Torque converter and system using the same

A torque converter includes a flywheel rotating about a first axis, the flywheel including a first body portion, a first plurality of permanent magnets mounted in the first body portion, each of the first plurality of permanent magnets extending along a corresponding radial axis direction with respect to the first axis, and a second plurality of permanent magnets mounted in the first body portion, each of the second plurality of permanent magnets being located between a corresponding adjacent pair of the first plurality of permanent magnets, and a generator disk rotatable about a second axis perpendicular to the first axis, the generator disk including a second body portion, and a third plurality of permanent magnets within the second body portion magnetically coupled to the first and second pluralities of permanent magnets.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a torque converter and a system using a torque converter. More specifically, the present invention relates to a torque converter that is capable of multiplying a given torque input based upon compression and decompression of permanent magnetic fields. In addition, the present invention relates to a system that uses a torque converter.

2. Discussion of the Related Art

In general, torque converters make use of mechanical coupling between a generator disk and a flywheel to transmit torque from the flywheel to the generator disk. However, due to frictional forces between the generator disk and the flywheel, some energy provided to the generator disk is converted into frictional energy, i.e., heat, thereby reducing the efficiency of the torque converter. In addition, the frictional forces cause significant mechanical wear on all moving parts of the torque converter.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to a torque converter that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.

An object of the present invention is to provide a torque converter having an increased output.

Another object of the present invention is to provide a system using a torque converter that reduces frictional wear.

Another object of the present invention is to provide a system using a torque converter that does not generate heat.

Another object of the present invention is to provide a system using a torque converter than does not have physical contact between a flywheel and a generator disk.

Another object of the present invention is to provide a system using a torque converter that allows an object to be inserted or reside between a flywheel and a generator disk.

To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, a torque converter includes a flywheel rotating about a first axis, the flywheel including a first body portion, a first plurality of permanent magnets mounted in the first body portion, each of the first plurality of permanent magnets extending along a corresponding radial axis direction with respect to the first axis, and a second plurality of permanent magnets mounted in the first body portion, each of the second plurality of permanent magnets being located between a corresponding adjacent pair of the first plurality of permanent magnets, and a generator disk rotatable about a second axis perpendicular to the first axis, the generator disk including a second body portion, and a third plurality of permanent magnets within the second body portion magnetically coupled to the first and second pluralities of permanent magnets.

In another aspect, a system for generating electrical power includes a motor, a flywheel coupled to the motor, the flywheel rotating about a first axis and including a first body portion, a first plurality of permanent magnets mounted in the first body portion, each of the first plurality of permanent magnets extending along a corresponding radial axis direction with respect to the first axis, and a second plurality of permanent magnets mounted in the first body portion, each of the second plurality of permanent magnets being located between a corresponding adjacent pair of the first plurality of permanent magnets, at least one generator disk rotatable about a second axis perpendicular to the first axis and magnetically coupled to the flywheel, the generator disk including a second body portion, and a third plurality of permanent magnets within the second body portion magnetically coupled to the first and second pluralities of permanent magnets, and an electrical generator coupled to the generator disk.

In another aspect, a system for converting torque to power includes a motor, a flywheel coupled to the motor, the flywheel rotating about a first axis and including a first body portion, a first plurality of permanent magnets mounted in the first body portion, each of the first plurality of permanent magnets extending along a corresponding radial axis direction with respect to the first axis, and a second plurality of permanent magnets mounted in the first body portion; each of the second plurality of permanent magnets being located between a corresponding adjacent pair of the first plurality of permanent magnets, at least one generator disk rotatable about a second axis perpendicular to the first axis and magnetically coupled to the flywheel, each generator disk including a second body portion and a third plurality of permanent magnets within the second body portion magnetically coupled to the first and second pluralities of permanent magnets, and a second drive shaft coupled to the second body portion rotating about the second axis.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to the illustrated embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

FIG. 1is a layout diagram of an exemplary flywheel according to the present invention. InFIG. 1, a flywheel109may be formed from a cylindrical core of composite material(s), such as nylon, and may be banded along a circumferential edge of the flywheel by a non-magnetic ring116, such as non-magnetic stainless steel or phenolic materials. The flywheel109may include a plurality of magnets disposed within a plurality of equally spaced first radial grooves101of the flywheel109, wherein each of the magnets may generate relatively strong magnetic fields, such as 48 mgoe(magnetic gauss orsted) or larger magnets. In addition, each of the magnets may have cylindrical shapes and may be backed by a cylindrically shaped backing plate203(in FIG.3), such as soft iron or steel, disposed within each of the plurality of first radial grooves101.

