Abstract:
An electric device includes: a first set of magnets arranged in an annular array about a central axis of the device; a second set of magnets arranged in an annular array about the central axis of the device; a first carrier supporting the first set of magnets, the first carrier rotatable about the central axis; a second carrier supporting the second set of magnets axially spaced along the central axis from the first set of magnets, the first and second carriers dimensioned to allow the first and second set of magnets to move past each other when the first carrier rotates. A method of moving magnets with respect to each other may also be provided.

Description:
FIELD OF THE INVENTION 
       [0001]    The present disclosure relates generally to an electric motor. More particularly, the present disclosure relates to a compact high output electric motor/generator. 
       BACKGROUND OF THE INVENTION 
       [0002]    Electric motors have been used for a long time for a variety of tasks. Electric motors can be used in commercial, domestic, construction and many other applications for converting electric power into mechanical power. For example, electricity may be converted to shaft power by electric motor. Of course, as one of ordinary skill in the art would understand, and electric motor, if run backwards, can be used as a generator. As a result, mechanical power such as a rotating shaft can be converted into electricity with a generator. Therefore as used in this disclosure, unless specifically indicated, the term electric motor is not meant to be exclusive of a generator which may be substantially the same structure running backwards. 
         [0003]    It may be desirable to have more compact electric motors in order to provide additional benefits such as making electric motors smaller and able to provide more output per unit of space taken up by the motor and making the motor more portable due to its decrease in size. 
         [0004]    Accordingly, it is desirable to provide a method and apparatus that results an electric motor more compact and smaller compared to conventional electric motors having similar outputs. 
       SUMMARY OF THE INVENTION 
       [0005]    The foregoing needs are met, to a great extent, by the present disclosure, wherein in one aspect an apparatus is provided that in some embodiments results an electric motor more compact and smaller compared to conventional electric motors having similar outputs. 
         [0006]    In accordance with one aspect of the present invention, An electric device includes: a first set of magnets arranged in an annular array about a central axis of the device; a second set of magnets arranged in an annular array about the central axis of the device; a first carrier supporting the first set of magnets, the first carrier rotatable about the central axis; a second carrier supporting the second set of magnets axially spaced along the central axis from the first set of magnets, the first and second carriers dimensioned to allow the first and second set of magnets to move past each other when the first carrier rotates. 
         [0007]    In accordance with another aspect of the present invention, a method of moving magnets with respect to each other may include: arranging a first set of magnets in an annular array about a central axis; arranging a second set of magnets in an annular array about the central axis; spacing the first and second set of magnets from each other axially with respect to the central axis; and energizing at least one of the set of magnets to cause one of the sets of magnets to rotate about the central axis and move past the other set of magnets. 
         [0008]    In accordance with yet another embodiment aspect of the present invention, an electric device includes: a first set of magnets arranged in an annular array about a central axis of the device; a second set of magnets arranged in an annular array about the central axis of the device; a first means for supporting the first set of magnets, the first means for supporting rotatable about the central axis; a second means for supporting the second set of magnets axially spaced along the central axis from the first set of magnets, the first and second means for supporting the magnets dimensioned to allow the first and second set of magnets to move past each other when the first means for supporting the first set of magnets rotates. 
         [0009]    There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto. 
         [0010]    In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. 
         [0011]    As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a perspective view illustrating an electric motor according to the present disclosure. 
           [0013]      FIG. 2  is a perspective view of a portion of the housing of the amount electric motor according to  FIG. 1 . 
           [0014]      FIG. 3  is a perspective view of an armature in accordance with the present disclosure. 
           [0015]      FIG. 4  is an exploded view of an electromagnet in accordance present disclosure. 
           [0016]      FIG. 5  is an assembled view of the electromagnet of  FIG. 4 . 
           [0017]      FIG. 6  is a cross-sectional view of the armature and shaft in accordance with the present disclosure. 
           [0018]      FIG. 7  is a perspective view of a part of the housing containing electromagnets in accordance with the present disclosure. 
           [0019]      FIG. 8  is a perspective view of a part of the housing containing electromagnets taken from a different viewpoint then the viewpoint shown in  FIG. 7 . 
           [0020]      FIG. 9  is a perspective view of a part of the housing and a cross-sectional view of the armature mounted to a shaft in an electric motor in accordance with the present disclosure. 
           [0021]      FIG. 10  is an end view of the shaft, armature, and housing containing the electromagnets in accordance with an electric motor of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    An embodiment in accordance with the present invention provides an electric motor that arranges the field magnets and armature magnets in a dense relationship. Magnets are arranged in the housing and armature in a radial orientation. Multiple arrays of magnets, some mounted to the armature and others to the housing are radially arranged in arrays about the axis of the armature shaft. Armature mounted arrays alternate with housing mounted arrays of magnets along a length of the shaft axis. The motor is configured to cause the armature (or in some embodiments the housing) to rotate about the shaft axis due to electromagnetic attraction and repulsion between the various armature and housing arrays of magnets. When the electric motor is operating, the field magnet arrays and armature magnet arrays move past each other without contacting each other. Various cooling vents and holes may be located throughout the armature and housing in order to allow air, or any other cooling fluid, to circulate amongst the magnets and cool the motor. 
