Patent Publication Number: US-2009230685-A1

Title: System and method for converting fluid pressure into electric energy

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is related to and claims priority from Provisional Patent Application Ser. No. 61/035,454 filed on Mar. 11, 2008. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates, in general, to electric generators and, more particularly, this invention relates to a system for a vehicle or dwelling that converts fluid flow pressure into electric energy. 
     BACKGROUND OF THE INVENTION 
     As is generally well known, due to costs and environmental effects of burning fossil fuels, various alternative systems have been used to generate electric energy. Significant technical advances have been achieved in the area of using electric energy to power an automobile. Subsequently, efforts have been made to harvest wind power, either as a primary or secondary source, in order to generate electric energy. Prior to the conception and development of the present invention, efforts have been also made to use fluid pressure to generate electric energy for automobiles. U.S. Pat. No. 3,379,008 issued to Manganaro, U.S. Pat. No. 6,054,838 issued to Tsatsis, U.S. Pat. No. 6,748,737 issued to Lafferty, U.S. Pat. No. 6,815,840 issued to Aldendeshe and U.S. Pub. 2008/0083222 disclose various systems for converting fluid pressure into electric energy. 
     While these prior art systems eliminate or significantly reduce burning of fossil fuels, there is a continuing need for improved systems capable of generating electrify by converting fluid pressure. 
     SUMMARY OF THE INVENTION 
     The invention provides a system for converting fluid pressure into electric energy. The system includes at least one storage tank having each of a flexible diaphragm attached to an inner surface thereof and forming each of a first and second sealed chamber, a first fluid stored under a first pressure in the first chamber, a second fluid stored under a second pressure in the second chamber, a first port for at least dispensing the first fluid under pressure from the second fluid, a second port for filling the second chamber with the second fluid and a third port for returning the first fluid into the first chamber. A valve is secured to the at least one storage tank in operable alignment with the second port thereof. A conduit connects the first port of the at least one storage tank to the third port thereof. A flow rate control valve is interposed within the conduit in series with the first port. The flow rate control valve is operable to modulate flow of the first fluid in proportion to received input current. At least one electric generator is interposed within the conduit and operable by the first fluid under pressure to generate electric energy. A reservoir is additionally interposed within the conduit in series with the at least one electric generator. A fluid pump is finally interposed within the conduit mediate the reservoir and the third port of the at least one storage tank. 
     The present invention also provides a system for converting fluid pressure into electric energy. The system includes a pair of storage tanks. Each of the pair of storage tanks includes each of a flexible diaphragm attached to an inner surface thereof and forming each of a first and second sealed chamber, a first fluid stored under a first pressure in the first chamber, a second fluid stored under a second pressure in the second chamber, a first port for at least dispensing the first fluid under pressure from the second fluid, and a second port for filling the second chamber with the second fluid. There is a pair of valves, each of the pair of valves secured to a respective storage tank in operable alignment with the second port thereof. A flow direction control valve is provided and has each of a first inlet port connected to one of the pair of storage tanks, a second inlet port connected to an opposed one of the pair of storage tanks, a third inlet port and an outlet port. A conduit connects the outlet port of the flow direction control valve to the third inlet port thereof. A flow rate control valve is interposed within the conduit in series with the flow direction control valve and operable to modulate flow of the first fluid in proportion to received input current. At least one electric generator is interposed within the conduit and operable by the first fluid under pressure to generate electric energy. A reservoir is interposed within the conduit in series with the at least one electric generator. A fluid pump is interposed within the conduit mediate the reservoir and the third inlet port of the flow direction control valve. A controller is electrically connected to each of the pump, the flow rate control valve and the flow direction control valve. A battery is also provided. 
     The present invention finally provides a method of converting fluid pressure into electric energy. The method includes the step of providing a storage tank having each of a flexible diaphragm attached to an inner surface of the storage tank for dividing the at least one storage tank into each of a first and second sealed chamber, a first port in communication with the first chamber and a second port in communication with the second chamber. Then, filling the second chamber with air to a first predetermined pressure. Next, filling the first chamber with fluid to a second predetermined pressure. Connecting, in fluid communication, an electrically operable flow rate control valve to the first port. Then, connecting, in the fluid communication, at least one electric generator to the electrically operable flow rate control valve. Next, connecting, in the fluid communication, a reservoir to the at least one electric generator. Connecting, in the fluid communication, a fluid pump to the reservoir. Then, connecting, in the fluid communication, the fluid pump to the storage tank. Next, dispensing the first fluid under pressure from the first chamber. Converting, at the at least one electric generator, mechanical energy from the first fluid under pressure into the electric energy. Then, temporarily storing the first fluid in the reservoir. Finally, activating the pump to return the first fluid into the first chamber. 
