Patent Publication Number: US-2018054093-A1

Title: Electric generator that generates electrical energy by magnetic induction

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates generally to a field of energy production by harnessing the forces of induction. More specifically, the invention relates to an electric generator that uses electric coils and magnets to induce electrical energy by magnetic induction. 
     Description Of The Prior Art 
     The demand for energy has increased dramatically in recent years partly due to the increase in the world&#39;s population. Furthermore, fossil fuels, such as oil and natural gas, are increasingly becoming higher in cost and their availability is limited. Additionally, efforts to generate energy by nuclear power have been tempered by environmental and safety concerns. In the face of these challenges and growing demand, energy generation has become the focus of much research. Energy generation through magnetic induction has become desirable because it can be converted to practical use without environmental contamination or chemical pollution concerns. 
     Electric generators are rotating devices that can be used for a variety of purposes. Using an electric generator provides a renewable source of electricity which does not require fossil fuels or excrete carbon byproducts. 
     Traditional electric generators are horizontal axis electric generators, wherein a horizontally supported shaft rotates and the rotation can be transformed in to electrical energy. Other generators have a vertical axis, wherein a rotating shaft is mounted vertically on a vertically supported axis. A problem with vertical axis electric generator is that the shaft has a tall and large surface area that create inefficiencies due to drag. 
     Whether an electric generator operates on a vertical or horizontal axis, the concept is still the same. The rotation of a shaft can be used to induce electrical energy using magnets that rotate around stationary coils, as described in detail in this application. 
     In recent years, various electricity generating utilities promoted schemes to decentralize the commercial electricity grid. Utilities have promoted the generation of energy by the use of decentralized devices located on buildings or on land or in yards belonging to small commercial companies or even individuals. In many areas of the country where grid connection is available, electrical utilities offer “net metering”, such that both the utility and the end user can generate electricity. Therefore, as the interest in co-generation of electrical energy grows, there will be a need for better, more efficient renewable-energy electricity generating devices. 
     The electric generator of the present invention maximizes the generation of electrical energy within the same size footprint as the prior art. The electric generator of the present invention is novel and nonobvious primarily due to the efficient arrangement of coils and magnets that jointly induce electrical energy from the rotation of a shaft. The inventor of this application believes that the most relevant prior art is U.S. Pat. No. 8,796,878 (hereinafter referred to as “the &#39;878 Patent”), which discloses a vertical axis electric generator having stationary coils attached to the center stat nary shaft and magnets attached to the housing or shell that is rotated by the vertical foils. Thus, the magnets rotate around the stationary coils. This rotation induces the generation of electrical energy by magnetic induction. The electrical energy is then transferred to batteries or coupled to the power grid. 
     As described in detail in this application, the electric generator of the present invention incorporates substantially more coils and magnets within substantially the same footprint size as the &#39;878 Patent to induce substantially more electrical energy. 
     in addition, unlike the prior art, the electric generator of the present invention also provides a cooling system driven by self-induced air flow combined with the use of heat fins configured to maintain the temperature within the system within a predetermined range. 
     Thus, based on the increase demand for electrical energy, a heretofore unaddressed need exists for an electric generator that can maximize the induction of electrical energy without overheating the system. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention has been made in view of the above-mentioned disadvantages occurring in the prior art. The present invention is an electric generator that efficiently induces electrical energy that can then be transferred to batteries or the power grid. 
     It is therefore a primary objective of the present invention to maximize the amount of electrical energy generated through magnetic induction by utilizing substantially more coils and magnets than the prior art. 
     A further objective of the present invention is to utilize coils on opposite sides of each magnet so as to maximize the induction of electrical energy. 
     A yet further objective of the present invention is to attach the magnets to a cylinder that is rotated around the coils that are stationary. 
     A yet further objective of the present invention is to induce air flow as part of its cooling system to dissipate excess heat and maintain the system within a predetermined temperature range. 
     A yet further objective of the present invention is to utilize heat fins as part of its cooling system to dissipate excess heat and maintain the system within a predetermined temperature range. 
     A yet further objective of the present invention is to include a robust housing that provides structural protection against sudden impact. 
     A yet further objective of the present invention is to include a base that allows the present invention to be installed either horizontally or vertically depending on the specific application. 
