Abstract:
A temperature regulation system with an integrated electrical generator is disclosed. In an exemplary embodiment, the temperature regulation system includes a combustion unit for producing heat energy. Further, a blower is in fluid communication with the combustion unit for dispersing air. Additionally, the integrated electrical generator is communicatively coupled to the combustion unit and the blower for providing electrical energy to the blower and the combustion unit. A flue is coupled to the combustion unit for drawing combustion waste products to an exterior environment. Furthermore, an exhaust system is coupled to at least one of the integrated electrical generator and the flue for drawing combustion waste products from the integrated electrical generator to an exterior environment. The integrated electrical generator is configured to provide electricity to the blower and the combustion unit upon interruption of the utility electrical energy supply to the temperature regulation system.

Description:
CROSS REFERENCE  
       [0001]     The present application is a continuation under 35 U.S.C. § 120 of U.S. patent application Ser. No. 11/141,264, filed May 31, 2005 which in turn claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application Ser. No. 60/575,352, filed May 28, 2004 which are herein incorporated by reference in their entireties. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to the field of heating, ventilating, and air-conditioning (HVAC) and more particularly to an integrated generator for providing an alternate or back-up power source for operating a heating unit.  
       BACKGROUND  
       [0003]     Typically, temperature regulation systems such as furnaces operate by combusting natural gas (predominately methane) or propane. Often local utility companies function as suppliers of the natural gas or propane. Due to the high heating value and prevalence of these gases, the majority of furnaces located in cold climates derive their heating capacity from such gases. While the furnace&#39;s heating ability is generated by combusting fuels of this nature, typical furnaces include electro-mechanical systems for assisting in combustion or heat distribution. For example, a blower may be employed for distributing air (a forced air system). In addition, the furnace may include electronics for controlling the burners, a thermostat for regulating temperature, and the like. A drawback to this type of furnace is that the furnace will not operate in the event of a loss of electricity. For example, an electronically controlled furnace will not ignite if an electrical power source is not available. Further, heat will not be distributed if electricity is not supplied to the blower, in the case of a forced air system.  
         [0004]     Therefore, it would be desirable to provide a temperature regulation system, such as a furnace or an HVAC system, with an integrated generator for producing electricity.  
       SUMMARY OF THE INVENTION  
       [0005]     Accordingly, the present invention is directed toward a temperature regulation system, such as a furnace, with an integrated electrical generator. As such, the integrated electrical generator provides electricity to the already existing furnace upon interruption of a utility electrical power supply. The integrated electrical generator may be incorporated into the furnace or, in the alternative, be retrofitted into an already existing furnace.  
         [0006]     In accordance with a first aspect of the present invention, an integrated electrical generator for providing electrical power energy to a temperature regulation system upon interruption of a utility electrical energy supply to the system is disclosed. In such aspect, the integrated electrical generator includes an alternator to supply energy at multiple voltages. Further, an engine is coupled to the alternator for providing rotational force to the alternator. In addition, a plurality of devices are operationally coupled to the engine for detection of an interruption of a utility electrical energy supply to the temperature regulation system. Moreover, at least one switch is operationally coupled to at least one of the alternator and the engine to operationally control the flow of electricity from the alternator. The integrated electrical generator is configured to provide electricity to a temperature regulation system upon interruption of the utility electrical energy supply to the temperature regulation system.  
         [0007]     In accordance with a further aspect of the present invention, a temperature regulation system with an integrated electrical generator is disclosed. In an exemplary embodiment, the temperature regulation system includes a combustion unit for producing heat energy. Further, a blower is in communication with the combustion unit for dispersing air fluid medium. Additionally, the integrated electrical generator is communicatively coupled to the combustion unit and the blower for providing electrical energy to the blower and the combustion unit. A flue is coupled to the combustion unit and engine for drawing combustion waste products to an exterior environment. Furthermore, an exhaust system is coupled to at least one of the integrated electrical generator and the flue for drawing combustion waste products from the integrated electrical generator to an exterior environment. The integrated electrical generator is configured to provide electricity to the blower and the combustion unit upon interruption of the utility electrical energy supply to the temperature regulation system.  
