Patent ID: 12202585

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of the present inventions, reference will now be made to the embodiments, or examples, illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the inventions as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.

Well-known elements are presented without detailed description in order not to obscure the present invention in unnecessary detail. For the most part, details unnecessary to obtain a complete understanding of the present invention have been omitted inasmuch as such details are within the skills of persons of ordinary skill in the relevant art. Details regarding control circuitry or mechanisms used to control the rotation of the various elements described herein are omitted, as such control circuits are within the skills of persons of ordinary skill in the relevant art.

When directions, such as front, rear, upper, lower, top, bottom, clockwise, counter-clockwise, are discussed in this disclosure, such directions are meant to only supply reference directions for the illustrated figures and for orientation of components in respect to each other or to illustrate the figures. The directions should not be read to imply actual directions used in any resulting invention or actual use. Under no circumstances, should such directions be read to limit or impart any meaning into the claims.

In this application, the phrase longitudinal or axial direction means the direction along or parallel to the component's longitudinal or axial axis. The phrase radial direction refers to the direction along a radius from the longitudinal axis and extending outwardly. The phrase circumferential refers to a direction along a circumference of a circle or circular rotation about the longitudinal or axial axis. Furthermore, the term “downstream” means positioned later or further down in the fluid flow. In contrast, the term “upstream” means positioned earlier in the fluid flow.

FIG.1Ais an isometric top view illustrating one embodiment of watercraft propulsion or jet pump system100looking from the inlet side of the system.FIG.1Bis an exploded isometric view of the pump system100illustrated inFIG.1Aillustrating some of the major components. In contrast,FIG.1Cis an isometric bottom view of the jet pump system100also looking from the inlet side of the system.FIG.1Dis an exploded view of the pump system100illustrated inFIG.1C.

Turning now toFIGS.1A,1B,1C, and1Din certain embodiments, the pump system's100main components comprise an inlet component200, an electronic controller or electronic speed controller250, an impeller stabilizer350positioned downstream of the inlet component, a motor-impeller component300positioned downstream of the impeller stabilizer, a vane guide400positioned downstream of the motor-impeller, a discharge cone500, and a nozzle or nozzle pump600positioned downstream of the vane guide.

FIG.2Ais an isometric bottom view illustrating one embodiment of the inlet component200which may be incorporated into the jet pump system100. In contrast,FIG.2Bis an isometric top view illustrating the inlet component200.FIG.2Cis an isometric top view illustrating the inlet component200physically coupled to the electric controller250.FIG.3is a section view showing the electric controller250physically coupled to the inlet component200.

Turning now toFIGS.2A,2B,2C, and3, the inlet component200comprises a main or inlet conduit201which defines a water inlet tunnel202allowing the motor-impeller component300to suck water into the impeller when in use. In certain embodiments, the inlet tunnel202also defines an inlet mouth204and an outlet or discharge opening206. In certain embodiments, a mounting surface or platform208may be formed on one exterior face of the main conduit201. In the illustrated example, the mounting surface208is formed on a top surface of the main conduit (seeFIG.2B). In certain embodiments, the mounting surface208is a flat contact surface positioned on the inside of the vessel or watercraft as illustrated inFIG.3. The electronic controller or electronic speed controller250may be positioned on the mounting surface208which is positioned on the inside (or in a relatively dry space) of the vessel or watercraft. In certain embodiments, the electronic controller250is waterproofed and/or uses water proof electrical wiring and connections as is known in the art. As illustrated inFIGS.2C and3, the electronic controller250is coupled to water electrical wires230and232(only part of the wires are illustrated inFIGS.2C and3). In certain embodiments, waterproof electrical and/or power wires230run from the electronic controller250to electrical connections (not shown) of the motor-impeller unit300. Additionally, waterproof electrical and/or power wires232may run from a main controller and/or battery (not shown) to the electronic controller250.