     OBJECTS OF THE INVENTION 
     It is, therefore, one of the primary objects of the present invention to provide a system for converting fluid flow pressure into electric energy. 
     Another object of the present invention is to provide a system for converting fluid flow pressure into electric energy that employs a pair of prepressurized storage tanks. 
     Yet another object of the present invention is to provide a system for converting fluid flow pressure into electric energy that is economical to manufacture. 
     A further object of the present invention is to provide a system for converting fluid flow pressure into electric energy that is simple to use. 
     Yet a further object of the present invention is to provide a system for converting fluid flow pressure into electric energy that is capable of supplying generally uninterrupted flow of fluid pressure. 
     An additional object of the present invention is to provide a system for converting fluid flow pressure into electric energy that employs a microprocessor based controller. 
     In addition to the several objects and advantages of the present invention which have been described with some degree of specificity above, various other objects and advantages of the invention will become more readily apparent to those persons who are skilled in the relevant art, particularly, when such description is taken in conjunction with the attached drawing Figures and with the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a block diagram of a fluid circuit employed by an electric energy generating system constructed according to one embodiment of the present invention; 
         FIGS. 2   a - 2   b  show block diagrams of a fluid circuit employed by an electric energy generating system constructed according to a presently preferred embodiment of the present invention; 
         FIG. 3  shows a block diagram of a storage tank employed in the electric energy generating system of  FIG. 1  or  FIG. 2 ; 
         FIG. 4  shows a block diagram of an electric circuit of the electric energy generating system of  FIG. 1  or  FIG. 2 ; 
         FIG. 5  illustrates isometric view of the electric energy generating system or  FIG. 2 ; 
         FIG. 6  illustrates environmental view of using the system of  FIG. 2  for generating electric energy for a vehicle; 
         FIG. 7  is a partial block diagram of the system of  FIG. 1  or  2 , particularly illustrating employment of plurality of electric generator arranged in series with each other; and 
         FIG. 8  is a partial block diagram of the system of  FIG. 1  or  2 , particularly illustrating employment of plurality of electric generator arranged both in series and parallel with each other. 
     
    
    
     BRIEF DESCRIPTION OF THE VARIOUS EMBODIMENTS OF THE INVENTION 
     Prior to proceeding to the more detailed description of the present invention, it should be noted that, for the sake of clarity and understanding, identical components which have identical functions have been identified with identical reference numerals throughout the several views illustrated in the drawing figures. 
     It is to be understood that the definition of a fluid applies to both liquid and gas. 
     The best mode for carrying out the invention is presented in terms of its embodiments, herein depicted within  FIGS. 1 through 8 . However, the invention is not limited to the described embodiments, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only two particular configurations shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope. 
     Now in a particular reference to  FIGS. 1 ,  3 - 4 , therein is illustrated a system, generally designated as  20 , for generating electric power by converting fluid flow under pressure and which is constructed in accordance with one embodiment of the invention. 
     The system  20  includes a storage tank, generally designated as  30  and best shown in  FIG. 3 . The storage tank  30 , essentially being a hollow pressure vessel, is defined by a peripheral side wall  32  having an inner surface  34  and a pair of ends  36 ,  38  closing the side wall  32  and forming a pressure tight storage tank  30 . A flexible diaphragm  40  is attached at a peripheral edge thereof to the inner surface  34  of the side wall  32 . The flexible diaphragm  40  divides the storage tank  30  into a first chamber  42  for storing a first fluid  44  to be dispensed and a second chamber  46  for storing a second fluid  48  under pressure. It is presently preferred for the first fluid  44  to be a conventional hydraulic fluid, for example of the type employed in automotive brake systems, while providing the second fluid  48  as air. 
     In the present invention, the storage tank  30  is mounted upright with the first chamber  42  disposed at the bottom of the storage tank  30  adjacent the first end  36  while the second chamber  46  is disposed above the first chamber  42  adjacent the second end  38 . 
     A first port  50  is provided in open communication with the first chamber  42  for at least one of filling the first chamber  42  with the first fluid  44  and dispensing the first fluid  44  therefrom. A second port  52  is provided in open communication with the second chamber  46  for filling such second chamber  46  with the second fluid  48  under pressure. Thus, the second chamber  46  of the storage tank  30  is prepressurized prior to its use for generating electric energy. 
     The storage tank  30  may be constructed in accordance with  FIGS. 1-4  of the U.S. Pat. No. 7,032,628 issued to Guillemette at al. whose teachings are incorporated into this document by reference thereto. However, it is not necessary for the first port  50  to be disposed in the center of the first end  36  of the storage tank  30  as the present invention provides for a minimum volume of the first fluid  44  to remain in the first chamber  42  at all times. It is actually preferred to dispose the first port  50  in the side wall  32  in close proximity to the first end  36  so as to eliminate the need to elevate the bottom end  36  above the surface that the storage tank  30  to be supported on, thus simplifying the construction of the storage tank  30  and subsequently reducing its manufacturing costs. 