         [0008]     In accordance with an additional aspect of the present invention, an additional temperature regulation system is provided which includes a combustion unit for producing heat energy. Further, in such aspect, a blower is in fluid communication with the combustion unit for dispersing air. Moreover, an integrated electrical generator is communicatively coupled to the combustion unit and the blower for providing electrical energy to the blower and the combustion unit, a flue coupled to the combustion unit for drawing combustion waste products to an exterior environment. Additionally, an exhaust system may be coupled to at least one of the integrated electrical generator and the flue for drawing combustion waste products from the integrated electrical generator to an exterior environment. The integrated electrical generator and combustion unit are configured so that they operate from a common fuel supply and exhaust fumes at generally similar temperature ranges.  
         [0009]     It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles of the invention.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:  
         [0011]      FIG. 1  is an illustration of a furnace in accordance with the present invention, wherein an integrated electrical generator is positioned inside the furnace;  
         [0012]      FIG. 2  is an illustration of a furnace, wherein the furnace includes a combustion unit for producing heat, a flue for carrying waste products away from the combustion unit, a blower for dispersing air across the combustion unit and out to an area to be heated, and an exhaust system that couples with the flue for carrying waste products away from the integrated electrical generator;  
         [0013]      FIG. 3A  is an illustration of an integrated electrical generator in accordance with the present invention, wherein the integrated electrical generator includes a relay switch for sensing when utility power is being supplied to the furnace;  
         [0014]      FIG. 3B  is an illustration of an integrated electrical generator, wherein the integrated electrical generator includes a transfer switch coupled to a utility power cable for preventing electricity produced by the integrated electrical generator from traveling to an outside circuit, such as the building&#39;s electrical system;  
         [0015]      FIG. 4A  is an illustration of an integrated electrical generator in accordance with an exemplary embodiment of the present invention, wherein the integrated electrical generator includes numerous components which regulate generator activities such as an integrated circuit and a central processing unit;  
         [0016]      FIG. 4B  is an illustration of an integrated electrical generator in accordance with an exemplary embodiment of the present invention, wherein the integrated electrical generator includes various regulatory components such as a master switch, a gas detector, and a battery pack;  
         [0017]      FIG. 5  is a flow diagram illustrating a method by which an integrated electrical generator may be retro-fitted into an already existing furnace; and  
         [0018]      FIG. 6  is an illustration of an existing furnace retrofitted with an integrated electrical generator by the method provided in  FIG. 5 . 
     
    
     DESCRIPTION OF THE INVENTION  
       [0019]     Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.  
         [0020]     Referring generally to  FIGS. 1 through 6 , exemplary embodiments of a temperature regulation system equipped with an integrated electrical generator in accordance with the present invention are provided. The instant temperature regulation system is equipped with an integrated electrical generator that allows electricity to be produced when a conventional electrical source is unavailable or has failed. The integrated electrical generator of the present invention may be integrated with a variety of temperature regulation systems such as a furnace, an HVAC system, a heat pump, an air conditioner, or the like. Further, the integrated electrical generator may be disposed within a furnace or retrofitted into a preexisting furnace.  
         [0021]     Referring now to  FIGS. 1 and 2 , in accordance with an embodiment, a furnace  200  includes a combustion unit  202  for producing heat energy. For example, the combustion unit  202  may burn a gas such as propane or natural gas to produce heat. In an exemplary embodiment, the combustion unit  202  is comprised of a system of burners  204  and a heat exchanger  206 . In such embodiment, the blower  208  is in fluid communication with the combustion unit  202  so that fresh, non-combustion air may be dispersed throughout the area enclosure being heated. Suitable blowers  208  include a centrifugal fan, an axial fan, and the like. In additional embodiments, a flue  210  is coupled to the combustion unit  202  to draw exhaust gases to an exterior environment. It is contemplated that the flue  210  may include a system of pipes or the like for drawing combusted gases to the exterior of an enclosure/building.  
         [0022]     In the present embodiment, as illustrated in  FIG. 2 , an integrated electrical generator  100  of the present invention is coupled to the flue  210  via an exhaust system  102 . In an embodiment, the exhaust system  102  includes a system of pipes. In an advantageous embodiment, the generator engine is formed so that exhaust gas produced by the integrated electrical generator  100  is of substantially the same temperature range as the exhaust gas produced by the furnace  200  such that the HVAC flue piping may be utilized. One method of achieving the desired temperature is by adjusting the amount of fuel burned per unit of oxygen. With exhaust gases of the same temperature range, the flue  210  is able to handle the exhaust gases from the integrated electrical generator  100  without having to be reinforced with a more heat resistant material. In an exemplary embodiment, the exhaust system  102  is constructed of materials which are relatively heat resistant, weather resistant, and cost efficient such as polyvinyl chloride (PVC), galvanized steal, and the like. It is contemplated that standard pipe fittings may be used to couple the exhaust system  102  to the flue  210 .  
         [0023]     In additional exemplary embodiments, as shown in  FIGS. 3A-4B , the integrated electrical generator  100  includes electrical components such as an alternator  104 . For example, the alternator  104  may be equipped with an outlet that supplies twelve volts of direct current and another outlet that provides one hundred and twenty volts of alternating current. The twelve-volt output may be used as a supplier of electricity for a variety of operations such as a battery charger, powering a thermostat, or the like. Likewise, the one hundred and twenty-volt output may be used for a variety of operations including the providing power to a blower utilized by the furnace, a window-heating unit, or the like.  
         [0024]     In further exemplary embodiments, as illustrated in  FIGS. 3A-4B , the integrated electrical generator  100  may also include an engine  106  for providing rotational force to the alternator  104 . The engine  106  in the exemplary embodiments is an internal combustion engine. Further, a right-angle drive  108  may be disposed within the integrated electrical generator  100  for coupling a crankshaft  110  of the engine  106  to a crankshaft  112  of the alternator  104 . The right angle drive  108  allows the integrated electrical generator  100  to fit into a confined space such as a corner of the furnace  200 . In an exemplary embodiment, the right angle drive  108  is comprised of a bevel gear system. In an alternative embodiment, the right angle drive  108  is comprised of a gearbox that houses a worm gear meshed with a spur gear. Both the bevel gear system and the worm gear/spur gear system are suitable for the right angle drive  108  for they allow the plane of rotation to be translated by 90° (ninety degrees).  
         [0025]     Referring now specifically to  FIG. 3A , additional exemplary embodiments of the integrated electrical generator  100  are shown in which the generator  100  includes a relay switch  114 . In such embodiment, the relay switch  114  detects whether electricity is being supplied to the furnace  200  from a standard utility  400 . When power returns to the standard utility  400 , the relay switch  114  also allows the furnace  200  to resume operation on commercially available power. In other embodiments, the integrated electrical generator  100  employs different devices to detect a loss of power. For instance, in one embodiment, the integrated electrical generator  100  includes a voltmeter and integrated circuit  116  to detect a loss of power (as shown in  FIG. 4A ). In such instance, the integrated circuit may be hardwired to the voltmeter and be configured to initiate operation of the generator  100  when the voltmeter signals a loss of utility power. In another embodiment, the integrated electrical generator  100  includes a central processing unit  118 , illustrated in  FIG. 4A , for detecting a power loss. For instance, the central processing unit may be included for monitoring the electrical output of the integrated electrical generator and for terminating the electrical generation in the event of an excess voltage.  
         [0026]     As illustrated in  FIG. 3B , in addition to being equipped with devices that detect power loss, the integrated electrical generator  100  may be equipped with a transfer switch  120 . In such embodiment, the transfer switch  120  prevents electricity produced by the integrated electrical generator  100  from traveling throughout an outside circuit, such as a building&#39;s electrical system.  
         [0027]     In an exemplary embodiment of the present invention, the integrated electrical generator  100  is capable of sensing when the furnace  200  has been requested to produce heat. Preferably, a hard-wire connection between the integrated electrical generator  100  and a thermostat switch of the furnace  200  enables the integrated electrical generator  100  to detect the request so that the generator  100  may cycle on/off. In other embodiments, various wireless connections may be used such as an RF connection, a blue-tooth connection, an infrared connection, or the like.  
         [0028]     As illustrated in  FIG. 4A , an exemplary embodiment of the present invention includes a timer  124  coupled to the integrated circuit  116 . The timer  124  may initiate routine exercise cycles to identify operability issues. For instance, the timer  124  is set for one month so that the integrated circuit  116  closes the circuit to a starter of the engine  106  and resets the timer  124  when the timer  124  reaches one month. In an alternative embodiment, the central processing unit  118  is coupled to the integrated electrical generator  100  and is programmed to run the routine exercise cycles.  
         [0029]     Referring now to  FIG. 4B , the integrated electrical generator  100  may be configured to detect when a battery  122  of the integrated electrical generator  100  is in need of charging. The battery  122  is for supplying start-up power to the engine  106 . In the preferred embodiment, the integrated electrical generator  100  is equipped with a voltmeter coupled to the integrated circuit  116  to detect low battery levels. In such embodiment, the voltmeter determines how many volts the battery  122  is producing. The integrated circuit  116  is designed to close the circuit from the alternator  104  to the battery  122  when the voltmeter indicates that the battery  122  has dropped below a minimal accepted level for having sufficient energy to cause a starter to operate. Thus, the coupling of the battery  122  to the voltmeter and the integrated circuit  116  reduces, if not eliminates, the possibility that the integrated electrical generator  100  will be without start-up power in the event of a loss of utility power. In another embodiment, the integrated electrical generator  100  is equipped with trickle chargers for continuously charging the battery  122 . In yet another embodiment, the central processing unit  118  (as shown in  FIG. 4A ) detects when the battery  122  is low and, in turn, instructs the alternator  104  to charge the battery  122 .  
         [0030]     In further exemplary embodiments, the integrated electrical generator  100  may be equipped with devices that prevent the integrated electrical generator  100  from damaging the furnace  200 . For instance, as illustrated in  FIG. 4B , the integrated electrical generator  100  may include a master switch  126  which acts as a manual override so that users may terminate operation of the integrated electrical generator  100 . In an advantageous embodiment, the master switch  126  is positioned in a location where current can be completely restricted from flowing through the integrated electrical generator  100  such as on the electrical power cable running from the integrated electrical generator  100  to the furnace  200 . Further, in such embodiment, the integrated electrical generator  100  includes a voltage regulator so that the amount of power delivered to the furnace  200  may be limited.  
         [0031]     In additional embodiments, as illustrated in  FIG. 4B , the integrated electrical generator may be equipped with a gas detector  128 . In an exemplary embodiment, the gas detector  128  detects the ultrasonic sound emitted during gas leaks such as natural gas leaks, propane gas leaks, carbon monoxide leaks, carbon dioxide leaks, and the like. In one embodiment, the gas detector  128  is equipped with an alarm  130  that simply alerts a user when a gas leak has been detected. In an alternative embodiment, the gas leak detector  128  is hardwired to the integrated electrical generator  100  and halts operation upon the detection of a gas leak.  
         [0032]     As illustrated in  FIGS. 5 and 6 , a preexisting furnace  300  may be retrofitted with an electrical generator  302 .  FIG. 5  provides a flow diagram illustrating a method  500  which may be utilized to retrofit an existing furnace with an electrical generator. A user may hardwire the electrical generator to a power cable  502  that supplies electricity to the furnace. The user may then join an exhaust system of the electrical generator with a flue of the furnace  504  wherein the exhaust gases of the electrical generator are drawn to an exterior environment by the flue. Subsequently, a gas line of the furnace may be tapped  506  wherein the fuel source supplying the furnace may also supply the electrical generator. Upon completion of the retrofit, the electrical generator may then supply electricity to the furnace upon interruption of an alternate power supply, such as an electric utility. A furnace  300  which has been retrofitted with the electrical generator  302  is shown in  FIG. 6 .  
         [0033]     It is understood that the specific order or hierarchy of steps in the foregoing disclosed methods are examples of exemplary approaches. Based upon design preferences, it is understood that the specific order or hierarchy of steps in the method can be rearranged while remaining within the scope of the present invention. The accompanying method claims present elements of the various steps in a sample order, and are not meant to be limited to the specific order or hierarchy presented.  
         [0034]     It is believed that the integrated electrical generator of the present invention and many of its attendant advantages will be understood by the forgoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely an explanatory embodiment thereof.