through the housing. The electrical conductor can, in turn, be coupled to a Cockcroft Walton voltage multiplier circuit. 
         [0019]    Optionally, the outer shell of the housing is sealed against the atmosphere. Thus, for example, the outer shell of the housing can maintain an environment above atmospheric pressure. 
         [0020]    According to another aspect of the disclosure, an inductive energy converter includes: a non-magnetic housing having a longitudinal axis; at least one magnet disposed within the housing; at least one induction coil disposed within the housing; and at least one spring coupled to the at least one magnet or the at least one induction coil, thereby forming a spring-mass system that oscillates along an axis substantially parallel to the longitudinal axis of the housing when the housing is subjected to movement. Preferably, the at least one spring is a flexure spring. The at least one spring is typically coupled to the at least one magnet such that, when the housing is subjected to movement, the at least one magnet oscillates along an axis substantially parallel to the longitudinal axis of the housing. 
         [0021]    In another embodiment, an inductive energy converter includes: a housing having an upper surface and a lower surface; a push plate forming a portion of the upper surface; a spring disposed within the housing that biases the push plate into a first, undisplaced position; a latch wheel disposed within the housing; a twisted shaft coupled at a first end to the push plate and at a second end to the latch wheel such that, when the push plate is depressed from the first, undisplaced position in a direction substantially towards the lower surface of the housing, the latch wheel rotates; a magnet wheel; mating latches on the latch wheel and the magnet wheel such that, when the latch wheel rotates, the mating latches engage and rotate the magnet wheel; at least one ring magnet segment oriented circumferentially relative to the magnet wheel; and at least one induction coil positioned interior to a circumference of the ring magnet (e.g., radially relative to the magnet wheel), wherein one of the ring magnet and the at least one induction coil is attached or coupled to the magnet wheel such that it rotates when the magnet wheel rotates. In some aspects, the ring magnet is fixed to the magnet wheel such that the ring magnet rotates as the magnet wheel rotates. In other aspects of the invention, the induction coils are attached to the magnet wheel, such that the ring magnet remains stationary and the induction coils rotate with human movement. In either case, when the magnet wheel rotates, the ring magnet and the induction coils are inductively coupled. 
         [0022]    Preferably, the twisted shaft is rigidly coupled to the push plate and movably coupled to the latch wheel. Thus, as the push plate is compressed against the spring, the latch wheel will slide relative to the twisted shaft, causing rotation of the latch wheel. This rotation is, in turn, communicated to the magnet wheel via the mating latches, which can include a plurality of protrusions on the latch wheel and a plurality of corresponding recesses on the magnet wheel. 
         [0023]    The foregoing and other aspects, features, details, utilities, and advantages of the present invention will be apparent from reading the following description and claims, and from reviewing the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]      FIG. 1  depicts an inductive energy converter according to a first embodiment of the invention. 
           [0025]      FIG. 2  depicts an energy harvesting circuit. 
           [0026]      FIG. 2A  is a detail of the Cockcroft Walton Voltage Multiplier Circuit shown in  FIG. 2 . 
           [0027]      FIG. 3  depicts an inductive energy converter according to a second embodiment of the invention. 
           [0028]      FIG. 4  is a plot of voltage vs. charging time using an inductive energy converter according to the present invention subjected to the motion of human walking at approximately 1 Hz. 
           [0029]      FIG. 5  depicts an inductive energy converter according to a third embodiment of the invention. 
           [0030]      FIG. 5A  depicts a suitable latching mechanism for the one-way latches illustrated in  FIG. 5 . 
           [0031]      FIG. 6  depicts an energy converter circuit suitable for use with the embodiment of the invention depicted in  FIG. 5 . 
           [0032]      FIG. 7  is a plot of power density delivered to a 1 kΩ load resistor vs. magnet wheel rotation in accordance with the embodiment of the invention depicted in  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0033]    Voluntary human motion involves kinetic energy. For example, heel striking during walking exhibits a pattern of repeated motion with an approximate periodicity of 1 Hz (higher in the case of running) that can be related to kinetic energy. The instant invention provides an apparatus to convert this mechanical energy into electrical energy. 
         [0034]      FIG. 1  illustrates an inductive energy converter  100  according to a first embodiment of the invention. Inductive energy converter  100  includes a housing  102 , which in turn is made up of an outer shell  104  (e.g., outer shell halves  104   a ,  104   b ) and an inner shell  106  (e.g., inner shell halves  106   a ,  106   b ). 
         [0035]    Housing  102  is preferably made of a non-magnetic material. One suitable material for use in housing  102  is polyvinyl chloride (PVC). Typically, housing  102  is less than about one inch tall and less than about two inches in diameter, making it suitable for installation into small spaces, such as the heel of a shoe. 
         [0036]    The various components of housing  102  (e.g.,  104   a ,  104   b ,  106   a ,  106   b ) are joined to each other in any suitable fashion, including the use of adhesives and fasteners. Once joined, inner shell  106  defines a travel channel  108  that is substantially parallel to the longitudinal axis of housing  102 . Similarly, outer shell  104  and inner shell  106  together define at least one annular chamber  110  (e.g., annular chambers  110   a ,  110   b ). 
