Patent Description:
Military planners commonly look for ways to provide soldiers with improved protection and mobility, greater firepower, and the ability to carry additional equipment into battle without feeling the effects of fatigue. Various types of electrically powered equipment have been developed with these needs in mind, the power requirements of such equipment generally being accommodated by rechargeable batteries. In some applications the power requirement of the electrically powered equipment can exceed the capability of rechargeable batteries to provide electric power. In such situations it may be necessary to either limit the duration of the operation or tether the equipment to a power source.

Such power sources have generally been acceptable for their intended purpose. However, there remains a need for improved sources of electrical power. The present disclosure provides a solution to this need.

An energy storage system for wearable power modules is provided. The energy storage system includes a harness with a torso segment and a limb segment, a turboalternator supported by the torso segment of the harness, and a chemical energy source. The chemical energy source is in fluid communication with the turboalternator and is supported by the harness, the chemical energy source is supported on the limb segment of the harness in a distributed arrangement to allow for support of a mechanical load by the torso segment of the harness.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein the limb segment of the harness includes a left-leg portion and a right-leg portion, wherein the chemical energy source is distributed between the left-leg portion and right-leg portion of the limb segment.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein the chemical energy source comprises a first pressure vessel and one or more second pressure vessel, the one or more second pressure vessel in fluid communication with the turboalternator.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein the first pressure vessel is fluidly connected to the turboalternator by the one or more second pressure vessel.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein the first pressure vessel contains a compressed gas charge, wherein the one or more second pressure vessel contains a fuel charge.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein the one or more second pressure vessel contains a liquid fuel charge, wherein the liquid fuel charge is pressurized by a compressed gas communicated by the first pressure vessel.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein limb segment of the harness comprises a left-leg portion and right-leg portion, wherein the first pressure vessel is supported by one of the left-leg portion and the right-leg portion, wherein the one or more second pressure vessel is supported by the other of left-leg portion and the right-leg portion.

In addition to one or more of the features described above, or as an alternative, further embodiments may include a turbine speed control valve fluidly connecting the chemical energy source to the turboalternator.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein the torso segment of the harness has a shoulder portion and a lower back portion, wherein the turboalternator is supported by the lower back portion of the torso segment, and further comprising a mechanical load supported by the lower back portion of the harness.

In addition to one or more of the features described above, or as an alternative, further embodiments may include an electrical load electrically connected to the turboalternator.

In addition to one or more of the features described above, or as an alternative, further embodiments may include a ballistic shield at least partially enclosing the chemical energy source.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein the ballistic shield comprises an outer case, wherein the chemical energy source is arranged between the harness and the outer case of the ballistic shield.

In addition to one or more of the features described above, or as an alternative, further embodiments may include that the ballistic shield includes an inner case arranged between the chemical energy source and the harness, an outer case arranged on a side of the chemical energy source opposite the inner case, and a shear thickening fluid disposed between the inner case and the outer case, the shear thickening fluid enveloping at least a portion of the chemical energy source.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein the ballistic shield comprises a fiber reinforced ceramic material.

In addition to one or more of the features described above, or as an alternative, further embodiments may include wherein the chemical energy source comprises a first pressure vessel and one or more second pressure vessel, wherein the ballistic shield encloses the first pressure vessel and the one or more second pressure vessel.

A wearable power module is also provided. The wearable power module includes an energy storage system as described above. The chemical energy source includes a first pressure vessel and one or more second pressure vessel, the one or more second pressure vessel in fluid communication with the turboalternator, wherein the limb segment of the harness includes a left-leg portion and a right-leg portion, wherein the first pressure vessel and the one or more second pressure vessel are distributed between the left-leg portion and right-leg portion of the limb segment; and a ballistic shield at least partially enclosing the first pressure vessel and the one or more second pressure vessel.

In addition to one or more of the features described above, or as an alternative, further embodiments may include that the torso segment of the harness has a shoulder portion and a lower back portion, wherein the turboalternator is supported by the lower back portion of the torso segment, and the wearable power module additionally includes a mechanical load including a cargo pack supported by the lower back portion of the harness, and an electrical load electrically connected to the turboalternator.

An exoskeleton is additionally provided. The exoskeleton includes at least one of a load-carrying member and load-transfer member and an energy storage system as described above. The chemical energy source is supported by the exoskeleton through the harness of the energy storage system.

Technical effects of the present disclosure include wearable power modules with distributed energy storage systems. In certain embodiments the distribution of the energy storage system is such that chemical energy for the wearable power module leaves the shoulder portion of a harness available for a mechanical load, such as a cargo pack. In accordance with certain embodiments a turboalternator is provided to provide electrical power for one of more electrical loads and is distributed such that the shoulder portion of the harness is available for the mechanical load.

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of an energy storage system constructed in accordance with the disclosure is shown in <FIG> and is designated generally by reference character <NUM>. Other embodiments of energy storage systems, wearable power modules, and exoskeletons having distributed energy systems in accordance with the present disclosure, or aspects thereof, are provided in <FIG>, as will be described. The systems and methods described herein can be used for generating electrical power from a wearable power module, such as military applications, though the present disclosure is not limited to military applications or to wearable application in general.

Referring to <FIG>, the energy storage system <NUM> is shown. The distributed energy system is configured to provide chemical energy to a turboalternator <NUM> and includes a harness <NUM> and a chemical energy source <NUM> (shown in <FIG>) with a plurality of fuel pressure vessels <NUM> and a plurality of compressed gas pressure vessels <NUM>. The harness <NUM> includes a torso segment <NUM> and a limb segment <NUM>. The torso segment <NUM> is configured and adapted to be worn by a user <NUM>, e.g., a soldier, and has a shoulder portion <NUM> and a lower back portion <NUM>. The shoulder portion <NUM> is configured to be suspended from the shoulders of the user <NUM>. The lower back portion <NUM> is configured to be suspended from the lower back of the user <NUM>. As used herein the term fuel encompasses mono-propellants, which can provide a flow of high pressure decomposition products without an oxidizer, and liquid fuels requiring an oxidizer to generate high pressure combustion products.

The limb segment <NUM> is configured and adapted to be worn by the user <NUM> and has a right-leg portion <NUM> and a left-leg portion <NUM>. The right-leg portion <NUM> is configured to be suspended from the right-leg of the user <NUM>. The left-leg portion <NUM> is configured to be suspended from the left-leg of the user <NUM>. In certain embodiments the harness <NUM> can be included in an exoskeleton <NUM> having a one or more support member element <NUM> and one or more load transfer member <NUM> operably connected to the one or more support member <NUM> to manipulate loads, e.g., the mechanical load <NUM>, according instructions received from the user <NUM>.

The turboalternator <NUM> is supported by the torso segment <NUM> of the harness <NUM>. More specifically, the turboalternator is supported by the lower back portion <NUM> of the torso segment <NUM> of the harness <NUM>. The fuel pressure vessels <NUM> and the compressed gas pressure vessels <NUM> are supported by the limb segment <NUM> of the harness <NUM>, and are each distributed on the limb segment of the harness <NUM>. It is contemplated that one or more of the fuel pressure vessels <NUM> be supported by the right-leg portion <NUM> of the harness <NUM> and that one or more of the fuel pressure vessels <NUM> be supported by the left-leg portion <NUM> of the harness <NUM>. It is also contemplated that one or more of the compressed gas pressure vessels <NUM> be supported by the right-leg portion <NUM> of the harness <NUM> and one or more of the compressed gas pressure vessels <NUM> be supported by the left-leg portion <NUM> of the harness <NUM>. This allows the shoulder portion <NUM> of the harness <NUM> to be free such that a mechanical load <NUM> may be positioned on the shoulder portion <NUM> of the torso segment <NUM> of the harness <NUM>. As shown in <FIG> the mechanical load <NUM> includes a cargo pack <NUM>, e.g., a rucksack-type military cargo pack, which is supported by the harness <NUM> above the turboalternator <NUM>, the fuel pressure vessels <NUM>, and the compressed gas pressure vessels <NUM>.

With reference to <FIG>, the turboalternator <NUM> is shown. The turboalternator <NUM> is configured and adapted to convert chemical energy from the chemical energy source <NUM> (shown in <FIG>) contained in one or more of the fuel pressure vessels <NUM> (shown in <FIG>) into mechanical energy, and therefrom electrical energy for powering an electrical load <NUM>. In this respect the turboalternator <NUM> includes a power converter <NUM>, a permanent magnet generator <NUM>, and an interconnect shaft <NUM>. The turboalternator <NUM> also includes a turbine <NUM>, a diffuser <NUM>, and a gas generator <NUM>.

The gas generator <NUM> fluidly connects the energy storage system <NUM> with the turbine <NUM>, includes a decomposition or combustion chamber <NUM>, and is configured and adapted to generate a flow of high pressure combustion products <NUM> from a fuel flow <NUM> provided to the decomposition or combustion chamber <NUM> by the energy storage system <NUM>. The high pressure combustion products <NUM> are communicated to the turbine <NUM>. As shown in <FIG> a mono-propellant is provided to a decomposition chamber and decomposed therein without utilization of an oxidizer to generate high pressure decomposition products. In certain embodiments a liquid fuel and an oxidizer, e.g., compressed air, can be provided to a combustion chamber and combusted therein to generate high pressure combustion products.