     A first valve  54  is secured to the storage tank  30  in operable alignment with the first port  50  thereof. Preferably, the first valve  54  is provided as an electrically operated proportional flow control valve  54  that modulates fluid flow in proportion to the input current it receives. An optional manually operable ON/OFF valve  57  may be also provided being interposed between the first port  50  and the proportional flow control valve  54 . 
     An air valve  56  is secured to the storage tank  30  in operable alignment with the second port  52  thereof. The air valve  56  may be of any conventional type enabling filling the second chamber  46  with pressurized air and refilling as necessary if the leakage develops during use. Prepressurizing the second chamber  46  with air pressure of about 1,000 pounds per square inch (PSI) has been found desirable for use in the present invention for generating electric energy on most vehicles  2 . 
     The system  20  also includes an electric generator  60  capable of converting mechanical energy from the flow of first fluid  44  under pressure from the first chamber  42  into electric energy. The electric generator  60  has a connection  62  for routing generated electric energy to a drive system  4  of the vehicle  2 . Any conventional fluid pressure driven electric generator is contemplated for use in the present invention. By way of one example only, the electric generator  60  may be of the type disclosed in U.S. Pat. No. 6,011,334 issued to Roland, whose teachings are incorporated into this document by reference thereto. The specific size of the electric generator  60  will generally depend on the amount of electric energy to be generated and physical confines of a specific application. The prior art electric generator disclosed in U.S. Pat. No. 6,011,334 may be advantageous for mounting underneath the floor portion of a conventional automobile due to its in-line construction and generally reduced radial circumference. 
     In order to mount the electric generator  60 , a conduit  62  is provided and has one portion  64  thereof coupled at a respective end thereof in fluid communication to each of the outlet port of the proportional flow control valve  54  and the inlet port of the electric generator  60 . Another portion  66  of the conduit  62  is coupled at a respective end thereof in fluid communication to each of the outlet port of the electric generator  60  and the inlet port  72  of a reservoir  70  which is provided to collect the first fluid  44  dispensed from the storage tank  30  and passed through the electric generator  60 . Thus the electric generator  60  is interposed into the conduit  62 . 
     Yet another portion  68  of the conduit  62  connects the outlet port  74  of the reservoir  70  with a third port  58  of the storage tank  30  for enabling the dispensed first fluid  44  to return into the first chamber  42 . An electrically operable pump  80  is also interposed into the conduit  62  and is provided to extract the first fluid  44  from the reservoir  70  and return it under increased pressure into the first chamber  42 . Again, any conventional fluid pump  80  may be employed. A controller  90 , preferably of a microprocessor type, is coupled to the pump  80  and energizes the pump  80  upon receipt of a control signal. Discontinuation of this control signal or receipt of another control signal causes the controller  90  to deenergize the pump and discontinue flow of the first fluid  44  into the first chamber  42 . Since return of the first fluid  44  into the first chamber  42  generally prevents generation of the electric power and since efficiency is lost during conversion of the fluid pressure into electrical energy, the system  20  and, more particularly, the controller  90  and the pump  80  are coupled to a source of electric power, such as a battery  6  of the vehicle  2 . Alternatively or in combination with the vehicle battery  6 , a battery  98  can be interposed into the system  20  of the present invention. In operation, the battery  98  provides auxiliary electric power to the system  20  and may be employed to start operation of the system  20 . The battery  98  may be coupled to the drive system  4  of the vehicle  2  or may be coupled to the connection  62  on the electric generator  60  in order to be recharged thereby through conventional recharging devices (not shown). 
     In operation, the second chamber  46  is prepressurized with air  48  to about 1,000 PSI through the air valve  56 . Then, the first chamber  42  is filled with the hydraulic fluid  44  through the first port  50  further increasing the pressure of the air in the second chamber  46  to about 3,000 PSI. When the system  20  is activated, preferably through the controller  90 , the hydraulic fluid  44  is dispensed from the first chamber  42  by the pressure from air  48  and passes through the electric generator  60  that converts the mechanical energy from the fluid pressure into electric energy. The hydraulic fluid  44  passed through the electric generator  60  flows into the reservoir  70 . As the hydraulic fluid  44  flows out from the first chamber  42 , the flexible diaphragm  40  moves downwardly and the air pressure decreases. The flow of the hydraulic fluid  44  from the first chamber  42  terminates when the flexible diaphragm  40  is in its most downward position and when the air pressure reaches the initial value of about 1,000 PSI. When the flow of hydraulic fluid  44  from the first chamber  42  is terminated, the hydraulic fluid  44  is returned from the reservoir  70  to the first chamber  42  through the by the pump  80 . 
