Charging system for an electric vehicle

A system that produces electrical power for an electric vehicle while in motion, utilizing a roof-mounted ductwork, is herein disclosed. The ductwork tunnel comprises a plurality of fan alternator assemblies which rotate due to an air flow therethrough, thereby producing an electrical current which is in-turn used to charge a plurality of on-board batteries and alternately to provide power directly thereto the electric motor portion of the electric vehicle.

FIELD OF THE INVENTION

The present invention relates generally to power generation for motor vehicles, and more particularly, to a power generation and charging system for an electric vehicle utilizing air flow created while the vehicle is in motion.

BACKGROUND OF THE INVENTION

Mankind has always depended upon nature's stores of resources to provide the source of energy to build, explore, and experiment. As our knowledge and technology have improved we have moved from the burning of wood, coal, oil, and gas to harnessing the power of the atom to provide nuclear energy. Unfortunately, each form of energy that has been discovered has associated disadvantages such as, pollution, destruction of the ozone layer, nuclear contamination, accidental release of harmful radiation and the like. Mankind continues to seek better, more efficient forms of energy and with global energy consumption increasing at alarming rates, the need for a clean, renewable source of energy is more important than ever.

Traditional sources of producing energy from the combustion of fossil fuels is not only expensive but has become widely accepted as a main contributor to a rise in the greenhouse gas carbon dioxide believed to be a cause of global climate change. The goal has been to find an energy source that does not require replenishment, does not consume natural resources, is continuous, does not possess deleterious side effects and does not emit pollutants and renewable sources of clean energy from wind, water, and solar offer an alternative. Unfortunately many renewable energy sources suffer from deficiencies in efficiency do to their intermittent nature and cost. This also makes their use impractical for one of the most common consumers of energy, the automobile. An average household with two (2) mid-sized vehicles emits more than twenty thousand (20,000) pounds of carbon dioxide per year. Attempts to improve the fuel efficiency of the internal combustion engine are slow and producing lighter vehicles negatively impact the safety of passengers. Efficiency of electricity storage devices for electric vehicles currently only provides for short periods of operation and hybrid vehicles still utilize gasoline engines.

Examples of relevant attempts to provide power generation to vehicles and address these problems can be seen by reference to several U.S. patents, including: U.S. Pat. No. 4,211,930, issued in the name of Fengler, which describes a vehicle propulsion system by individual stepping motors from continuously-running engine-driven alternator and/or pulsating battery current; U.S. Pat. No. 6,605,880, issued in the name of Jaunich, which describes an energy system providing continual electric power using wind-generated electricity coupled with fuel-driven electricity generators; U.S. Pat. No. 4,951,769, issued in the name of Kawamura, which describes a motor vehicle driving system; U.S. Pat. No. 5,771,478, issued in the name of Tsukamoto et al., which describes a vehicle drive system with electrical power regeneration; U.S. Pat. No. 6,806,687, issued in the name of Kajiura, which describes a vehicle motor-generator apparatus utilizing synchronous machine having field winding; and U.S. Pat. No. 7,019,413, issued in the name of Kinoshita, which describes a system having an electric device which functions both as an electric motor for driving machines and as a generator to generate electrical power, and having a power source for driving the electric device.

While these devices fulfill their respective, particular objectives, each of these references suffers from one (1) or more of the aforementioned disadvantages. Accordingly, there is a need for a means by which energy can be produced that is continuous in nature, does not require the consumption of natural resources or other replenishment and produces no pollution or other deleterious side effects. The development of the present invention substantially departs from the conventional solutions and in doing so fulfills this need.

SUMMARY OF THE INVENTION

In view of the foregoing references, the inventor recognized the aforementioned inherent problems and observed that there is a need for a means to provide power to operate a motor vehicle through the use of renewable wind power utilizing the energy produced while the vehicle is in motion and thus, the object of the present invention is to solve the aforementioned disadvantages and provide for this need.

To achieve the above objectives, it is an object of the present invention to provide an air-movement powered charging system for electric motor vehicles that utilizes a flow of air, which flows across a moving electric vehicle to produce electrical power that used to provide the motion of the electric vehicle.