     The above objects and other features of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below and with reference to the accompanying drawings. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings which are incorporated by reference herein and form part of the specification, illustrate various embodiments of the present invention and, together with the description, further serve the explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. In the drawings, like reference numbers indicate identical or functional similar elements. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of the electric generator of the present invention in its assembled state as it would be used to induce electrical energy. 
         FIG. 2  is an exploded view of the electric generator of the present invention. 
         FIG. 3  is a sectional view of the electric generator of the present invention. 
         FIG. 4  is a perspective view of the rotor assembly of the electric generator of the present invention. 
         FIG. 5  is a sectional view of the rotor assembly of the electric generator of the present invention. 
         FIGS. 6 a  and 6 b    is a perspective view of the coil shaft of the electric generator of the present invention. 
         FIGS. 7 a  and 7 b    is a perspective view of the rear end caps of the electric generator of the present invention. 
         FIGS. 8 a  and 8 b    is a perspective view of the shell of the electric generator of the present invention. 
         FIGS. 9 a  and 9 b    is a perspective view of the housing of the electric generator of the present invention. 
         FIGS. 10 a  and 10 b    is a perspective view of the front end caps of the electric generator of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Reference will not be made to the drawings in which various elements of the present invention will be given numerical designations and in which the invention will be discussed so as to enable one skilled in the art to make and use the invention. 
     The electric generator  100  of the present invention comprises a housing  10 , a base  11 , a front end cap  12 , a rear end. cap  13 , a shell  20 , a plurality of inner coils  25 , a gear box  30 , a generator shaft  35 , a rotor cylinder  40 , a rotor shaft  45 , a plurality of magnets  50 , a plurality of fan blades  55 , a coil shaft  60 , a plurality of outer coils  65 , and a bearing plate  70 .  FIG. 1  shows a perspective view of the electric generator  100  of the present invention in its assembled state as it would be used to generate electrical energy.  FIG. 2  shows an exploded view of the electric generator  100  of the present invention to depict in greater detail the various components that comprise the electric generator  100 . 
       FIGS. 4 and 5  show a perspective view and a sectional view of the rotor assembly in which the rear end of the rotor shaft  45  is centrally attached to a plate  41  of the rotor cylinder  40 . Further, a sidewall  42  is attached to the perimeter of the plate  41  and extends so as to define a hollow cylinder. Finally, attached to the sidewall  42  are a plurality of magnets  50  and a plurality of fan blades  55 . As shown in  FIG. 5 , each magnet  60  has a positive polarity side and a negative polarity side. The magnets  50  are attached to the sidewall  42  in an alternating polarity configuration. In other words, the magnets  50  are attached to the rotor cylinder  40  in alternating positive polarity side and negative polarity side. 
     Thereafter, the rotor shaft  45  is connected to the gear box  30  as show in  FIG. 1 . In addition, the generator shaft  35  is attached to the gear box  30 . The gear ratio of the gear box  30  is configured so that for every rotation of the generator shaft  35 , the rotor shaft  45  is rotated at least twice. Furthermore, the generator shaft  35  is caused to rotate by a mechanical force, for example, it can be attached to the rotating wheel of an automobile or the rotating blades of a wind turbine. In essence, the mechanical force rotates the generator shaft  35  on its axis. The gear box  30  then transmits the rotating power of the generator shaft  35  to rotate the rotor shaft  45  at a higher rate and at a perpendicular angle relative to the generator shaft  35 . The rotation of the rotor shaft  45  then induces the rotation of the rotor cylinder  40 . 
     As shown in  FIG. 3 , the coil shaft  60  is rigidly attached to the bearing plate  70 . Furthermore, the plurality of inner coils  25  are attached along the coil shaft  60 , as shown in  FIG. 5 . The plurality of inner coils  25  are stationary along the coil shaft  60 , thus, the inner coils are stators of the electric generator  100  of the present invention. The coil shaft  60  is hollow so that wires from the inner coils  25  are routed through the hollow section of the coil shaft  60 . 
     Then the rotor cylinder  40  is positioned so that it encloses the coil shaft  60 , as shown in  FIG. 3 . In fact, the magnets  50  are attached to the rotor cylinder  40  such that each magnet  50  is in alignment with an inner coil  25  on one side and an outer coil  65  on the other side. Furthermore, the rotor cylinder rests against a plurality of bearings  75  placed on the bearing plate  70 , as shown in  FIG. 3 . The bearings  75  reduce any frictional forces that would resist the rotation o the rotor cylinder  40 . 