         [0023]    Example aspects and embodiments will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. 
         [0024]    An example embodiment is illustrated in  FIG. 1 .  FIG. 1  illustrates an electric motor  10  which, as discussed above can also be an electric generator. One of ordinary skill in the art after reviewing this disclosure will understand the generators also fall within the scope of the present disclosure. However, for simplicity the apparatus shown in figures will be referred to as a motor  10 . The electric motor  10  includes a housing  11 . The housing  11  may include a first clamshell  12  and a second clamshell  14 . A seam  16  may be located where the first clamshell  12  and the second clamshell  14  come together. In some embodiments, the housing  11  may include cooling vents  18  which are configured to allow air or any other cooling fluid to circulate through the motor  10  in order to provide cooling to the motor  10 . 
         [0025]    The motor  10  may be equipped with a first end cap  20  and a second end cap  22 . The electric motor  10  may also be equipped with a shaft  24  which contacts the end caps  20  and  22  via bearings  26  and  28  respectively. The electric motor  10  may also be equipped with armature commutators  30  and brushes  32 . As is well known, the commutators  30  and brushes  32  may control the polarity of various electromagnets  64  (shown and described in more detail with respect to  FIGS. 4 and 5 ). While the illustrated embodiment has commutators and brushes  30  and  32  one of ordinary skill in the art after reviewing this disclosure, will appreciate that other techniques for controlling the polarity of the electromagnets may also be used. For example, in environments that need to be fireproof or spark free, solid-state systems may be used. Other suitable systems and techniques for controlling the polarity may also be used. 
         [0026]      FIG. 2  illustrates an interior portion of one of the clamshells  12  of the housing  11 . The clamshell  12  includes sets  38  of holes  40  and  42  extending through the length of the clamshell  12 . In some embodiments, the sets  38  of holes  40  and  42  are located in an array based radially from the central axis A-A of the motor  10 . These sets  38  may be comprised of groups of two holes  40  and  42 . 
         [0027]    The clamshell  12  may also contain structure  44  in the form of support ridges  44  for supporting magnets  64  (best shown in  FIGS. 4 and 5 ). The support ridges  44  may define magnet slots  46 . In some embodiments and as shown, the magnet slots  46  are U-shaped. In many embodiments the magnet slots  46  will be dimensioned and shaped in order to correspond to the shape of the magnets  64  in order to support the magnets  64  in position. In some embodiments, the support ridges  44  are arranged and configured to have the magnet slots  46  located in an array  45  about the central axis A-A of the motor  10 . The support ridges  44  may be axially spaced from each other with spaces  50  in the clamshell  12 . The support ridges  44  may also include or define cooling holes  48 . The cooling holes  48  allow air or any other cooling fluid to circulate through the motor  10  in order to cool the motor  10 . The clamshell  12  may also include cooling vents  18  which will allow air or any other cooling fluid to circulate in and out of the housing  11 . 
         [0028]      FIG. 3  is a perspective view of an armature  52  in accordance with the disclosure. The armature  52  may be equipped with commutator slots  54  and be integrated with the shaft  24 . In other embodiments, the armature  52  may not necessarily be integrated with the shaft  24 . Further, as stated above, some embodiments may not use commutators  30  and thus will not need commutator slots  54 . The armature  52  also has support fins or ridges  56 . The armature support fins  56  may be dimensioned and configured to be arranged in armature radial arrays  57 . Each array  57  may be at the scene place along the longitude of the axis A-A and encompasses the axis A-A. The armature support fins or ridges  56  may include slots  58 . The slots  58  may be U-shaped as shown in the figures or may have other shapes that are designed to correspond to magnets  64  (see  FIGS. 4 and 5 ) to secure the magnets  64  in position within the support fins  56 . The Armature support fins  56  may also define cooling slots  60  which may allow air or any other cooling fluid to circulate about the armature  52 . 
         [0029]    In some embodiments, the commutator  52  may also define holes  62  extending in an axial direction. In some embodiments the holes  62  are located in an array about the central axis A-A of the motor  10 . The holes  62  may be substantially parallel to the axis A-A. 
         [0030]      FIG. 4  illustrates an exploded view of an electromagnet  64  that may be used in accordance with the present disclosure. The magnet  64  includes a body portion  66  which defines a coil groove  68 . A coil  70  may be made of copper any other suitable conductor. The coil  70  includes two ends  72  and  74 . The two ends  72  and  74  may be connected to different conductors in order to energize the coil  70 . 
         [0031]      FIG. 5  is an assembled view of the magnet  64  illustrated in an exploded view in  FIG. 4 . The electromagnet  64  includes a body portion  66  defining a coil groove  68  into which a coil  70  having two ends  72  and  74  is located. The particular configuration illustrated in  FIGS. 4 and 5  is meant to be exemplary only. Other suitable electromagnet configurations may also be used in accordance with the disclosure. 