In certain embodiments, the electronic controller250is designed so that the heat generating components (e.g., metal oxide semiconductor field effect transistors, “MOSFETS”) are spread out to increase the area of contact with the mounting surface208to allow a greater heat transfer from the controller to the mounting surface. Thus, in certain embodiments, the entirety of the inlet component200extracts heat from the electronic controller250and becomes a heat sink for the various components and MOSFETS of the electronic controller.

During operation of the watercraft, water enters the mouth204of the inlet tunnel202in the general direction indicated by arrow210, the water flows through the tunnel and makes contact with inner surfaces212of the inlet component and heat is transferred to the flowing water through physical contact with the inner surfaces. Therefore, the water flowing through the inlet tunnel202becomes a cooling system for the electronic controller250. In certain embodiments, the MOSFETS and other heat generating components may be directly connected to the inlet component200, which is made from a heat conducting material—such as aluminum.

In some embodiments, a mounting surface208allows the electronic controller250to be coupled to the main conduit201as illustrated inFIGS.2C and3. Heat is generated by the electronic controller250is conducted to the mounting surface208and spreads to other portions of the main conduit201in embodiments where the mounting platform208is homogenous with the main conduit201.

As discussed above, in certain embodiments, the inlet component200may be homogenous and formed of aluminum or another heat conducting material. Thus, the entire inlet component (or much of the inlet component) may become a heat sink for the electronic controller250. In other embodiments, the inlet component200may be formed of plastic or fiberglass and have a heat conducting platform or plate embedded in the inlet component. In such embodiments, most of the heat transfer occurs between the embedded conducting plate and the flowing water.

Yet in other embodiments, an electronic controller enclosure or compartment255may be formed and may be integral with the inlet component200. In such an embodiment, a plurality of walls256may extend outward from the mounting surface208to form an enclosure255comprising, for instance, four upward extending walls and a bottom surface which is the mounting surface208. In such an embodiment, a top plate258may couple to the walls to seal the enclosure. In certain embodiments, the perimeter mating surfaces of the top plate and the walls256may form one or more steps (not shown) to accommodate a waterproof seal, such as a silicone seal. In certain embodiments, the entire enclosure may be encased in epoxy or an appropriate potting compound.

In yet other embodiments, an embedded platform or heat transfer plate may be positioned in other places along a submersible portion of the hull of the watercraft or vessel (not shown). Thus, the electronic controller may be positioned on the interior side of the submersed hull next to a heat transfer platform embedded in the hull. For instance, the hull could be made of fiberglass, carbon fiber, or wood, but have an embedded plate made of aluminum or another heat conducting metal. The electric controller may then be positioned directly adjacent to the embedded platform so that the embedded platform becomes a heat sink for the electronic controller. Flowing water (relative to the hull) on the external side of the hull cools the heat sink which also results in a cooling of the electronic controller. Consequently, aspects of the invention may be used in any situation where electric motors and/or pump jets are used with vessels and other forms of watercraft.

Turning back toFIG.2A, in certain embodiments there may be an inlet flow plate260which may separate high speed flow from low-speed flow going through the intake mouth204. In certain embodiments, the inlet flow plate260creates a low-pressure zone of flow that creates a barrier of water (i.e., a zone of lubricity) for the high-speed flow so the high speed flow does not encounter resistance due encountering stationary walls of the inlet conduit201. Furthermore, in use, an inlet flow plate260may help keep the board “sucked” down to keep enough flow of water going through the inlet tunnel202at high speed on straights.

In certain embodiments, an impeller stabilizer350couples the outlet portion of the inlet component200to the motor-impeller component300.FIG.4Aillustrates one embodiment of the impeller stabilizer350illustrated from the inlet perspective (facing the discharge opening206). In contrast,FIG.4Billustrates one embodiment of the impeller stabilizer350from the outlet perspective (facing the motor-impeller component300). In certain embodiments, the impeller stabilizer350provides stabilization for a stabilizing shaft308(SeeFIG.5A) of the motor-impeller component300, and is either designed to reduce the amount of hydrodynamic and/or aerodynamic drag on the intake side of the motor-impeller component. In certain embodiments, a plurality of radially spaced vanes352connect a center hub354to a stabilizing rim356which is coupled to an outer mounting ring358. The shape of center hub354is designed to reduce the amount of hydrodynamic drag on the intake side of the motor-impeller component300.

