Patent Publication Number: US-2015076825-A1

Title: Inline electric generator with magnetically suspended axial flow open center impeller

Description:
RELATED APPLICATION 
     The present application claims the benefit of U.S. Provisional Patent Application No. 61/879,043 filed on Sep. 17, 2013, incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     Climate change and geopolitical concerns continue to focus our need for sources of green or renewable energy. Currently the largest investments in this technology are being made in the fields of solar and Wind technologies. Hydropower, with essentially no emissions, currently accounts for only about 7% of the electricity produced in the United States. However, these projects, including Hydropower, Pumped Storage or Run-of-River facilities, are generally very large, costly and take years of environmental impact studies, construction, licensing and regulations and have enormous long term maintenance costs making them less appealing than other forms of renewable energy. 
     Today energy costs and consumption are primary concerns globally. Every industrial nation is currently searching for new innovative technology to reduce consumption, emissions, and costs while taking advantage of available resources that do not negatively affect the environment. 
     There have been many attempts to capture the existing energy in closed loop fluid and gas systems, but all attempts use existing technologies and install in the pipe some form of paddle wheel, impeller with support bearings and/or shafts, or other mechanical means that is coupled to an electric generator to capture the kinetic energy that exists within the pipe. These mechanical systems are very inefficient, only capturing about 12-19% of the potential energy that exists within the pipe. Due to these inefficiencies and the high costs of the equipment needed to generate this energy relative to the value of energy created, there have been no designs developed for practical low cost-effective applications of these systems. 
     Therefore, there is currently a need in the art for a method and system of generating electricity from closed loop fluid or gas systems with optimal efficiency to capture the potential energy in these systems while remaining cost-effective and environmentally friendly. 
     BRIEF SUMMARY OF THE INVENTION 
     An electric power generator for placement inline with a conduit comprises a substantially cylindrical housing defining an elongated chamber configured to be coupled to the conduit so that a fluid flowing in the conduit flows through the elongated chamber, an impeller defining a central channel disposed in the elongated chamber and an inner surface of the central channel having a plurality of blade members shaping fluid flow in the central channel, where the impeller further including a matrix of permanent magnets secured to an exterior surface wall. The generator further comprises a copper coil assembly coupled to the substantially cylindrical housing and comprising a plurality of copper coils arranged circumferentially about the cylindrical housing, and configured to interact with the matrix of permanent magnets to generate electricity when the impeller rotates due to fluid flowing in the central channel and acting on the blade members. 
     An electric power generator for placement inline with a conduit comprises a housing defining an elongated chamber configured to be coupled to the conduit so that a fluid flowing in the conduit flows through the elongated chamber, an impeller defining a central channel configured to be magnetically-suspended in the elongated chamber, the central channel defining a plurality of spiral blade members configured for shaping fluid flow in the central channel, and a copper coil assembly coupled to the housing and having a plurality of copper coils arranged circumferentially about the housing, and configured to generate electricity in response to a rotational motion of the impeller within the elongated chamber. 