The turbine <NUM> fluidly connects the gas generator <NUM> with the ambient environment <NUM> and is operably connected to the permanent magnet generator <NUM> by the interconnect shaft <NUM>. In this respect the turbine <NUM> receives the high pressure combustion products <NUM>, expands the high pressure combustion products <NUM> as the high pressure combustion products <NUM> traverse the turbine <NUM>, extracts work from the high pressure combustion products <NUM> as they traverse the turbine <NUM>, and communicate the work to the permanent magnet generator <NUM> as mechanical rotation R through the interconnect shaft <NUM>. Once expanded, the high pressure combustion products <NUM> are communicated to the ambient environment <NUM> through the diffuser <NUM>. The diffuser <NUM> converts the remaining dynamic energy of the turbine exhaust into static pressure, which increases the available pressure ratio across the turbine <NUM> and turbine nozzles. In certain embodiments the turbine <NUM> includes an impulse turbine <NUM>, providing radial compactness to the turbine <NUM>. In accordance with certain embodiments the turbine <NUM> can include a single stage <NUM>, providing axial compactness to the turbine <NUM>.

The permanent magnet generator <NUM> is operatively associated with the turbine <NUM>, is electrically connected to the power converter <NUM>, and is configured and adapted to generate variable frequency alternating current (AC) power <NUM> using the mechanical rotation R provided to the permanent magnet generator <NUM> by the turbine <NUM> through the interconnect shaft <NUM>. In this respect the permanent magnet generator <NUM> includes one or more permanent magnet <NUM>, fixed in rotation relative to the interconnect shaft <NUM>, and supported for rotation relative to a stator winding <NUM>. The permanent magnet <NUM> generates magnetic flux, which is communicated to the stator winding <NUM> during rotation and which induces a flow of alternating current in the stator winding <NUM>.

The power converter <NUM> electrically connects the stator winding <NUM> with the electrical load <NUM> and is configured and adapted to convert the variable frequency AC power <NUM> provided by the permanent magnet generator <NUM> into direct current (DC) power <NUM>. Conversion is accomplished by a rectifier circuit <NUM>, which in certain embodiments is a rectifier circuit <NUM>. In certain embodiments the rectifier circuit <NUM> includes a diode bridge, which passively rectifies the variable frequency AC power <NUM> into DC power <NUM> with a relatively simple circuit arrangement.

With reference to <FIG>, a portion of the energy storage system <NUM> is shown. The energy storage system includes the fuel pressure vessels <NUM> and the compressed gas pressure vessels <NUM>. A first compressed gas pressure vessel 108A, a first fuel pressure vessel 106A, and one or more second fuel pressure vessel 106B are supported by the right-leg portion <NUM> of the limb segment <NUM> of the harness <NUM>. The first compressed gas pressure vessel 108A contains a compressed gas charge <NUM>. In certain embodiments the compressed gas charge <NUM> includes an inert gas, such as substantially pure nitrogen by way of non-limiting example. The first fuel pressure vessel 106A and the one or more second fuel pressure vessel 106B respectively contain a fuel charge <NUM>. In certain embodiment the fuel charge <NUM> is a liquid fuel charge, such as a kerosene-based liquid fuel like JP-<NUM> in conjunction with an oxidizer in a combustion chamber by way of non-limiting example.

The first fuel pressure vessel 106A and the one or more second fuel pressure vessel 106B are in fluid communication with the turboalternator <NUM>. More specifically, the first fuel pressure vessel 106A is connected to the turboalternator <NUM> in parallel with the one or more second fuel pressure vessel 106B. In this respect a throttle valve <NUM> fluidly connects the first fuel pressure vessel 106A and the one or more second fuel pressure vessel 106B to the turboalternator <NUM>, the throttle valve <NUM> controlling the speed of the turbine <NUM> by throttling the rate of the flow of the fuel charge <NUM> to the turbine <NUM>. It is contemplated that the compressed gas charge <NUM> from the compressed gas pressure vessel <NUM> drive fuel from the liquid fuel charge <NUM> to the turboalternator <NUM>. In certain embodiments the energy storage system <NUM> provides a liquid fuel <NUM> to the turboalternator <NUM>.

The first compressed gas pressure vessel 108A is fluidly coupled to the turboalternator <NUM> by the first fuel pressure vessel 106A and the one or more second fuel pressure vessel 106B, respectively, in a blowdown arrangement. In this respect the first compressed gas pressure vessel 108A is fluidly connected to the first fuel pressure vessel 106A and the one or more second fuel pressure vessel 106B at the right-leg portion <NUM> to pressurize the fuel contained in both the first fuel pressure vessel 106A and the one or more second fuel pressure vessel 106B. As will be appreciated by those of skill in the art in view of the present disclosure, pressurizing the fuel charge <NUM> within the first fuel pressure vessel 106A and the one or more second fuel pressure vessel 106B using the compressed gas charge <NUM> within the first compressed gas pressure vessel 108A simplifies the control scheme for delivery of fuel to the turboalternator <NUM>, the turbine speed control valve <NUM> employing a variable orifice structure in certain embodiments.

The second compressed gas pressure vessel 108B is similar to the first compressed gas pressure vessel 108A, and is additionally supported on the left-leg portion <NUM> of the limb segment <NUM> of the harness <NUM>. Further, the second compressed gas pressure vessel 108B is connected to the turboalternator <NUM> through both a third fuel pressure vessel 108C and one or more fourth fuel pressure vessel 108D. As will be appreciated by those of skill in the art in view of the present disclosure, this distributes fuel contained in the energy storage system <NUM> both between the plurality of fuel pressure vessels <NUM> supported on the left-leg portion <NUM> and the right-leg portion <NUM> of the limb segment <NUM> of the harness <NUM>.

With reference to <FIG>, a ballistic shield arrangement <NUM> is shown. The ballistic shield arrangement <NUM> is configured an adapted to provide ballistic protection and includes a left-leg ballistic shield <NUM> (shown in <FIG>) and a right-leg ballistic shield <NUM>. The right-leg ballistic shield <NUM> includes a fiber reinforced ceramic material <NUM>. The fiber reinforced ceramic material <NUM> is configured and adapted to fragment an incoming projectile upon impact. Examples of suitable fiber-reinforced ceramic materials include those described in <CIT>, the contents of which are incorporated herein by reference in its entirety.

With reference to <FIG>, the left-leg ballistic shield <NUM> and the right-leg ballistic shield <NUM> are shown. The left-leg ballistic shield <NUM> includes an inner case <NUM>, an outer case <NUM>, and a shear thickening fluid <NUM>. The inner case <NUM> is arranged between the first fuel pressure vessel 106A and the left-leg portion <NUM> of the harness <NUM>. More specifically, the inner case <NUM> is arranged between each of the first fuel pressure vessel 106A, the one or more second fuel pressure vessel 106B (shown in <FIG>), and the first compressed gas pressure vessel 108A (shown in <FIG>).

The outer case <NUM> is arranged on a side of the first fuel pressure vessel 106A opposite the inner case <NUM>. More specifically, the outer case <NUM> is arranged on a side of the first fuel pressure vessel 106A, the one or more second fuel pressure vessel 106B, and the first compressed gas pressure vessel 108A opposite the inner case <NUM>. The shear thickening fluid <NUM> is disposed between the inner case <NUM> and the outer case <NUM>. In this respect the shear thickening fluid <NUM> envelopes the first fuel pressure vessel 106A, the one or more second fuel pressure vessel 106B, and the first compressed gas pressure vessel 108A in a cavity defined between the outer case <NUM> and the inner case <NUM>. Examples of suitable shear thickening fluids include ArmourGel®, available from the Dow Corning Company of Midland, Michigan.

As shown in <FIG> and <FIG>, the left-leg ballistic shield <NUM> at least partially encloses the first fuel pressure vessel 106A, the one or more second fuel pressure vessel 106B, and the first compressed gas pressure vessel 108A. The right-leg ballistic shield <NUM> is similar to the left-leg ballistic shield <NUM>, and additionally encloses the third pressure vessel 106C, the one or more fourth pressure vessel 106D, and the second compressed gas pressure vessel 108B.

Claim 1:
A wearable power module, comprising:
an energy storage system comprising:
a harness (<NUM>) with a torso segment (<NUM>) and a limb segment (<NUM>);
a turboalternator (<NUM>) supported by the torso segment of the harness; and
a chemical energy source (<NUM>) in fluid communication with the turboalternator and supported by the harness, wherein the chemical energy source is supported on the limb segment of the harness in a distributed arrangement to allow for support of a mechanical load by the torso segment of the harness, wherein the chemical energy source comprises a first pressure vessel and one or more second pressure vessel, the one or more second pressure vessel in fluid communication with the turboalternator;
wherein the limb segment of the harness includes a left-leg portion and a right-leg portion, wherein the first pressure vessel and the one or more second pressure vessel are distributed between the left-leg portion and right-leg portion of the limb segment; and
a ballistic shield at least partially enclosing the first pressure vessel and the one or more second pressure vessel.