The mounting ring358defines a plurality of circumferentially spaced apertures362for connectors, such as screws (not shown) to couple the stabilizer350to the motor-impeller component300. The stabilization vanes352provide support to the center hub354and also help control and stabilize the water flow before it reaches the impeller of the motor-impeller component300. In certain embodiments, a plurality of outlet ports360are defined within the stabilizing rim356. As will be explained later, the outlet ports360allow heated water from the motor-impeller300until to be injected back into the main water flow entering the motor-impeller.

FIG.5A, is a front or intake perspective view of one embodiment of the electric motor-impeller component300.FIG.5B, is a rear or outlet perspective view of one embodiment of the electric motor-impeller component300.

The electric motor-impeller300includes a non-rotating stator (not shown) and a rotating rotor (not shown). A non-magnet impeller304is coupled to the rotor or rotor yoke and, therefore, follows as the rotor rotates. A non-rotating center stabilizing shaft308reduces vibrations and stabilizes the impeller. The front or inlet end310of the non-rotating shaft308couples to the center hub354of the impeller stabilizer350(seeFIG.4B). A rear or outlet end312of the non-rotating shaft308couples to the vane guide400(seeFIG.6A). As illustrated inFIGS.5A and5B, a sleeve302is shown wrapped around the motor-impeller300. In certain embodiments, the sleeve302may be formed from a thin layer of material, such as carbon fiber. As will be explained below, in certain embodiments, the sleeve302creates a void or channel for water to flow through and around the motor-impeller300. Thus, some of the heat generated from the motor-impeller component300can be transferred to the surrounding water via a cylindrical channel created by the space between the sleeve302and the motor stator (not shown).

For more information about the motor-impeller component300, see the Applicant's U.S. Provisional Patent No. 63/459,534, entitled CASELESS ELECTERIC MOTOR WITH A STATIONARY SHAFT; filed on Apr. 14, 2023; U.S. provisional patent application Ser. No. 63/554,831, entitled CASELESS ELECTRIC MOTOR WITH A STATIONARY SHAFT FOR MARINE ENVIROMENTS, filed on Feb. 16, 2024; PCT Application No. PCT/US24/24623, entitled “CASELESS ELECTRIC MOTOR WITH A STATIONARY SHAFT FOR MARINE ENVIROMENTS,” filed on Apr. 15, 2024, the disclosures of which are incorporated by reference into this Application for all purposes. The use of the electric motor coupled to and surrounding the impeller304eliminates the need for a rotating shaft passing through the inlet tunnel202—as used with most conventional jet pumps. The elimination of a rotating shaft in the inlet tunnel202results a much smoother and predictable water flow through the inlet tunnel202.

FIG.5Bis a rear or discharge isometric view of the motor-impeller300illustrating a portion of a stationary shaft308which couples to components of the vane guide400and discharge cone500to be discussed later in reference toFIG.6C. A plurality of circumferentially spaced threaded apertures316allow a plurality of connectors, such as threaded inserts (not shown) to mechanically couple of the motor-impeller unit to the vane guide400.

FIG.6Ais a front or intake perspective view illustrating one embodiment the vane guide400.FIG.6Bis a rear or outlet perspective view of the vane guide400.FIG.6Cis a exploded perspective view of the vane guide400from a rear or discharge view with the addition of the discharge cone500and an O-ring502.

In certain embodiments, the vane guide400comprises a center shaft402defining a longitudinal bore404for accepting the outlet end312of the stationary shaft308of the motor-impeller component300(SeeFIG.5Babove). In certain embodiments, a portion413of the longitudinal bore404may be threaded to accept a threaded outlet end312of the stationary shaft308(seeFIG.8A).

A plurality of de-swirling vanes406extending in a radial direction from the center shaft402to an exterior cylindrical wall408and are designed to minimize the turbulence of the water produced by the impeller304(SeeFIG.5B). The de-swirling vanes are designed to start de-swirling the flow as soon as practical after being driven by the impeller.