The magnets may be charged prior to installation within the plurality of first radial grooves101of the flywheel109by applying approximately ±485,500 watts of electricity (475 volts×1022 amps) to uncharged material for approximately 0.01 seconds. Alternatively, the magnets may be charged by application of specific amounts of power and/or specific periods of time depending on the desire magnetic strength of the magnets.

InFIG. 1, the flywheel109may also include a plurality of suppressor magnets disposed within a plurality of second radial grooves107along a circumferential face of the flywheel109, wherein surfaces of the suppressor magnets may be recessed from the nonmagnetic ring116. In addition, each of the plurality of second radial grooves107may be disposed between each of the plurality of first grooves101. For example, each one of eight suppressor magnets may be disposed within each of eight grooves107and each one of eight magnets may be disposed within each of eight grooves101. Of course, the total number of magnets within the first and second grooves101and107may be changed. Accordingly, the suppressor magnets in the eight grooves107and the magnets in the eight grooves101of the flywheel109have their north magnetic fields facing toward the circumference of the flywheel109and their south magnetic fields facing radial inward toward a center portion of the flywheel109.

The backing plates203(inFIG. 3) disposed at end portions of the magnets disposed within the plurality of first grooves101at the south poles of the magnets force a magnetic field strength along a radial direction toward the circumference of the flywheel109. Accordingly, interactions of the magnetic fields of the magnets within the plurality of first grooves101and the suppressor magnets disposed within the plurality of second grooves107create a magnetic field pattern (MFP), as shown inFIG. 3, of repeating arcuate shapes, i.e. sinusoidal curve, around circumferential edge portions of the flywheel109.

FIG. 2is a layout diagram of an exemplary generator disk according to the present invention. InFIG. 2, a generator disk111, preferably made from a nylon or composite nylon disk, may be banded by a stainless steel ring112. The generator disk111may include two rectangular magnets301opposing each other along a common center line CL through a center portion C of the generator disk111, wherein each of the rectangular magnets301may be disposed along a circumferential portion of the generator disk111. Each of the rectangular magnets301may have a first length L extending along a direction perpendicular to the common center line, wherein a thickness of the rectangular magnets301may be less than the first length. In addition, each of the rectangular magnets301may have a relatively large magnetic strength, such as about 48 mgoeor more, wherein surfaces of the rectangular magnets301parallel to a major surface of the generator disk may be one of south and north poles. Although the total number of magnets301is shown to be two, a plurality of magnets301may be used. Moreover, either an even-number or odd-number of magnets301may be used, and interval spacings between the magnets301may be adjusted to attain a desired magnetic configuration.

FIG. 4is a schematic diagram of an exemplary initial magnetic compression process of the torque converter according to the present invention,FIG. 5is a schematic diagram of an exemplary magnetic compression process of the torque converter according to the present invention, andFIG. 6is a schematic diagram of an exemplary magnetic decompression process of the torque converter according to the present invention. In each ofFIGS. 4,5, and6, the schematic view is seen from a rear of the generator disk, i.e., the surface opposite to the surface of the generator wheel111having the rectangular magnets301, and the flywheel109is located behind the generator wheel111. In addition, the flywheel109is rotating in a downward clockwise direction and the generator wheel111is rotating along an upward counterclockwise direction, wherein the generator disk111may be spaced from the flywheel109by a small air gap, such as within a range of about three-eighths of an inch to about 0.050 inches. Alternatively, the small air gap may be determined by specific application. For example, systems requiring a larger configuration of the flywheel and generator disk may require larger or smaller air gaps. Similarly, systems requiring more powerful or less powerful magnets may require air gaps having a specific range of air gaps. Moreover, for purposes of explanation the plurality of first grooves101will now simply be referred to as driver magnets101, and the plurality of second grooves107will now simply be referred to as suppressor magnets107.