         [0037]    Outer shell  104  of housing  102  may be sealed against the atmosphere, which isolates the internal components of inductive energy converter  100  from the environment, for example to render inductive energy converter  100  waterproof. It is also contemplated that outer shell  104  of housing  102  may maintain any desirable environment, such as an inert gaseous environment or an environment above atmospheric pressure, which may increase the reliability and/or performance of inductive energy converter  100 . 
         [0038]    At least one magnet  112  (e.g., magnets  112   a ,  112   b ) is disposed within travel channel  108 . Magnets  112  are oriented such that their magnetic poles are arranged along an axis that is substantially parallel to the longitudinal axis of housing  102 . Suitable materials for magnets  112  include neodymium, iron, and boron. 
         [0039]    At least one induction coil  114  (e.g., coils  114   a ,  114   b ) is disposed within annular chamber  110  (e.g., within annular chambers  110   a ,  110   b  respectively). Induction coils  114  are oriented such that their cross-sections are substantially perpendicular to the longitudinal axis of housing  102 . That is, induction coils  114   a ,  114   b  are oriented such that (1) they coil around annular chambers  110   a ,  110   b  and (2) magnets  112   a ,  112   b  pass through the centers of coils  114   a ,  114   b , respectively. 
         [0040]    Induction coils  114  may be pre-wound or wound directly on inner shell  106 . It is also desirable to bond induction coils  114  to outer shell  104  and/or inner shell  106  to prevent them from moving within annular chambers  110 . 
         [0041]    Typically, induction coils  114  will include between about 3000 to about 4000 turns of wire. Suitable wire includes, but is not limited to, 36-gauge copper wire. One of ordinary skill in the art will appreciate, however, that the specific number of turns and wire type and size can be adjusted to satisfy specific applications for energy converter  100 . 
         [0042]    At least one spring  116  is coupled to magnets  112   a ,  112   b , as well as to housing  102 , for example where inner shell halves  106   a ,  106   b  are joined. Spring  116  is preferably a flexure disk spring. The use of a flexure disk spring reduces the overall size and weight of inductive energy converter  100 . Flexure disk springs also exhibit higher resonant frequencies and result in less wobbling in the motion of magnets  112   a ,  112   b , which in turn increases the output of inductive energy converter  100 . Of course, other springs, such as coil springs, may be employed, for example where the small size achieved via use of a flexure disk spring is of less necessity. One of ordinary skill in the art will appreciate how to design a suitable spring-mass system (e.g., magnets  112  and springs  116 ) for a particular application of energy converter  100 . 
         [0043]    Movement of housing  102  will set the spring-mass system of magnets  112   a ,  112   b  and spring  116  in motion. Magnets  112   a ,  112   b  will oscillate within travel channel  108  through an interior region of induction coils  114   a ,  114   b  and substantially in a direction parallel to the longitudinal axis of housing  102 . This, in turn, will induce a current in induction coils  114   a ,  114   b . Electrical energy can thereby be harvested, for example via electrical conductors  118  (e.g.,  118   a ,  118   b ) passing through housing  102 , and either stored or used to power an external device. One suitable circuit for harvesting energy is shown in  FIG. 2 .  FIG. 2A  depicts in detail the Cockcroft Walton Voltage Multiplier Circuit shown in block form in  FIG. 2 . 
         [0044]      FIG. 3  depicts an inductive energy converter  100 ′ according to a second embodiment of the present invention. Inductive energy converter  100 ′ is generally similar to inductive energy converter  100 . The principal difference between inductive energy converter  100  and inductive energy converter  100 ′ is that, whereas inductive energy converter  100  utilizes a spring  116  positioned between magnets  112   a  and  112   b , inductive energy converter  100 ′ utilizes two springs  116   a ,  116   b  positioned at opposite ends of housing  102 . 
         [0045]    Extant inductive energy converters often increase output by increasing the strength of the magnetic field by using larger magnets and/or by using ferromagnetic materials to channel magnetic flux. Both of these design considerations adversely impact apparatus size and weight. It is therefore desirable to avoid the use of ferromagnetic materials to guide magnetic flux in inductive energy converters according to the present invention. This allows inductive energy converters according to the present invention to be lighter and smaller for a given energy output than extant inductive energy converters. 
         [0046]    The typical output of an inductive energy converter according to either of the embodiments described above is plotted in  FIG. 4 .  FIG. 4  relates recharged battery voltage to charging time when an inductive energy converter according to the present invention, having dimensions of 0.75 inches tall and 1.75 inches diameter, is subjected to motion at approximately 1 Hz (e.g., human walking) As can be seen in  FIG. 4 , such an inductive energy converter delivers about 6.9 μW to a 1.5 V rechargeable battery. 
         [0047]    Another embodiment of an inductive energy converter  500  according to the present invention is depicted in  FIG. 5 . This embodiment of the invention utilizes heel strike displacement of about 0.2 inches and at a frequency of about 1 Hz (when walking) as an initial mechanical input, and does not rely upon vibrational energy. 
         [0048]    Energy converter  500  includes a housing having a top surface  502   a  and a bottom surface  502   b . An internal separator element  503  may also separate the interior of the housing into two separate chambers. A portion of top surface  502   a  is devoted to a push plate  504 , which is mounted above a leaf spring  505 . Leaf spring  505  biases push plate  504  into a first, undisplaced position. Push plate  504  may be attached to the balance of top surface  502   a  via an elastic membrane, which further serves to bias push plate  504  into the undisplaced position. Additionally, the membrane may provide hermetic sealing for the interior of energy converter  500 . 
         [0049]    A twisted shaft  506  is also attached to push plate  504 , with the opposite end of twisted shaft  506  connected to a latch wheel  507  via a retainer element  509 . The opening of latch wheel  507  within which twisted shaft  506  is received is slightly larger than the cross-sectional area of twisted shaft  506  itself. 
         [0050]    Also contained within the housing of energy converter  500  is a magnet wheel  513 , which is mounted on a wheel bearing  510 . A ring magnet  512 , which may be a single, continuous magnet or a series of magnetic segments, is attached to magnet wheel  513  (e.g., to the underside thereof) so as to rotate with magnet wheel  513 . 
         [0051]    One or more induction coils  511  are located interior to ring magnet  512 , typically arranged radially. Induction coils may take any form, but preferably will have about 40 turns and a resistance of about 4.8Ω. Of course, power density can be increased many times over by increasing the number of turns, while still remaining within size constraints (e.g., small enough to fit within a shoe heel) and the wire gauge size. 
         [0052]    When in use, a heel strike causes axial displacement of push plate  504  in an axial direction (i.e., towards bottom side  502   b  of the housing), compressing leaf spring  505 . Moreover, as push plate  504  displaces downwards, latch wheel  507  rotates as it slides along the surface of twisted shaft  506 . 
         [0053]    Latch wheel  507  in turn engages with magnet wheel  513  via a series of mating one-way latches  508  on latch wheel  507  (e.g., on the lower side of latch wheel  507 ) and magnet wheel  513  (e.g., on the upper side of magnet wheel  513 ). Thus, as latch wheel  507  turns, so does magnet wheel  513 . One-way latches  508  disengage when push plate  504  returns to its original, neutral position (e.g., when leaf spring  505  is released from heel strike compression). 
         [0054]    Suitable one-way latches  508  are depicted on latch wheel  507  and magnet wheel  513  in  FIG. 5A . The left-hand side of  FIG. 5A  depicts a series of protrusions  603  on latch wheel  507 ; also shown is a slot  601  through which twisted shaft  506  passes. On the right-hand side of  FIG. 5A , magnet wheel  513  is shown including a series of mating recesses  604 . Of course, one of ordinary skill in the art will appreciate that there are numerous ways in which to construct one-way latches  508 , all of which are within the spirit and scope of the present invention. 
         [0055]    Rotation of magnet wheel  513 , and thus ring magnet  512 , relative to induction coils  511  yields current and thus electrical energy, which can be harvested using the rectifier circuit depicted in  FIG. 6 . As shown in  FIG. 6 , energy converter  500  is arranged so it is connected to a 3-phase generator, with three induction coils connected to terminals A, B, and C of the depicted circuit. Three diodes lead to a positive terminal, while three more diodes lead to a negative terminal. The three DC voltages are added to increase the overall DC output voltage, which does not become zero. 
         [0056]      FIG. 7  illustrates power density vs. magnetic wheel rotation for energy converter  500 . For three induction coils as described above in a star connection, the resistance is 1 kΩ. The inventors estimate that, at a frequency of about 1 Hz (e.g., walking frequency), magnet wheel  513  will achieve a rotational speed of about 500 RPM, yielding a power density of over 1 mW/cm 3 . If the volume of the magnetic wheel  513  and induction coils  511  is about 21.7 cm 3 , the power delivered from energy converter  500  to the 1 kΩ load is over 21 mW. 
         [0057]    Although several embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. For example, although  FIGS. 1 and 3  depict axisymmetric devices, human motion will not necessarily impart a perfectly symmetrical motion along the longitudinal axis of the device. Thus, slightly non-symmetrical structures can be used without departing from the spirit and scope of the present invention. 
         [0058]    As another example, the device could be modified such that the magnets remain stationary while the induction coils vibrate with human motion. That is, the mass in the spring-mass system set in motion by movement of the housing may be either the magnets or the induction coils. Similarly, energy converter  500  could be constructed such that ring magnet  512  remains stationary while induction coils  511  rotate with human motion. 
         [0059]    Still another example is the addition of magnets outside of the induction coils (e.g., mounted on the outer surface of the outer shell) to increase the magnetic flux linkage for an increased induction voltage. 
         [0060]    All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader&#39;s understanding of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other. 
         [0061]    It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.