In some embodiments, the inlet face of the vane guide400may have an intake mounting flange410with a plurality of circumferentially spaced mounting apertures412design to receive screws or bolts (not shown) which can be coupled to the threaded insert apertures316of the motor-impeller component300(SeeFIG.5B, above). A motor mounting rim424extends in a longitudinal direction towards the motor-impeller300and may engage various seals (not shown) of the motor-impeller. One or more pluralities of inlet apertures426may be defined around the mounting rim424which allow water to injected into the inlet apertures426to cool the motor impeller component300.

In certain embodiments a fitting414for a clean-out plug416(SeeFIG.6B) may be coupled to the intake mounting flange410to a allow a user to clean or wash out impurities such as sand and other particulates that may accumulate in the motor-impeller unit during use.

As illustrated inFIGS.6B and6C, the discharge end of the center shaft402defines a threaded aperture418which is sized and configured to accept a male threaded portion504of the nose cone500. In certain embodiments, an O-ring502may be used to seal the nose cone500against the center shaft402.

In certain embodiments, the discharge cone500is designed and shaped to reduce the amount of hydrodynamic drag on the discharge side of the impeller. For instance, rather than using a traditional screw slot to mount the discharge cone500, the discharge cone may be mounted to the center shaft402through the use of a specialized tool (not shown) which engage a plurality of linear slots506formed on the face of the nose cone to allow a torque to be applied to the nose cone so that the threaded portion504of the nose cone can engage the threaded aperture418the of the center shaft402. The linear slots506are also designed to reduce the amount of hydrodynamic drag on the discharge cone500.

Conventional system will use screws and Allen wrenches to attach the impeller which will cause breaks in the water flow and additional surface tension. Such effects are undesirable because they will disturb the overall pressure and speed of the water flow—which causes inefficiencies. Incorporating smooth surfaces, for instance on the discharge cone500, will reduce hydro-shearing and increase the efficiency of the propulsion system so that the vast majority of the water exiting the discharge end of the nozzle pump is near or at the same speed as the water exiting the motor-impeller unit300.

At the discharge end of the outer cylinder wall408, a second or rear mounting flange420extends outwardly for supporting a plurality of apertures422circumferentially spaced around the flange420. The apertures422are designed to align with another plurality of apertures602defined within a mating flange604of the nozzle cone or pump600as illustrated below inFIGS.7A and7B.

FIG.7Ais a front or intake perspective view illustrating one embodiment of the nozzle pump600.FIG.7Bis a rear or discharge perspective view illustrating the nozzle pump600. As illustrated, the nozzle pump600is generally cone shaped where the inlet or front mouth606has a larger diameter than the discharge aperture608. In certain embodiments, a mounting flange604surrounds the inlet mouth606.

A plurality of circumferentially spaced interior vanes610project from an interior surface612of the throat of the nozzle pump600towards the center or longitudinal axis (not shown) of the nozzle pump600.

FIG.8Ais a section view from the discharge perspective of the embodiment of the vane guide400positioned adjacent to the nozzle pump600.FIG.8Bis a section view from the discharge perspective of the embodiment of the vane guide400positioned adjacent to the nozzle pump600with the addition of the discharge cone500. As discussed above, the plurality of apertures422of the vane guide400are longitudinally aligned with the plurality of apertures602of the mounting flange604of the nozzle pump600to allow for the insertion of mounting screws (not shown). In certain embodiments, the mounting screws may be mated to an equal number of threaded acorn nuts to secure the nozzle pump600to the vane guide400.

As can be seen inFIGS.8A and8B, when the vane guide400is coupled to the nozzle pump600, the interior vanes406of the vane guide400are also aligned with the interior vanes610of the nozzle pump600. In yet, other embodiments, the combination of the vane guide400and the nozzle pump600may be formed as a single piece in order to eliminate the weight of the mounting flanges420,604and the associated hardware.

Operation

FIG.9Ais a longitudinal section view of the entire jet pump system100. Referring now toFIGS.9A, the manner of using one embodiment of the jet pump system100will now be described.