Another object of the air-movement powered charging system for electric motor vehicles is to provide a system comprising a roof-mounted air tunnel assembly that directs an air flow through six (6) fan assemblies mounted within the tunnel assembly, an automatic microprocessor system control module, a voltage regulator, a plurality of rechargeable batteries, and a dashboard-mounted system monitor.

Yet still another object of the air-movement powered charging system for electric motor vehicles is to provide a tunnel assembly that is mounted to a roof portion of the electric vehicle comprising a lower enclosure, a removable upper panel, a front panel, a rear panel, a front opening, a rear opening, a heating coil, a front and rear louver, and a front and rear screen panel and provides a means of compression and velocity control via a motorized front and rear louvers to an incoming flow of air traveling across a hood and a windshield of the electric vehicle. The removable upper panel provides a means to access the internal components of system. The air enters the front opening and passes through the tunnel assembly and is compressed via a plurality of stationary baffle plates directing the air toward and causing the rotation of the six (6) horizontal cage-type fan assemblies located within and exits through the rear opening.

Yet still another object of the air-movement powered charging system for electric motor vehicles is to provide a fan assembly comprising a fan frame, a fan bearing, a pair of fan hubs, a plurality of fan spokes, a plurality of fan blades, an alternator, and an alternator shaft that produces an output electrical current, which is in-turn used to power an electric motor of the vehicle or charge a plurality of on-board batteries, thereby enabling the electric vehicle to travel greater distances. Each fan assembly is affixed to the upper removable panel and the lower enclosure a fan bearing and an alternator mounting bracket.

Yet still another object of the air-movement powered charging system for electric motor vehicles is to provide a motorized louver located at both the front and rear openings of the tunnel assembly that provides a means to variably regulate a flow of air through the tunnel openings.

Yet still another object of the air-movement powered charging system for electric motor vehicles is to provide an air heating coil located at the front and rear openings that melt snow or ice that may enter the tunnel assembly during inclement weather conditions. The air heating coils work in conjunction with a temperature sensor that provides temperature monitoring of air flowing through the tunnel assembly.

Yet still another object of the air-movement powered charging system for electric motor vehicles is to provide a system control module that provides overall control of the system and monitors the alternators and the temperature sensor and outputs the data to the system monitor.

Yet still another object of the air-movement powered charging system is to provide a system monitor comprising a housing, a display, and a plurality of control buttons that provides a user a means to monitor various system parameters such as, battery charge level, system activation or deactivation status, air flow volume, system faults, and the like.

Yet still another object of the air-movement powered charging system is to provide a voltage regulator assembly that insures that the batteries receive equivalent amperage and voltage at all times during operation since each alternator may produce a slightly different current level.

Yet still another object of the air-movement powered charging system is to provide a method of utilizing the system that provides for virtually unlimited clean, quiet and free electrical power for use with any energy need.

Further objects and advantages of the air-movement powered charging system will become apparent from a consideration of the drawings and ensuing description.

DESCRIPTIVE KEY

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention describes an air-movement powered charging system for electric motor vehicles (herein described as the “system”)10, which utilizes a flow of air100which flows across a moving electric vehicle15to produce electrical power used to motion said electric vehicle15. The system10comprises a roof-mounted air tunnel assembly20to direct said air30therethrough which engages six (6) fan assemblies42mounted therewithin. Each fan assembly42comprises an integral alternator50which produces an output electrical current which is in-turn used to power an electric motor portion200of the vehicle15and/or charge a plurality of on-board batteries145, thereby allowing the electric vehicle15to travel greater distances. The system10further provides automatic microprocessor control and a dashboard-mounted monitor180.

Referring now toFIG. 1, a side view of the system10installed therein an electric motor vehicle15, according to the preferred embodiment of the present invention, is disclosed. The system10as illustrated here, depicts internal wiring120and major components installed therein respective locations therewithin and thereupon said electric vehicle15depicting a typical installation; however, it is understood that any number of different equipment arrangements of system10components may be provided based upon different electric vehicle models15, electrical output current requirements, and the like, and as such should not be a limiting factor of the system10. The system10is depicted here being installed therewithin a generic electric motor vehicle15; however, it should be noted that any type or style electric vehicle15, including a sport utility van, van, truck, bus, off-road vehicle, emergency vehicles, and the like, may utilize the system10and as such should not be interpreted as a limiting factor of the present invention. The system10comprises a tunnel assembly20, six (6) fan assemblies42, a voltage regulator assembly140, a system control module160, a plurality of batteries145, and a dashboard-mounted system monitor180. The tunnel assembly20comprises a generally rectangular open-ended box providing internal compression and velocity control thereto a flow of entering air100which travels across hood and windshield portions of the electric vehicle15before entering a front tunnel opening portion24of said tunnel assembly20. The tunnel assembly20is approximately four (4) to six (6) feet wide and approximately six (6) to eight (8) feet long and approximately four (4) to eight (8) inches in height. Said entering air100passes therethrough said tunnel assembly20subsequently causing rotation thereof the six (6) horizontal cage-type fan assemblies42located therewithin, before being exhausted as exiting air105via a rear tunnel opening28.

The flow of air100,105therethrough the front24and rear28tunnel openings is regulated via a pair of respective motorized louvers30(seeFIGS. 2a,2b,2d). Each fan assembly42directly drives an integral alternator50which produces a flow of electrical current which is conducted thereto the voltage regulator assembly140which provides regulating and conditioning thereof said electrical power. Said electrical power may be used to directly power an electric motor portion200of the electric vehicle15and/or may be directed thereto the batteries145which are envisioned to be arranged thereat various locations within the vehicle15such as, but not limited to: a forward compartment, along side rocker-panel portions, therewithin a trunk area, or the like. The storage batteries145are envisioned to comprise a primary means to motion the electrically-powered motor vehicle15in a conventional manner.

Referring now toFIGS. 2a,2b, and2c, depicting front perspective, rear perspective, and cut-away views of a tunnel assembly portion20of the system10, according to the preferred embodiment of the present invention, are disclosed. The tunnel assembly portion20of the system10comprises an upper removable panel22, a lower enclosure23, a front tunnel panel24, a rear tunnel panel25, a front tunnel opening26, and a rear tunnel opening28. The front26and rear28tunnel openings comprise large rectangular-shaped apertures formed therein respective front24and rear25tunnel panels, respectively. Said front26and rear28tunnel openings comprise outer perimeter edges being slightly smaller than that of the respective front24and rear25tunnel panels. The front24and rear25tunnel panels are envisioned to be orientated at an inward biased angle, thereby providing a matching aerodynamic angle with respect to adjacent body panels of the vehicle15. It is further understood that the tunnel assembly20is to comprise particular shapes, edge-radii, contours, and the like, which may vary therefrom those depicted herein, being particularly designed and developed based upon aerodynamic testing, installation requirement of particular vehicle makes and models, and other specific requirements to yield desired stability and wind resistance efficiencies. The tunnel assembly20is envisioned to be made using light-weight metals such as aluminum or high-impact plastics such as performance polyester resins, fiberglass-impregnated plastic compounds, acrylonitrile butadiene styrene (ABS), or the like.

The tunnel assembly20provides an attachment means thereto the electric vehicle15via a plurality of equally-spaced weld stud fasteners112and corresponding locknut fasteners114being pre-installed therein a roof portion of the vehicle15and arranged at approximately six (6) inch centers, thereby allowing installation and removal of the tunnel assembly20therefrom the vehicle15by accessing said weld stud fasteners112and locknut fasteners114using the upper removable panel22.

The upper removable panel portion22of the tunnel assembly20provides a means to sufficiently expose internal portions of the tunnel assembly20to perform maintenance and repair tasks thereupon the system10, as required. The tunnel assembly20provides an attachment means therebetween the lower enclosure23and the upper removable panel22via a plurality of common axle-type hinges116arranged along a forward edge and a plurality of equally-spaced common fasteners110and fastener apertures111arranged therearound three (3) remaining side edges using fastening means such as screws, bolts, studs, or the like. The upper removable panel22further comprises an overlapping edge region having a gasket seal118therebetween said upper removable panel22and the mating lower enclosure23to seal out debris and liquids in an expected manner.

The system10preferably comprises six (6) fan assemblies42located therewithin the tunnel assembly20being arranged in two (2) rows, each comprising three (3) fan assemblies42. Each fan assembly42is securely affixed thereto the upper removable panel22and lower enclosure23via a fan bearing49and an alternator mounting bracket54, respectively. The alternator mounting bracket54is integrally incorporated thereinto a housing portion of the alternator50along a lower surface thereof, thereby enabling easy detachment therefrom the lower enclosure23for maintenance purposes (seeFIG. 3b).

The tunnel assembly20is to be positioned above a wind shield portion of the vehicle15, thereby directing a flow of entering air100thereinto the front tunnel opening26. Said flow of entering air100passes therethrough said front tunnel opening26; engages the fan assemblies42; and, exits the tunnel assembly20as exiting air105therethrough the rear tunnel opening28. The open area of the front26and rear28tunnel openings is controlled via a pair of motorized louvers30(seeFIG. 2d). Once entering air100is inside the tunnel assembly20, said air100is directed and subsequently compressed via a plurality of stationarily mounted baffle plates80. The baffle plates80are affixed thereto the lower enclosure23and comprise contoured vertical panels being curved in an inward funneling manner to compress and direct the entering air100thereto the fan assemblies42. In like manner, said baffle plates80curve in a divergent manner thereat a rear portion of the tunnel assembly20to depressurize the exiting air flow105. The baffle plates80are envisioned to be made using similar materials as the aforementioned tunnel assembly20. It is understood that specific design characteristics of said baffle plates80such as number of plates, position of plates, curvature and shape of said plates, and the like, may vary therefrom the illustration shown here based upon factors such as desired air flow dynamics, flow testing, engineering calculations, and the like, and as such should not be interpreted as a limiting factor of the system10.

The fan assemblies42are arranged along right and left side portions of the tunnel assembly20so as to progressively protrude thereinto said air flow100approximately two (2) to three (3) inches between subsequent fan assemblies42, thereby utilizing a linear force exerted by said entering air100, thereby efficiently rotating the fan assemblies42. A quantity of six (6) fan assemblies are illustrated here; however, it is understood that any practical number of fan assemblies42having respective geometries and dimensions, may be introduced based upon space limitations, desired electricity production, aerodynamic characteristics, and the like, and as such should not be interpreted a limiting factor of the system10(seeFIGS. 3aand3b).

Referring now toFIG. 2d, a close-up view of a motorized louver portion30of the system10, according to the preferred embodiment of the present invention is disclosed. The front tunnel opening26is depicted here comprising a motorized louver30and a screen panel58. Both of the previously described tunnel openings26,28comprise a motorized louver30and a screen panel58in a similar manner.

The motorized louver30provides a means to variably regulate a flow of air100therethrough said tunnel openings26,28. The motorized louver30comprises a rigid flat rectangular panel made using similar materials as the tunnel assembly20being affixed thereto a louver shaft35which extends along a long axis of said louver30thereat an intermediate location along a rear surface. The louver shaft35is affixed thereto using a plurality of “U”-shaped mounting brackets36and common fasteners110. Each motorized louver30further comprises a pair of electric motors34which work in tandem fashion to apply a rotating torque thereto the louver shaft35. Said electric motors34are coupled thereto opposing end portions of said louver shaft35in a non-rotating manner. As a flow of entering air100passes therethrough the tunnel assembly20, a proportional analog signal enables the louver motor34to tilt the motorized louver30thereto a desired angle, thereby restricting a part or all of said air volume from passing therethrough. Operation of the motorized louver30is based upon primary automatic control therefrom the system control module160or may also be controlled manually using the system monitor180(seeFIGS. 4 and 5). Each louver motor34is anchored thereto respective opposing inside surfaces of the lower enclosure22using integral motor mounting features of said louver motor34and common fasteners110.

Located therebetween each motorized louver30and the fan assemblies42is a respective rectangular screen panel58. Each screen panel58comprises a rigid coarse air filtration means which extends across the tunnel assembly20and is made using a fabricated metal screen material, thereby keeping bugs, airborne debris, and other items from entering the system10. It is envisioned that the screen panels58may be easily removed for cleaning via access therethrough the aforementioned upper removable panel22. It is expected that rain water is to pass therethrough the tunnel assembly portion20and screen panel portions58of the system10without interfering with the normal operation thereof.

Referring now toFIG. 2e, a close-up view of an air heating coil portion62of the system10, according to the preferred embodiment of the present invention, is disclosed. The system10comprises a pair of air heating coils62providing heating of front26and rear28tunnel openings, respectively, to melt snow or ice which may enter the tunnel assembly20during inclement weather conditions. The air heating coils62work in conjunction therewith a temperature sensor66which provides temperature monitoring of air flowing therethrough the tunnel assembly20. Said air heating coils62are affixed thereto the lower enclosure23being routed therearound an inner perimeter edge region of said front26and rear28tunnel openings being affixed thereto via a plurality of “U”-shaped mounting brackets36and common fasteners110. Electrical power is supplied to the air heating coils62via wiring120therefrom the voltage regulator assembly portion140of the system10and automatically activated by software embedded therein the system control module160(seeFIG. 5).

Referring now toFIGS. 3aand3b, top and bottom perspective views of a fan assembly portion42of the system10, according to the preferred embodiment of the present invention, are disclosed. Each fan assembly42comprises a fan frame44, a fan bearing49, an alternator50, and an alternator shaft52.

The fan frame47comprises a cylindrical shape approximately three (3) to five (5) inches tall envisioned to be made of light-weight metal or plastic forming a one-piece unit being approximately twenty-four (24) inches in diameter and rotating therein a horizontal plane therewithin the tunnel assembly20. Arranged therealong an outer vertical surface of said fan frame47are a plurality of vertical fan blades46which comprise rectangular protrusions being integral thereto said fan frame47. Said fan blades46are cut along three (3) sides and protruding outwardly in a parallel fashion as seen here. Said fan blades46are envisioned to be spaced at an approximate pitch of one (1) to three (3) inches therealong an outer perimeter area of said fan frame47.

The fan frame47further comprises a plurality of integral fan spokes47which extend therefrom top and bottom perimeter edges of the fan frame47at right angles and extend inwardly thereto a pair of central hub portions48in a parallel manner along top and bottom horizontal planes. Said fan hub portions48provide a non-rotating attachment means thereto a central vertical alternator shaft portion52of the alternator50. Said alternator shaft52extends in a downward direction thereto the alternator50being positioned slightly below the fan frame47. Rotation of the fan frame47due to the aforementioned flow of entering air100subsequently rotates the alternator shaft52in a direct-drive manner to produce an electric current therefrom said alternator50in an expected manner.

Referring now toFIG. 4, a close-up view of a system monitor portion180of the system10mounted thereto a vehicle dashboard area210, according to the preferred embodiment of the present invention, is disclosed. The system10provides a user a means to monitor various system parameters such as, but not limited to: battery charge level, system activation/deactivation status, air flow volume, system faults, and the like, via a dashboard-mounted system monitor180. Said system monitor180may be included as original equipment therewithin the electric vehicle15being permanently integrated thereinto the dashboard portion of said vehicle15or may be retrofitted thereto said dashboard portion in a similar manner as an aftermarket vehicle stereo system. The system monitor180comprises a plastic rectangular housing182, a digital display185to display the aforementioned data, and a plurality of input push buttons190to access particular data, as well as interface therewith operation of the system10. The system monitor180is in electronic communication therewith the system control module160, thereby receiving and displaying data received therefrom said system control module160(seeFIG. 5).

Referring now toFIG. 5, an electrical block diagram disclosing the major electrical components as used with the system10, according to the preferred embodiment of the present invention, is disclosed. The features and components of the system10would be used in conjunction with the standard charging system which resides therewithin the electric vehicle15. The block diagram of the system10illustrated here depicts a single arrangement of components being integrated thereinto an electric vehicle charging system15; however, it is understood that arrangement of said components, wiring schematics, means of connecting the system10thereto a charging system of the electric vehicle15, and other specific installed characteristics may vary based upon specific installation requirements, and as such should not be interpreted as a limiting factor of the system10.

The system control module160provides overall control of the system10. Said system control module160is envisioned to comprise a plastic enclosure and be located discreetly therewithin a dashboard portion of the electric vehicle15. The system control module160comprises electronic and electrical components necessary for operation thereof the system10. Said system control module160comprises components such as, but not limited to: circuit boards, relays, embedded software, a plurality of microprocessors, and the like. Said system control module160monitors current therefrom the alternators50, monitors the temperature sensor66, and outputs data thereto the system monitor180. Power is supplied thereto the system control module160therefrom the voltage regulator assembly140and output thereto the louver motors34and system monitor180as directed by embedded software therewithin said system control module160.

Electric power therefrom the alternators50is conducted therethrough respective electrical wiring120thereto the voltage regulator assembly140which provides regulation and conditioning of said electrical power for normal use in the electric vehicle15. It is anticipated that each alternator50may produce a slightly different current level during operation, For example, one (1) alternator50may be producing one-hundred (100) amps while another alternator50may be producing one-hundred fifty (150) amps. The voltage regulator assembly140insures that the batteries145are to receive the same amperage and voltage at all times. The batteries145are depicted here being connected in a combination of series and parallel circuits to obtain a particular desired output voltage. It is understood that various arrangements of interconnected wiring120of said batteries145may be incorporated to produce other desired corresponding output voltages and as such should not be interpreted as a limiting factor of the system10. Power from the batteries145is then provided thereto the electric car power controller205and subsequently thereto the electric vehicle motor200.

Power is also provided thereto the air heating coils62from the voltage regulator module140as directed thereby the system control module160based upon an analog signal received therefrom the temperature sensor66. It is envisioned that the system control module160is to provide power thereto the louver motors34to adjust said louvers30thereto a particular opening angle based upon monitored data such as a current battery charge level, alternator output50, system activation/deactivation status, and the like.

The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. It is envisioned that the system10would be installed and utilized in general accordance withFIG. 1. The system10is envisioned as being installed as original equipment on a conventional electric vehicle15. The features as presented by the system10would be integrated therewith and function in conjunction with the standard charging system of the electric vehicle15. In addition, the system10could be provided in kit format for aftermarket installation on existing electric vehicles15to provide a continuous charging current thereto on-board batteries145and/or the electric vehicle motor200. After installation and checkout, the system10is ready for operation.

The method of installing an aftermarket kit version of the system10may be achieved by performing the following steps: procuring a particular model of the system10comprising a tunnel assembly portion20particularly sized and contoured for an anticipated electric vehicle15; pre-installing a plurality of weld stud fasteners112along a roof line of said vehicle15being arranged so as to match corresponding fastening features of the tunnel assembly20; installing and securing the tunnel assembly20by threadingly installing and tightening the locknut fasteners114thereto the weld stud fasteners112; installing the major components of the system10throughout the vehicle15including the voltage regulator assembly140, system control module160, batteries145, and system monitor180, based upon available space and access characteristics; routing electrical wiring120discreetly within body panels and interior spaces of the electric vehicle15to interconnect said system components; and, connecting the system10electrically and electronically therewith the existing vehicle charging system.

Once installed, operation of the system10may be achieved by performing the following steps: initiating power to the system10by pressing appropriate input push buttons190thereupon the system monitor180; operating the system10in an automatic manner during normal driving; manually configuring the operation of the system10, if desired, using said input buttons190and digital display185portions of the system monitor180, thereby altering particular system characteristics such as an angle of one (1) or both louvers30, manually initiating of the air heating coils62, and the like; operating the electric vehicle15thereto a desired destination in a normal manner; providing a flow of current therefrom the alternators50thereto the batteries145and/or electric vehicle motor200while the vehicle15is in motion.

During utilization of the system10, entering air100flows therethrough the tunnel assembly20causing rotation of the fan assemblies42. Rotation of said fan assemblies42and affixed alternators50produces a flow of current thereto the voltage regulator assembly140where said current is conditioned and conducted thereto the batteries145. Based upon current draw from the electric vehicle motor200and/or said batteries145, the system control module160will provide volumetric regulation of entering air100and subsequent power generated by proportionally adjusting an angle of the motorized louvers30. As such, current generated by the system10will allow the electric vehicle15to travel greater distances, have increased efficiency, and provide an increase in performance when equipped with the present invention10.