     An electric power generator for placement inline with a conduit comprises an impeller defining a central channel configured to be magnetically-suspended in the conduit, the central channel defining a plurality of spiral blade members configured for shaping fluid flow in the central channel, and a copper coil assembly coupled to the conduit and having a plurality of copper coils arranged circumferentially about the conduit, and configured to generate electricity in response to a rotational motion of the impeller within the conduit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete appreciation of the invention, features and many of the attendant advantages of the various embodiments thereof will be readily obtained as the same becomes better understood by reference to the following detailed descriptions when considered in connection with the accompanying drawings in which like numbers refer to like parts throughout, and in which: 
         FIG. 1A  is a side view of an exemplary embodiment of an inline electric generator attached to a fluid conduit having an array of copper coils placed outside the conduit according to the teachings of the present disclosure; 
         FIG. 1B  is a cross-sectional view of an exemplary embodiment of an inline electric generator attached to a fluid conduit having an array of copper coils placed outside the conduit according to the teachings of the present disclosure; 
         FIG. 1C  is a cross-sectional partial view of an exemplary embodiment of an inline electric generator attached to a fluid conduit having an array of copper coils placed outside the conduit according to the teachings of the present disclosure; 
         FIG. 2A  is a side view of an exemplary embodiment of a magnetically suspended axial flow open center impeller with axially formed internal impeller blades according to the teachings of the present disclosure; 
         FIG. 2B  is a cross-sectional view of an exemplary embodiment of a magnetically suspended axial flow open center impeller with axially formed internal impeller blades according to the teachings of the present disclosure; 
         FIG. 2C  is an end view of an exemplary embodiment of a magnetically suspended axial flow open center impeller with axially formed internal impeller blades according to the teachings of the present disclosure; 
         FIG. 2D  is a perspective view of an exemplary embodiment of a magnetically suspended axial flow open center impeller with axially formed internal impeller blades according to the teachings of the present disclosure; 
         FIG. 3A  is a side view of an exemplary embodiment of an electric generator non-magnetic copper coil mounting assembly according to the teachings of the present disclosure; 
         FIG. 3B  is a perspective view of an exemplary embodiment of an electric generator non-magnetic copper coil mounting assembly according to the teachings of the present disclosure; 
         FIG. 3C  is a top view of an exemplary embodiment of an electric generator non-magnetic copper coil mounting assembly according to the teachings of the present disclosure; 
         FIGS. 4A-4C  are various views of an exemplary embodiment of a coil mount for the noon-magnetic copper coil mounting assembly according to the teachings of the present disclosure; 
         FIG. 5  is a perspective view of an exemplary embodiment of an impeller assembly showing the exterior wall surface for receiving permanent magnets according to the teachings of the present disclosure; and 
         FIG. 6  is a simplified schematic diagram of an exemplary embodiment of an inline electric generator according to the teachings of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION AND BEST MODE OF IMPLEMENTATION 
     Referring now to the accompanying drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, there is illustrated an embodiment of an inline electric generating system for use in generating electricity, primarily from the kinetic energy in flowing pressurized fluids in a conduit. Other applications and embodiments are contemplated herein. As will become clear from the following description, the system embodies a number of distinct benefits over the related art, in particular a broad field of in-pipe applications, improved reliability, improved efficiency, lower costs to produce, very low maintenance and a lighter weight construction. 
     Referring to  FIGS. 1A ,  1 B, and  5 , the inline electric generating system  1  is generally configured for placement inline of a conduit  20  conducting a flowing fluid (gas and/or liquid). The system  1  generally includes a non-magnetic generally cylindrical housing  3  with a wall that defines an inner cylindrical elongated chamber  21  ( 21   a - 21   c ) for accommodating a magnetically suspended axial flow open center impeller assembly  2 . The impeller assembly  2  is generally cylindrical with a central fluid flow conductive channel. The conduit  20 , cylindrical housing  3 , and impeller assembly  2  are co-axially aligned (sharing a common longitudinal center axis). The impeller assembly  2  defines an interior surface of the central fluid flow conductive channel that includes a plurality of blade members that interact with the fluid flowing in the channel, causing the impeller to rotate. A plurality of magnets are embedded in the exterior wall of the impeller assembly  2 . A copper coil assembly having a plurality of copper coils is affixed to the exterior of the cylindrical housing  3 . When the fluid flows in the conduit to the cylindrical housing  3  and through the central conductive channel of the impeller assembly  2 , the forces of the fluid causes the impeller assembly  2  to rotate within the chamber, and the rotation of the embedded magnets induces an electric current in the copper coils of the copper coil assembly. The generated electric current is collected by a power circuitry  22 , which may supply the generated electricity to the power grid, to a bank of batteries, and other power systems. 
     Continuing to refer to  FIGS. 1A-1C , more details of the inline electric generating system  1 , with a magnetically suspended axial flow open center impeller assembly  2  (shown in  FIGS. 2A-2D ), are shown. In this embodiment, the inline electric generating system  1  comprises a non-magnetic cylindrical housing  3  to which permanent ring magnets  4  are affixed at each end of the non-magnetic cylindrical housing  3  with a specific magnetic north and south orientation. The axial flow open center impeller assembly  2  comprises an array of permanent magnets  5  disposed at both ends thereof, which interacts with the permanent ring magnets  4  to cause the impeller assembly  2  to counteract the pull of gravity and flow of the fluid to magnetically levitate within a defined area of the cylindrical housing  3  between the two permanent ring magnets  4 . As used herein the term “permanent ring magnet” or “permanent magnet” shall mean an object made from a material that is magnetized and creates its own persistent magnetic field. Some non-limiting examples of magnetic material include hard ferromagnetic materials such as alnico and ferrite. 