     As shown in  FIG. 3 , the shell  20  is a hollow cylindrical shell that is rigidly attached to the bearing plate  70  and encloses the coil shaft  60  and the rotor cylinder  40 . Furthermore, the plurality of outer coils  65  are rigidly attached to the interior face  21  of the shell  20 , as shown in  FIG. 3 . In the preferred embodiment of the present invention, the outer coils  65  are positioned so as to be in alignment with the inner coils  25 . 
     As shown in  FIGS. 1 and 3 , the rear end cap  13  is then placed over the bearing plate  70  and is coupled with the housing  10  that is placed over the shell  20 . The front end cap  12  is then coupled to the other end of the housing  10  with the rotor shaft  45  passing through the hole  12   b  is said front end cap  12 . 
     Once the electric generator  100  of the present invention is assembled as shown in  FIG. 1 , the generator shaft  35  is rotated and the gear box  30  induces at least two rotations of the rotor shaft  45  for every rotation of the generator shaft  35 . Rotation of the rotor shaft  45  facilitates the rotation of the rotor cylinder  40 . The rotation of the rotor cylinder  40  causes the rotation of the magnets  50  around the coil shaft  60 . Thus, the rotation of the rotor cylinder  40  induces the rotation of the magnets  50  around the inner coils  25  and the outer coils  65 . The rotational motion of the magnets  50  induces electrical energy in the inner coils  25  and outer coils  65  by magnetic induction. The electrical energy is then transferred through wires attached to the inner coils  25  and outer coils  65 . The wires attached to the inner coils  25  and outer coils  65  are routed rearward into the rear end cap  13  and out through a wire hole  13   b  in the rear end cap  13 . The wires can then he connected to batteries or coupled to the power grid. The electrical energy can then be transferred to batteries or coupled to the power grid through said wires. 
     Furthermore, as electrical energy is induced, the temperature inside the shell  20  may have a tendency to increase. However, the fan blades  55  attached to the sidewall  42  of the rotor cylinder  40  are configured to induce air flow inside the shell  20  as the rotor cylinder  40  rotates. The air flow allows for cooling within the shell  20  so that the temperature therewithin is maintained within a predetermined range. 
     In addition, a plurality of heat fins  21  are attached to the outer surface of the shell  20 . The heat fins  21  allow for the dissipation of heat out of the shell  20 . The heat fins  21  are configured with sufficient surface area to allow heat from within the shell  20  to dissipate by induction and convection at a predetermined rate. Even further, a plurality of venting boles are added throughout the shell  20  and the rotor cylinder  40  to allow the air to flow and circulate within the housing  10 . Then another set of venting boles are location in the housing  10  to allow the air to flow and circulate within the electric generator  100  of the present invention. 
     Additionally, the preferred embodiment of the present invention has another set of fins  16  attached to the outer surface of the housing  10 . The fins  16  are configured to induce some heat dissipation and to provide structural support and protection against sudden impact. Thus, the housing  10  is configured to provide robust protection to the electric generator  100  of the present invention. 
     Even more, the preferred embodiment of the present invention has a base  11  that allows the electric generator  100  of the present invention to provide stability as it is installed horizontally. However, a similar base can be added to the rear end of the electric generator  100  of the present invention to allow for a vertical installation. 
     Finally, the preferred embodiment of the present invention has a plurality of ball bearings  77  around the rotor cylinder  40  and the rotor shaft  45  to facilitate their rotation as described above, as shown in  FIG. 3 . 
     The electric generator  100  of the present invention is configured to maximize the induction of electrical energy as compared to the prior art, in particular, U.S. Pat. No. 8,796,878 (hereinafter referred to as “the &#39;878 Patent”). The &#39;878 Patent teaches an electric generator with magnets that revolve around one set of coils to induce electrical energy. However, the electric generator  100  of the present invention in a novel and non-obvious manner incorporates the rotor cylinder  40  so that the magnets  50  would be rotated around two sets of coils, the inner coils  25  and the outer coils  65 , so as to induce substantially more electrical energy within the same structural footprint as the prior art. In addition, unlike the prior art, the electric generator  100  of the present invention incorporates a novel and non-obvious cooling system. 
     It is understood that the described embodiments of the present invention are illustrative only, and that modifications thereof may occur to those skilled in the art. Accordingly, this invention is not to be regarded as limited to the embodiments disclosed, but to be limited only as defined by the appended claims herein.