Abstract:
A boundary layer turbine that uses flat disks that can be precision cut at low cost is more cost-effective to construct and maintain than conventional turbines. Bolt-on hub design significantly decreases breakage and distortion. Delta-wing shaped center spacers and flow enhancing, teardrop-shaped outer spacers further increase durability by providing improved support for the disks while minimizing the disturbance of the natural flow of fluids. Use of endplates with heavy outer rims results in turbines with greater gyroscopic effect and greater mass for kinetic energy storage. A disk-directed inlet valve and focused inlet nozzle system increases efficiency by directing flows to the individual disks valve in a low friction containment case. The directed flow tuned inlet nozzle system further increases efficiency. Coating the inner case of the turbine&#39;s enclosure with Teflon or similar materials reduces friction and further improves efficiency.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 61/824,829 filed on May 17, 2013 by David Allan Ryker and Clyde Igarashi, entitled Expandable Boundary Layer Turbine With Bolt-on Hubs, Center Support Spacers, Directed Stream Inlet Valve, and Gyro Endplates; which is hereby incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention is generally in the field of boundary layer turbines. More specifically, the present invention teaches a low-cost boundary layer turbine comprising a bolt-on hub and directed-flow tuned inlet nozzle design that significantly decreases breakage and distortion and increases the efficiency of the system. 
         [0004]    2. Background Art 
         [0005]    Conventional turbine blades are expensive to construct because of their complexity and level of detail. The complexity also adds to fragility and the exposed blades make them prone to breakage, increasing maintenance cost and decreasing dependability. Nikola Tesla&#39;s boundary layer turbine employed a simpler design but did not gain widespread application at the time of its invention in part due to limitations of metallurgical technology. Subsequent attempts by experimenters have failed to produce a turbine of significant capacity and durability because they follow the original concept with a large hole through the center, thereby weakening the structure and leaving the disks susceptible to distortion and breakage. Recent experiments have been limited to smaller boundary layer turbines with limited water or air pressure applied. Because of the limitations of the experiments, there is also a question of the efficiency of the turbines. 
         [0006]    Conventional turbines are costly to manufacture and maintain, due largely to the fragile nature of their blades. The open blade design leaves them vulnerable to damage. Boundary layer turbines in the past have been susceptible to breakage and distortion, and thus efficiency numbers have been questionable and difficult to verify. 
       SUMMARY OF THE INVENTION 
       [0007]    This invention provides a method to construct a boundary layer turbine that is much cheaper to construct and maintain than conventional turbines because it uses flat disks that can be precision cut at low cost. The design of this invention is an improvement over previous boundary layer turbines because the bolt-on hub design significantly decreases breakage and distortion. Delta-wing shaped center spacers and teardrop shaped outer spacers further increases durability by providing improved support for the disks while minimizing the disturbance of the natural flow of fluids. The use of endplates with heavy outer rims results in turbines with greater gyroscopic effect and greater mass for kinetic energy storage. The focused inlet nozzle system increases efficiency by directing flows to the individual disks. Coating the inner case of the turbine&#39;s enclosure with Teflon or similar materials will reduce friction and further improve efficiency. 
         [0008]    As stated above, conventional turbine blades are expensive to construct because of their complexity and level of detail. The complexity also adds to fragility and the exposed blades make them prone to breakage, increasing maintenance cost and decreasing dependability. Nikola Tesla turbine&#39;s employed a simpler design but did not gain widespread application at the time of its invention in part due to limitations of metallurgical technology. Subsequent attempts by experimenters have failed to produce a turbine of significant capacity and durability because they follow the original concept with a large hole through the center, thereby weakening the structure and leaving the disks susceptible to distortion and breakage. Recent experiments have been limited to smaller boundary layer turbines with limited water or air pressure applied. Because of the limitations of the experiments, there is also a question of the efficiency of the turbines. The invention claimed here solves this problem. 
         [0009]    By bolting on hubs directly to disks and not putting a hole through the middle of them, this invention is much stronger and less susceptible to distortions and breakage. Furthermore the delta wing shaped center spacers and teardrop shaped outer spacers in this invention improve support for the disks while minimizing the disturbance of the natural flow of fluids. The use of endplates with heavy outer rims results in turbines with greater gyroscopic effects and greater mass for kinetic energy return. The tuned inlet nozzle system within the containment case with directed streams going to each individual disk increases the efficiency of the system. Coating the inner case of the turbine&#39;s enclosure with Teflon or similar materials will reduce friction and further improve efficiency. 