     As best seen in  FIG. 2B , the impeller assembly  2  comprises a generally cylindrical impeller  14  with an impeller housing cover  13 . The impeller housing cover  13  has an exterior surface formed with patterns of grooves  15   a - 15   c  defined thereon. Like the different blade patterns in the central conductive channel of the impeller, the groove patterns may also vary along the length of the housing cover. A primary function of the grooves  15   a - 15   c  is to provide for and/or increase the stability of the impeller assembly  2  as it rotates inside the cylindrical housing  3 . Additionally, the impeller  14  comprises a plurality of permanent magnets  9  (the recesses  18  to receive the permanent magnets  9  are shown in  FIG. 4 ) affixed axially to the exterior surface of the impeller  14 . The impeller housing cover  13  protects the permanent magnets from exposure to the fluids flowing inside the conduit. The permanent magnets  9  generate and encourages maximum rotational magnetic field potential from the rotation of the impeller assembly  2 . 
     The generally cylindrical impeller  14  comprises an inner wall surface that generally defines a central fluid flow conductive channel that have successively smaller diameters (or circumference), shown as segments  21   a,    21   b,  and  21   c  in  FIG. 2B . As fluids enter from one end of the cylindrical housing and the center of the impeller  14 , the conductive channel defined by the impeller  14  becomes increasingly smaller and more constricted. The smaller conductive channel causes the flow of the fluids to increase in flow rate and thus increase the efficiency of the system. 
     The impeller  14  interior wall surface comprises a plurality of axially formed blade members  16  ( 16   b  and  16   c ) that define spiral fluid flow channels within the impeller central conductive channel. In a preferred embodiment, the blade members in segments  21   a,    21   b,  and  21   c  of the impeller  14  are preferably different in numbers, shape, angles, and overall configuration, and may serve different functions. The decreasing dimensions of the central conductive channel and the spiral fluid flow channel configurations work together to increase the efficiency of electricity generation by the system. As shown in  FIG. 2B , segment  21   a  has an absence of blade members, segment  21   b  has gently spiraling blade members, and segment  21   c  has blade members with aggressive angles, surfaces, and orientation relative to the direction of fluid flow. 
     In a preferred embodiment of the impeller  14 , the impeller may be formed by injection molding, 3D printing, or other suitable manufacturing methods. In these methods, the blade members are formed integral to the rest of the impeller. In other manufacturing methods, the impeller and the blade members may be formed from distinct pieces fastened together. 
       FIGS. 3A-3C  are various views of an exemplary embodiment of an electric generator non-magnetic copper coil mounting assembly  30  according to the teachings of the present disclosure. In one embodiment of a non-magnetic copper coil mounting assembly  30  (shown in FIGS.  1 A and  3 A- 3 C), there is an array  11  of individual copper coils  10 . Each coil  10  is affixed to a non-magnetic coil mount  12   c  (shown in  FIGS. 4A-4C ) and affixed to a non-magnetic coil support frame  6 , then secured with non-magnetic threaded bolts  12   b  to a non-magnetic mounting ring  12   a.  The non-magnetic mounting ring  12   a  is externally affixed to the conduit for the purpose of holding the copper coils  10  in a fixed position with respect to the non-magnetic cylindrical housing unit  3 , and affixed to the conduit. 
     The fluid circulating in the conduit acts on (i.e. comes in contact with and induces rotation of) the magnetically suspended axial flow open center impeller assembly  2  located within the conduit and between the two permanent ring magnets  4  affixed at each end of the non-magnetic housing  3  affixed to the conduit. The rotational movement of the magnetically suspended axial flow open center impeller assembly  2  induces an electric current in each of the individual externally affixed copper coils  10 . The copper coils  10  are connected in such a manner  11  as to produce maximum electric current generated in the rotational magnetic field. 
     The features of the present disclosure which are believed to be novel are set forth below with particularity in the appended claims. However, modifications, variations, and changes to the exemplary embodiments described above will be apparent to those skilled in the art, and the inline electric generator described herein thus encompasses such modifications, variations, and changes and are not limited to the specific embodiments described herein.