     The controller  90  may receive the control signal from the drive system  4  or the ignition system (not shown) of the vehicle  2 . The flow rate of the first fluid  44  is controlled by the controller  90  through the proportional flow control valve  54  based on the amount of electric energy to be generated. 
     In order to at least minimize interruption of electric energy generation, the system, generally designated as  100 , is provided in accordance with a presently preferred embodiment of the invention. The system  100  is constructed according to the principles of above described system  20 , except that the system  100  includes a pair of storage tanks  30  and an electrically controlled flow direction control valve  110 . 
     Now, in reference to  FIGS. 2-6 , the pair of tanks  30  are usually juxtaposed with each other. The flow direction control valve  110  has each of a first inlet port  112  connected in fluid communication to each of the first ports  50 , a second inlet port  114  connected in fluid communication to the flow rate control valve  54 , a third inlet port  116  and an outlet port  118 . The third inlet port  116  is connected in fluid communication to the outlet of the pump  80  and the outlet port  118  is connected in fluid communication to the inlet port of the electric generator  60 . The flow direction control valve  110  also has an electrical connection with the controller  90  and electrical connection with the battery  98 . 
     Prior to operation, one of the storage tanks  30 , referenced with numeral  30   a  and shown to the left of  FIGS. 2   a  and  2   b,  receives the entire amount of first fluid  44 , while the opposed tank  30 , referenced with numeral  30   b,  receives only the amount of first fluid  44  generally equal to the amount of first fluid  44  remaining in the first chamber  42  at all times. Each storage tank  30  receives the first fluid  44  after the second chamber  46  is pressurized. 
     In operation, the first fluid  44  is dispensed from the storage tank  30   a  at a controlled rate from the fully filled first chamber  42  and is routed through the flow direction control valve  110  to the electric generator  60 . The first fluid  44  exiting the electric generator  60  flows into the reservoir  70  and is pumped by the pump  80  to the second storage tank  30   b  increasing pressure of the second fluid  48  in the second storage tank  30   b  to about 3,000 PSI. This process continues until the predetermined volume of the first fluid  44  is dispensed from the first storage tank  30   a.  Then, the controller  90  reverses flow of the first fluid  44  wherein the first fluid  44  flows out from the second storage tank  30   b  and is returned to the first storage tank  30   a.  This alternating flow of the first fluid  44  provides for substantially uninterrupted generation of the electric energy by the electric generator  60 . Again, due to efficiency losses, battery  98  is employed in the system  100 . The third port  58  is not required in the system  100  and may be permanently capped or eliminated. 
     It is also within the scope of the present invention, in order to minimize height of the system  20  or  100 , to provide a plurality of electric generators  60  connected in series with each other, as best shown in  FIG. 7 , as well as to provide plurality of branches connected parallel to each other relative to the flow of the first fluid  44 , each of the branches having at least one and, preferably a predetermined plurality of electric generators  60  connected in series with each other, as best shown in  FIG. 8 . 
     The quantity of electric generators  60  is determined based on the flow of the first fluid  44 , amount of electric energy to be generated and further based on utilization of the usable pressure range of the first fluid  44  which is, in the above example, is about 2,000 PSI. 
     In further reference to  FIG. 6 , therein is shown one example of installation of the system  100  on the vehicle  2 , wherein the storage tanks  30  are mounted in the rear storage compartment  8  while the remaining components are generally mounted under the floor area. However, it would be understood that the entire system  100  may be mounted within the rear storage compartment  8  or in any other locations a dictated by the design of the vehicle  2 . 
     It has also been found that the pair of storage tanks  30 , each having a five (5) gallon capacity, wherein the first fluid  44  occupies between 60 and 80 percent of the inner space is sufficient to generate electric energy to power most automobiles. 
     The present invention also contemplates that the connection between the outlet  74  from the reservoir  70  and the pump  80  may be directed first through separate branch within the electric generator  60 , as best shown in  FIG. 5 , so as to maximize use of the fluid pressure and thus increase generation of the electric energy. 
     Although the present invention has been shown in terms of the electric energy generating system in combination with the automobile, it will be apparent to those skilled in the art, that the present invention may be applied for generating electric energy for a residential or commercial dwelling by varying the size of the components. 
     It is also within the scope of the present invention to integrate the functionality provided by the controller  90  into the control system of the vehicle  2  wherein the system  20  or  100  is operable for example when the starting system of the vehicle  2  is activated. 
     Thus, the present invention has been described in such full, clear, concise and exact terms as to enable any person skilled in the art to which it pertains to make and use the same. It will be understood that variations, modifications, equivalents and substitutions for components of the specifically described embodiments of the invention may be made by those skilled in the art without departing from the spirit and scope of the invention as set forth in the appended claims.