         [0010]    The present invention differs from existing prior art because of its simple design. The expandable turbine is much cheaper to build and maintain than a conventional turbine, while also being less fragile. 
         [0011]    The present invention provides a method to construct a boundary layer turbine that is much cheaper to construct and maintain than conventional turbines because it uses flat disks that can be precision cut at low cost. The design of this invention is an improvement over previous boundary layer turbines because the bolt-on hub design significantly decreases breakage and distortion. Delta wing shaped center spacers and teardrop shaped outer spacers provide improved support for the disks while minimizing the disturbance of the natural flow of fluids. The use of endplates with heavy outer rims results in turbines with greater gyroscopic effects and greater mass for kinetic energy storage. The directed-flow tuned inlet nozzle system further increases efficiency. Coating the inner case of the turbine&#39;s enclosure with Teflon or similar materials will reduce friction and further improve efficiency. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  illustrates a single precision cut disk with laser cutouts with no hole in the very center of the disk. 
           [0013]      FIG. 2  illustrates a laser cut disk with the precision cutouts with overlay of delta wing shaped center spacers. 
           [0014]      FIG. 3  illustrates a side view of the completed disk pack with hubs bolted on, and outline of delta wing shaped center spacers. 
           [0015]      FIG. 4  illustrates a tuned inlet nozzle for fluids including liquids, gases and steam. 
           [0016]      FIG. 5  illustrates a casing with inlets and outlets for a six disk turbine. 
           [0017]      FIG. 6  illustrates a completed unit from the outside. 
           [0018]      FIG. 7  illustrates a stack of disks, endplates with heavy outer rim and bolt-on hubs. 
           [0019]      FIG. 8  illustrates a top and side view of a two-piece heavy outer rim with side view of bolt-on hub. 
           [0020]      FIG. 9  illustrates teardrop shaped spacers facilitating unimpeded flow of fluids. 
           [0021]      FIG. 10  illustrates a disk pack with hubs bolted on, and outline of modified triangle center spacers. 
           [0022]      FIG. 11  illustrates a disk with the precision cutouts and delta wing shaped center spacers designed to reduce the number of support bolts in the inner rim of the turbine. 
           [0023]      FIG. 12  illustrates a disk with precision cutouts and rounded delta wing shaped center spacers designed to eliminate support bolts on the inner rim of the turbine. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    The present invention pertains to a low-cost boundary layer turbine comprising a bolt-on hub and directed-flow tuned inlet nozzle design that significantly decreases breakage and distortion and increases the efficiency of the system. The following description contains specific information pertaining to various embodiments and implementations of the invention. Furthermore, the present specification need not represent some of the specific details of the present invention in order to not obscure the invention. A person of ordinary skill in the art would have knowledge of such specific details not described in the present specification. Others may omit or only partially implement some features of the present invention and remain well within the scope and spirit of the present invention. 
         [0025]    The following drawings and their accompanying detailed description apply as merely exemplary and not restrictive embodiments of the invention. To maintain brevity, the present specification has not exhaustively described all other embodiments of the invention that use the principles of the present invention and has not exhaustively illustrated all other embodiments in the present drawings. 
         [0026]      FIG. 1  illustrates a single precision cut disk  100  with laser cutouts  101  with no hole in the very center of the disk  100 . 
         [0027]      FIG. 2  illustrates a laser cut disk  100  with the precision cutouts  101  with overlay of delta wing shaped center spacers  200 . The center spacers  200  fully support the inner portion of the disks  100 . When the tips of the spacers  200  extend beyond the cutout section as pictured in  FIG. 2 , they aid in initiating movement of the turbine. 
         [0028]      FIG. 3  illustrates a side view of the completed disk pack  300  with hubs  301  bolted on, and outline of delta wing shaped center spacers  200 . Use of bolts and spacers  302  on the outer and inner rim provide additional support while also aiding in initiating movement of the turbine. The placement and number of bolts and spacers  302  can be varied. Hubs  301  are bolted on each side without an axle going through the center. 
         [0029]      FIG. 4  illustrates a tuned inlet nozzle  402  for fluids including liquids, gases and steam. Smaller tubes  402  are placed within a larger tube  401  to direct the flow of fluids between turbine disks  100  and endplates  403 . As depicted in a strictly exemplary manner in  FIG. 4 , eight tubes  402  with endpoints placed between seven disks  100  and two endplates  403 . The edges of the disks  100  are sharpened for improved flow. A design embodying any number of tubes  402  or larger tubes  401  clearly remains within the scope and spirit of the present invention. 
         [0030]      FIG. 5  illustrates a casing  500  with inlets  402  and outlets  501  for a six-disk  100  turbine. The fluids  502  follow a natural course from the inlets  402  to the center and out through the outlets  501 . 
         [0031]      FIG. 6  illustrates a completed unit from the outside. Fluids  502  are injected into the outer periphery of the disks  100  then follow a natural path and exit through center. 
         [0032]      FIG. 7  illustrates a stack of disks, endplates  403  with heavy outer rim  701  and bolt-on hubs  301 . The heavy outer rim  701  facilitates a greater gyroscopic effect and greater potential for kinetic energy storage. 
         [0033]      FIG. 8  illustrates a top view  801  and side view  800  of a two-piece heavy outer rim  701  with side view of bolt-on hub  301 . 
         [0034]      FIG. 9  illustrates teardrop shaped spacers  901  facilitating unimpeded flow of fluids  502 . 
         [0035]      FIG. 10  illustrates a disk pack  300  with hubs  301  bolted on, and outline of modified triangle center spacers  1001 . 
         [0036]      FIG. 11  illustrates a disk  100  with the precision cutouts  101  and delta wing shaped center spacers  200  designed to reduce the number of support bolts  302  in the inner rim of the turbine. One bolt  302  goes through each of the three points of the delta wing shaped spacers  200  near the tips. 
         [0037]      FIG. 12  illustrates a disk  100  with precision cutouts  101  and rounded delta wing shaped center spacers  1201  designed to eliminate support bolts on the inner rim of the turbine. Support bolts  302  are placed inside the center cutout  101  area instead. This further facilitates the unimpeded flow of fluids  502 . 
         [0038]    Relationship Between the Components: 
         [0039]    Precision cut turbine disks  100  and endplates  403  have no axle going though a hole in the center, but instead use hubs  301  that are bolted  302  on to the sides. The number of disks  100  and spacers  200  should be varied depending on need, along with the size of the bolts  302 . Endplates  403  with heavy outer rims  701  would result in greater gyroscopic effect and the potential for greater kinetic energy storage. The delta wing shaped center spacers  200  are placed in between the endplates  403  and disks  100  to fully support the whole inner portion of the disks  100 . When the ends of the spacers  200  extend beyond the cutout section  101 , they aid in initiating movement by incorporating elements of an impulse turbine. Teardrop shaped spacers  901  can be used with bolts  302  on the outer and inner rim of the disks  100  to provide support, and to facilitate the streaming of fluids  502  from the outer portions of the disks  100  to proceed towards the cutout  101  section unimpeded. The turbine assembly is placed in a low friction case  500  with a tuned inlet nozzle  402  system that directs streams of fluid  502  in between the each of the disks  100  and endplates  403 . The low-friction inner case  500  keeps the propelled fluid  502  in a spiral vortex that is eventually expelled through the center cutout  101  of the turbine disks  100 . The fluids  502  exit through the exhaust system. 
         [0040]    How the Invention Works: 
         [0041]    The hubs  301  with low friction bearings are bolted on to the laser cutout endplates  403 , with disks  100  and spacers  200  in between. Using endplates  403  with heavy outer rims  701  would result in greater gyroscopic forces and the potential for greater kinetic energy storage. The turbine assembly is housed in a case  500  that is polished or coated with a low friction coating such as Teflon to reduce any resistance. A tuned inlet nozzle  402  system within the containment case  500  directs fluid  502  to the outer edges of each individual disk for improved efficacy. The edges of the disks  100  can be sharpened for improved flow. Bolts and spacers on the outer and inner rim support the disks  100 , and aid in initiating movement of the turbine. The fluids  502  pass the spacers  200  on the outer and inner rim of the disks  100  and flow towards the center cutout  101  section, which are supported by the delta wing spacers  200 . As the fluids  502  spiral in a vortex, the disk  100  rotates and accelerates in speed, providing the power and torque for useful work. The fluid  502  exits through the outlet nozzles  402 . When connected to a generator, this invention can be used to convert any flow of fluids  502  into electricity. The turbine can be used with geothermal steam, water current, or as a wind turbine to capture wind current. Steam can be produced by solar mirrors in combination with fluids  502  and used to power the turbine. The emissions from smokestacks can also be used. Because this invention can use a combination of fluids  502 , the possible applications are numerous. 
         [0042]    How to Make the Invention: 
         [0043]    Disks  100  and spacers  200  should be precision cut. The disks  100  can be constructed of steel, any high strength material or combinations of high strength materials and cut for high precision and balance. Laser cutting or the most advanced cutting technique available should be employed to achieve a high polished surface to enhance natural cohesion with fluids  502 . Epoxy resin and metal powders could also be used or any combination thereof. The edges of the disks  100  can be sharpened for more precise flow. The endplates  403  should also be precision cut using the same process but should be thicker than the inside disks  100 . The outside edge of the endplates  403  should be sharpened on the side facing the disks  100  and coated with a low friction material on the outside. The bolt-on hubs  301  should use bearings with the least amount of friction possible. There are no holes in the center of the disks  100  or endplates  403  to improve the durability of disks  100  and endplates  403 . Disks  100  are precision cut and drilled. This is a low-cost, simple bolt-together assembly. It is expandable by changing the length of bolts and adding more disks  100  and spacers  200 . Bolts  302  and spacers  200  on the outer and inner rim provide support for the disks  100 , and aid in initiating movement of the turbine by incorporating elements of an impulse turbine. The outer spacers  200  can be round or teardrop shaped  901  for improved flow. The delta wing shaped center spacers  200  fully support the center cut out portion of the disks  100  because they are the same shape in the shared areas. The center spacers  200  should also be precision cut and drilled. When the tips of the delta wing shaped center spacers  200  extend beyond the cutout  101  section, they also aid in initiating movement of the turbine by incorporating elements of an impulse turbine. A low friction outer containment case  500  and exhaust system can be machined or precision cut. The inside of the case  500  should be polished or coated with a low friction material such as Teflon for improved circulation. The tuned inlet nozzle  402  system within the containment case  500  can be made out of steel, copper, similar material. The individual tubes should be placed so that they will direct fluids  502  in between each of the disks  100  and endplates. 
         [0044]    More than one expandable turbine can be used together in a multi-stage system or in a closed loop. The delta wing shape spacer  200 , while being simple and efficient can be substituted with a modified triangle shape, star shape, star of David shape, or any other similar spacing support  200 . Rounds spacers  200  can be used with bolts  302  on the outer and inner rim of the disks  100  instead of teardrop shaped spacers  901 . 
         [0045]    How to Use the Invention: 
         [0046]    The bolt-on hub  301  design with no hole through the middle makes this invention much stronger than a standard Tesla turbine and less susceptible to distortion and breakage. Sharpening the edges of disk and inner portion of the endplates  403  will improve the flow of fluids  502 . The delta wing shaped center spacers  200  provide improved support for the inner portion of the disks  100  without disturbing the natural flow of the fluid  502 , while the teardrop shaped spacers  901  support outer portion of the disks  100 . A low friction containment case  500  reduces resistance. The tuned inlet nozzle  402  within the containment case  500 , with directed streams going to each individual disks  100  further increases efficacy. The major components of this invention can be precision laser cut by using CNC machines or similar methods, making it much cheaper to construct and maintain than conventional turbines. The disks  100  and endplates  403  are simple flat disks that are very sturdy. If any individual disk is damaged, it can be simply replaced at low cost. The thicker endplates  403  protect the disks  100  from exposure. Endplates  403  can also be made with a heavy outer rim  701  for greater gyroscopic effect and kinetic energy storage potential. 
         [0047]    Additionally: Like the Tesla turbine, the expandable turbine can be used as a pump by expanding the distance between disks  100 . The turbines can also be used as gyroscopes, and can be placed in gimbals. They can also be used as flywheels. When used in pairs and counter rotated, rotational bias can be cancelled out. The turbines can be used as a water jet for water craft of all types including jet skis or jet boats or any pressure type water system. 
         [0048]    Thus, an Expandable Boundary Layer Turbine has been described.