InFIG. 4, the two rectangular magnets301disposed on the generator disk111begin to enter one of the spaces within a magnetic field pattern (MFP) of the flywheel109between two north poles generated by the driver magnets101. The driver magnets101may be disposed along a circumferential center line of the flywheel109, or may be disposed along the circumference of the flywheel in an offset configuration. The gap between the driver magnets101in the flywheel109is a position in which the MFP where the south pole field is the closest to the outer perimeter of the flywheel109. As the flywheel rotates along the downward direction, the north poles of the rectangular magnets301on the generator disk111facing the circumferential edge portion of the flywheel109are repelled by the north poles of the driver magnets101of the flywheel109.

InFIG. 5, once one of the rectangular magnets301on the generator disk111fully occupies the gap directly between the north poles of two adjacent driver magnets101of the flywheel109, the weaker north pole of the suppressor magnet107on the flywheel109is repelled by the presence of the north pole of the rectangular magnet301on the generator wheel111. Thus, both the north and south magnetic fields of the MFP below the outer circumference of the flywheel109are compressed, as shown at point A (in FIG.7).

InFIG. 6, as the rectangular magnet301on the generator disk111begins to rotate out of this position and away from the flywheel109, the north pole of the rectangular magnet301is strongly pushed away by the repulsion force of the north pole of the trailing driver magnet101on the flywheel109and by the magnetic decompression (i.e., spring back) of the previously compressed north and south fields in the MFP along the circumferential portion of the flywheel109. The spring back force (i.e., magnetic decompression force) of the north pole in the MFP provides added repulsion to the rectangular magnet301of the generator disk111as the rectangular magnet301moves away from the flywheel109.

Next, another initial magnetic compression process is started, as shown inFIG. 4, and the cycle of magnetic compression and decompression repeats. Thus, rotational movement of the flywheel109and the generator disk111continues.

FIG. 8is a schematic diagram of an exemplary system using the torque converter according to the present invention. InFIG. 8, a system for generating power using the torque converted configuration ofFIGS. 4-7may include a motor105powered by a power source101using a variable frequency motor control drive103to rotatably drive a shaft407coupled to the flywheel109(also shown in FIGS.4-7). In addition, the generator disk111may be coupled to a drive shaft113, wherein rotation of the generator disk111will cause rotation of the drive shaft113. For example, a longitudinal axis of the drive shaft113may be disposed perpendicular to a longitudinal axis of the drive shaft107.

InFIG. 8, the drive shaft113may be coupled to an electrical generator comprising a rotor119and a plurality of stators117. Accordingly, rotation of the rotor119may cause the electrical generator to produce an alternating current output to a variable transformer121. Thus, the output of the variable transformer121may be provided to a load123.

FIG. 9is a schematic diagram of another exemplary system using the torque converter according to the present invention. InFIG. 9, a plurality of the generator disks111may be clustered around and driven by a single flywheel109, wherein the generator disks111may each be coupled to AC generators similar to the configuration shown in FIG.8.

The present invention may be modified for application to mobile power generation source systems, as drive systems for application in stealth technologies, as an alternative for variable speed direct drive systems, as drive systems for pumps, fans, and HVAC systems. Moreover, the present invention may be modified for application to industrial, commercial, and residential vehicles requiring frictionless, gearless, and/or fluidless transmissions. Furthermore, the present invention may be modified for application in frictionless fluid transmission systems through pipes that require driving of internal impeller systems. Furthermore, the present invention may be modified for application in onboard vehicle battery charging systems, as well as power systems for aircraft, including force transmission systems for aircraft fans and propellers.

In addition, the present invention may be modified for application in zero or low gravity environments. For example, the present invention may be applied for use as electrical power generations systems for space stations and interplanetary vehicles.

It will be apparent to those skilled in the art that various modifications and variations can be made in the torque converter and system using the same of the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.