         [0032]      FIG. 6  is a perspective view of an armature  52  having magnets  64  mounted into the armature support fins  56 . The armature  52  shown in  FIG. 6  is integrated with the shaft  24 . Commutators  30  are fit into commutator slots  54  as shown. A first armature rod  76  and second armature rod  78  are conductors. The armature rod  76  and  78  are fit into the holes  62  best shown in  FIG. 3 . The first and second armature rods  76  and  78  may be grouped in groups of two and are oppositely charged. As shown in  FIG. 6 , a first end  72  of a coil  70  may be connected to a first armature rod  76  and a second end  74  of the coil  70  may be connected to a second armature rod  78 . The armature rods  74  and  78  may be operatively connected to the commutators  30  by electrical connectors (not shown) so that the polarity of the current flowing through the armature rod  74  and  76  may be controlled and thereby control the polarity of the magnets  64 . The magnets  64  which are located on the armature  52  may be referred to as armature magnets  80 . When the armature  52  rotates the armature magnets  80  will rotate about the axis A-A of the armature  52 . The slots  60  not filled by armature magnets  80  are the cooling slots  60 . 
         [0033]      FIGS. 7 and 8  illustrate a portion of the housing  11  having magnets  64  located in the support ridges  44 . The magnets  64  are located in annular arrays  45 . The two ends  72  and  74  are connected to a first field rod  82  and second field rod  84  respectively in a similar manner that the armature magnets  80  are connected to the first armature rod  76  and second armature rod  78 . First field rod  82  and a second field rod  84  are located in the holes  40  and  42  in the housing  11  as shown. Because the two ends  72  and  74  are connected to a first field rod  82  and second field rod  84 , controlling the polarity of the first field rod  82  and second field rod  84  the polarity of the field magnets  86  may be controlled. Similar to that described above regarding the first armature rod and second armature rod  76  and  78  being found in groups of two of opposite polarity, the first field rod  82  and second field rod  84  are also located in groups of two having opposite polarity. The cooling holes  48  in the support ridges  44  are shown located between the field magnets  84 . 
         [0034]      FIGS. 9 and 10  illustrate a motor  10  having the housing  11  installed about the armature  52 .  FIG. 9  is a cross-sectional view of the motor  10  and  FIG. 10  is an end view. With reference to both  FIGS. 9 and 10  the shaft  24  is shown supporting the armature  52 . The armature magnets  80  are illustrated in arrays  45  arranged about the axis A-A of the armature  52 . Field magnets  84  are also located in arrays  57  located radially about the axis A-A. The arrays  45  and  57  of armature magnets  80  and field magnets  86  alternate along the longitudinal axis A-A. The first end  72  of the armature magnet  80  coil  70  attaches to the first armature rod  76  and the second end  74  of the coil  70  of the armature magnets  80  attaches to the second armature rod  78 . Likewise, the first ends  72  of the coils  70  of the field magnets  86  are operatively connected to the first field rod  82  and the second ends  74  of the coils  70  of the field magnets  86  are operatively connected to the second field rods  84 . Field rods  84  and  82  are located in holes  40  and  42  respectively. The arrays  45  and  57  of magnets  80 ,  86  are spaced by a gap  88  in order to allow the magnets  80  and  86  to slide past each other. 
         [0035]    As the motor  10  operates, the magnets  64  may become hot due to electrical resistance and eddy currents generated within the magnets  64 . As a result, it may be desirable to provide cooling to the magnets  64 . 
         [0036]    In some embodiments, the magnets  64  are wider than the support ridges  44  in the housing  11  and the armature support fins  56 . By having the magnets  64  wider than both the armature support fins  56  and the support ridges  44 , the magnets  64  are exposed to air or other cooling fluid as the magnets  64  move past each other during the relative rotation between the armature  52  and the housing  11 . When the armature  52  and housing  11  rotate with respect to each other, the magnets  64  to encounter moving air which can help cool the magnets  64 . Air or other cooling fluid movement through the motor  10  is also facilitated, at least in part, by the cooling vents  18  in the housing  11  and the cooling holes  48  in the housing  11  and cooling slots  60  in the armature  52 . 
         [0037]    Air or other cooling fluid may be forced axially through the motor  10  by a fan or any other suitable means. 
         [0038]      FIG. 10 , in particular, illustrates the clamshells  12  and  14  of the housing  10 . The commutators  30  are illustrated as being located on the armature  52 . The first and second armature rods  76  and  78  are seen located in holes  62 . The shaft  24  rests on the bearing  26 . The armature cooling slots  60  and cooling holes  48  are illustrated. As the armature  52  rotates with respect to the housing  11 , the cooling holes  48  and cooling slots  60  are at times aligned. 
         [0039]    By controlling the polarity of the magnets  64 , the magnet arrays  45  and  57  can rotate with respect to each other due to magnetic attraction and repulsion between the magnet arrays  45  and  57 . While some embodiments as shown discussed herein contemplate that both the armature magnets  80  and the field magnets  86  are electromagnets, in some embodiments either the armature magnets  80  or the field magnets  86  may be permanent magnets  64  and the other set of magnets  64  may be electromagnets  64 . 
         [0040]    The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.