In use, the jet propulsion system100will be mounted inboard in the aft section of a vessel (not shown). In certain embodiments, the inlet mouth204of the inlet component200is positioned along the bottom of the vessel. At vessel speed, water is sucked through inlet mouth204and flows through to the motor-impeller unit300. The turning of the impeller304increases the water pressure and discharges the water at a high velocity through the nozzle pump600at high velocity. The discharge of a high velocity stream of water generates a reactive force in the opposition direction which is transferred through the body of the jet pump system100to the vessel's hull, propelling the vessel forward.

As is well known, during operation, conventional electric motors will typically generate heat and cooling systems are introduced to manage the heat produced by the motor. In a conventional marine motorcraft cooling system, water is typically captured coming out of the propulsion system, removed from the fluid flow of the system, used to cool the motor or electronics, then the water is reintroduced back into the environment-resulting in less propulsion available to the system because some of the flow is used for cooling and not propulsion.

In contrast, in some of the disclosed embodiments, recirculated water is used for motor cooling. As will be explained below, in some embodiments, water is pushed or injected from a high-pressure compression zone650on the discharge side of the impeller304through the space between the sleeve302and the motor stator380back around to the inlet side region382of the motor-impeller component-which is a relatively low-pressure zone where the water is then sucked into the motor-impeller component. This results in a circulation where the high-pressure water from the back of the motor-impeller component300may be used to partially cool the motor.

In a conventional system, the impeller flings water to the exterior walls creating a turbulence which slows the overall water velocity and flow rate. However, when the water is recirculated around the motor-impeller component300, turbulence is reduced so the flow volume stays relatively consistent. In other words, rather than the water being pushed against the exterior walls creating areas of turbulence and eddies, the water is being fed backwards around the motor stator to the inlet side. At the inlet side, the water is transferred back to the general flow to minimize any losses in flow volume. So, the flow volume stays relatively consistent throughout the entire system.

FIG.9Bis a detailed section view illustrating one embodiment in which water may be recirculated to cool the motor. As water exits the area of the twirling impeller304, it may be immediately “flung” against an interior wall428of the vane guide400to create a high pressure, turbulent zone650of flow and strong water pressure. In certain embodiments, some of the water from this high pressure zone650will be injected into inlet apertures426defined in the interior wall428of the vane guide400. The direction of this fluid flow can be represented by arrow902. In turn, the injected water exiting the inlet apertures426creates a high pressure zone904between a motor stator380and the sleeve302—which creates a fluid flow back towards the impeller stabilizer350as indicated by arrows906. This fluid flow then exits through a plurality of outlet apertures362as indicated by arrows908. The water is then reintroduced into the lower pressure flow region382on the inlet side of the impeller304. This creates a zero loss or near zero loss cooling system which will result in minimal loss of back pressure or minimal negative effects on the propulsion of the system.

Any low gravity solids and solids should be able to flow through the inlet openings426because they will be carried by the flow of the water circulating in zone904. In order to reduce the likelihood that the solids are caught in zone904, the inlet apertures426are of a smaller diameter (e.g., 2 mm) in the high-pressure zone650than the diameter of the outlet apertures362(e.g. 3 mm) so that if any solids enter into the pressure zone904will be flushed out by the pressurized water flow circulating between the motor stator380and the sleeve302.

The circulation system described above passively cools the electric motor-eliminating traditional cooling lines and cooling systems-which minimizes the number of additional parts and weight and thereby providing increasing overall efficiencies of the system.

The abstract of the disclosure is provided for the sole reason of complying with the rules requiring an abstract, which will allow a searcher to quickly ascertain the subject matter of the technical disclosure of any patent issued from this disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Any advantages and benefits described may not apply to all embodiments of the invention.

The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many combinations, modifications and variations are possible in light of the above teaching. For instance, in certain embodiments, each of the above-described components and features may be individually or sequentially combined with other components or features and still be within the scope of the present invention. Undescribed embodiments which have interchanged components are still within the scope of the present invention. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims.