Patent Document

REFERENCES TO RELATED APPLICATIONS  
         [0001]    This application is based on Provisional Application No. 60/301,525, filed Jun. 28, 2001. This application includes subject matter protected by copyright.  
         TECHNICAL FIELD OF THE INVENTION  
         [0002]    The present invention relates generally to a portable electrical power generating unit that can be used with electrical appliances, and specifically to a portable hydrogen fuel cell electrical power generating unit that can supply sufficent power to power electrical appliances such as a vacuum cleaner.  
         BACKGROUND OF THE INVENTION  
         [0003]    Portable power supply units adapted to be carried by an operator of an appliance are well known. Additionally, portable electrical appliances are well known, for example see U.S. RE No. 37,081.  
           [0004]    Presently, portable electrical appliance designs that are available must deal with two considerations that affect customer choice and satisfaction. The first is the power requirement of the appliance. The second is the power supply available to the appliance.  
           [0005]    Power requirements for appliances are usually directly related to the appliances performance in accomplishing the designed task. For example, when a customer desires a vacuum cleaner that is able to provide a stronger vacuum, the customer must choose a vacuum cleaner that will have greater electrical power requirements.  
           [0006]    Additionally, when a customer is choosing a vacuum cleaner, often the extent of the portability is a consideration. For example, if a customer needs a vacuum cleaner for vacuuming a large area with few electrical power outlets, the customer may desire a vacuum cleaner with a battery powered source that is portable with the vacuum cleaner, so the operator is not limited by the length of the electrical power cord.  
           [0007]    One problem associated with the conventional vacuum cleaner is that the electrical cord wire which is attached to the vacuum mechanism has been known to create several obstacles during use of operation such as (1) locating a proper electrical outlet in which to plug the wire that is compatible to the area of the room; (2) moving electrical cord wire out of the way of vacuuming; and (3) storage of the electrical cord. In these instances, a battery powered cordless vacuum cleaner is an improvement. However, a battery powered cordless vacuum cleaner has been known to have limitations as well. A battery powered cordless vacuum mechanism has limited power, typically less than 500 watts, and is unable to successfully complete the process of removing dirt and particles from a carpet.  
         BRIEF SUMMARY OF THE INVENTION  
         [0008]    A portable power supply for electrical appliances includes a wearable frame, an electrical power generation unit, and a fuel supply container. An electrical connection permits an electrical appliance to be connected to the electrical power generation unit and receive its power therefrom. The electrical appliance may also be attached to the wearable frame.  
           [0009]    A method of using a portable electrical power unit with an appliance, the method comprising the steps of storing a fuel supply in a container, converting the fuel to electrical power using an electrical power generator, operating an electrical appliance, wherein the electrical appliance receives its electrical power from is the electrical power generator, and wearing the container and the electrical power generator on the back of an operator using the appliance.  
           [0010]    A backpack comprising of a backpack frame, a portable electrical power generating unit attached to the frame, and an electrical appliance electronically coupled to the portable electrical power generating unit.  
           [0011]    The foregoing has outlined some of the more pertinent objects and features of the present invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention as will be described. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the following Detailed Description of the Preferred Embodiment.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    For a more complete understanding of the present invention and the advantages thereof, reference should be made to the following Detailed Description taken in connection with the accompanying drawings in which:  
         [0013]    [0013]FIG. 1A shows an embodiment of the present invention in a schematic form;  
         [0014]    [0014]FIG. 1B shows a side view of the embodiment of the invention whereby the fuel container is visible;  
         [0015]    [0015]FIG. 2 shows another embodiment of the present invention, having a hinged cover;  
         [0016]    [0016]FIG. 3 shows an embodiment of the present invention, whereby the unit is latched onto a frame;  
         [0017]    [0017]FIG. 4 shows another embodiment of the present invention in a uniquely designed case;  
         [0018]    [0018]FIG. 5 shows a different embodiment of the present invention, having a handle;  
         [0019]    [0019]FIG. 6A shows an embodiment of a support unit for an embodiment of the present invention;  
         [0020]    [0020]FIG. 6B shows another view of this embodiment of the invention, detailing different mounting techniques for a cover plate;  
         [0021]    [0021]FIG. 7 shows the construction of a protective portion for an embodiment of the present invention;  
         [0022]    [0022]FIG. 8 shows an oblique view of an embodiment of the present invention;  
         [0023]    [0023]FIG. 9 shows an embodiment of the present invention as worn by an operator;  
         [0024]    [0024]FIG. 9A shows a top view of one embodiment of the present invention;  
         [0025]    [0025]FIG. 10 shows a composite diagram of an embodiment of the present invention;  
         [0026]    [0026]FIG. 11 shows an electrical wiring schematic drawing for an electrical appliance utilized in an embodiment of the present invention;  
         [0027]    [0027]FIG. 12 shows another embodiment of the present invention as worn by an operator;  
         [0028]    [0028]FIG. 12A shows an electrical generator utilized in an embodiment of the present invention without its protective cover;  
         [0029]    [0029]FIG. 13A shows another embodiment of the present invention in a modified form;  
         [0030]    [0030]FIG. 13B shows the fuel container bracket pursuant to the present invention;  
         [0031]    [0031]FIG. 13C shows a rear view of this embodiment of the present invention;  
         [0032]    [0032]FIG. 14A shows a close up of a fuel regulating unit for an embodiment of the present invention;  
         [0033]    [0033]FIG. 14B shows a schematic of the the fuel storage container and the fuel regulator with fuel line connected thereto to provide fuel to the electrical generation unit;  
         [0034]    [0034]FIG. 14C is provided to show the fuel line connected to the fuel container via the regulating system;  
         [0035]    [0035]FIG. 15A shows a side view of the electrical generation unit in an embodiment of the present invention;  
         [0036]    [0036]FIG. 15B shows the on/off switch connected to electrical generating unit;  
         [0037]    [0037]FIG. 16 shows a perforated cover for the fuel cell along with the location for the battery charging jacks for recharging the fuel cell batteries;  
         [0038]    [0038]FIG. 16A shows a front view of the electrical power generating unit; and  
         [0039]    [0039]FIG. 16B provides a back view of the electrical power generating unit.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0040]    Referring now to the figures, FIG. 1A shows an embodiment of the present invention in a schematic form. In FIG. 1A, frame  110  provides support for the embodiment of the present invention  120  so that  120  is wearable upon an operator&#39;s back. In order to reduce costs, the sides of unit  120  are open. Blow hose  125  is attached to blow hose air filter connection  128 , while suck hose  130  is attached to the base of unit  120  to the suction port  135 .  
         [0041]    In this embodiment of the present invention, the lower portion of case  140  is made of clear acrylic while the upper portion that houses the fuel cell may be made of perforated, or ventilated metal. FIG. 1B shows a side view of the present invention through the open side of unit  120  wherein the fuel supply storage container  150  can be seen.  
         [0042]    [0042]FIG. 2 shows another embodiment of the present invention. In FIG. 2 the case of unit  120  is attached to the top portion of frame  110  by hinge  210 . Unit  120  provides a space for the fuel supply container on the left most portion of the unit. Elastic bumpers  220  are provided at the base of unit  120  on the left most portion to protect the fuel supply container. Latch  230  is provided at the base of frame  110  whereby cover  240  may be secured when the cover is placed in the closed position.  
         [0043]    As before, suck hose  125  is attached to the lower portion of unit  120  through the suck hose connection  135 . Blow hose connection  128  is provided for connection of a blow hose. Fuel storage container  150  can be inserted into the void located on the left most side and protected by elastic bumpers  220 .  
         [0044]    [0044]FIG. 3 shows another embodiment of the present invention, whereby unit  120  is latched onto frame  110 . In FIG. 3, latches  310  hook on to frame  110  so that frame  110  supports unit  120  while the unit is worn on the back of the operator. The blow hose connection/air filter latch  320  is utilized to latch body  140  and connect blow hose  125  to the invention. Suck hose  130  is attached to suck hose connection  135 . Power generator  330  is provided ventilation and protection by upper portion  145  and body  140  protects fuel supply container  150  when unit is attached to frame  110 .  
         [0045]    [0045]FIG. 4 shows the present invention in a uniquely designed case. Unibody  420  is attached to frame  110  by hinge  410 . Unibody  420  includes an intake vent  425  to allow air to flow over the fuel cell, which is located on the upper portion of the unit underneath the ventilation portion  430 . The side portion of unibody  420  is constructed with elastic material to absorb shock from the operator&#39;s use. Fuel storage container  150  is attached to frame  110 , as is fuel cell  460 . Unibody  420  can be lifted up to gain access to fuel supply container  150  or to fuel cell  465 , or the appliance located underneath unibody at location  460 . Unibody  420 , when closed latches to frame  110  using either magnets or mechanical means. Unibody  420  is made of acrylic to allow instructions for operation of the present invention to be attached in area  450 . Blow hose connection/filter  440  is provided as is suck hose connection  135  where suck hose  130  can be attached for operation.  
         [0046]    [0046]FIG. 5 shows the present invention wherein unit  120  is provided in a different embodiment. In FIG. 5, frame  110  extends beyond the top of unit  120  to form a handle  510 . Handle  510  can be utilized to carry the unit. Air intake vent  520  is located on body  120  and is provided on the side to allow for airflow over and through the fuel cell located underneath section  540 . An acrylic portion covers fuel container  150  and space  550  is provided for instructions. Blow hose connection/filter  530  is provided as well as suck hose connection  135  for suck hose  130 . The appliance is located underneath portion  550 .  
         [0047]    [0047]FIG. 6A shows another embodiment of a support unit for the present invention. In FIG. 6A, frame  610  is used to support the weight of the unit on the operator&#39;s back. Brackets  620  are provided to accept case  630  when case  630  is used to enclose the vacuum cleaner  660  and fuel storage container  645 . Protective cover  640  is utilized and placed on top of fuel cell  670  to protect fuel cell  670 . Protective cover  640  is corrosion resistant and perforated to allow air to flow over fuel cell  670 . Cover  630  contains protective plate  685 , wherein filter  680  can be placed interior to the protective cover  685 . Blow hose connection  690  is modified to accept filter  680  during operations when vacuum cleaner  660  is utilized as a vacuum cleaner. During operations wherein vacuum cleaner  660  is utilized as a blower, hose  625  can be connected to blow hose connection  690 . When body  630  is slid in through bracket  620 , a magnetic latch  695  is utilized to secure body  630  to frame  610  in bracket  620 . Hinge  635  is provided on the vacuum cleaner side of unit  600 , wherein body  630  may be swiveled opened to gain access to the contents therein.  
         [0048]    Protective cover  685  contains air vents to allow air to pass through the protective cover. Additionally, protective cover  685  can be designed to allow for various methods of removal to gain access to either the filter  680  or blow hose connection  690  with hose  675 . As shown in FIG. 6B, protective cover  685  can be attached by hinge either at the top to flip up, at the bottom allow it to flip down, or it can be attached with a latching system so that the entire protective cover may be removed. When not employed over blow hole connection  690 , filter  680  can be stored as shown under another protective cover.  
         [0049]    [0049]FIG. 7 shows the construction of protective portion  640 . The top perforated portion  710  is connected to U-shaped body  720 , which is also perforated. Once connected, body  720  is attached to either frame  610  or brackets  620  of FIG. 6A so that it is secured to protect fuel cell  670 . In order to protect the fuel cell,  720  is attached using a nut and bolt, or screw mechanism.  
         [0050]    [0050]FIG. 8 shows an oblique view of an embodiment of the present invention. Protector  720  is attached on top of body  885 . The fuel cell is protected by  720  and fits underneath it on top of the contents located inside body  885 . Air vent  810  is located on either side of protector  720  to allow airflow across the fuel cell. Frame  830  is attached to the contents interior to  885  and  720 , including the fuel container  850 , fuel regulator  860  and appliance  870 . Protective cover  880  is attached to cover  885  to protect both the air filter and blower/air filter connection port. A clear window,  840 , provides the operator with a view of fuel container  850  and regulator  860 .  
         [0051]    [0051]FIG. 9 shows an embodiment of the present invention as worn by an operator. Unit  900  is attached to a frame  905 , which is supported on the shoulders of the operator. Attached to frame  905  is the electrical power-generating unit or fuel cell  910 , a fuel storage unit  920  and a fuel regulator  935 . The electrical power generating unit provides power to an electrical appliance, in this case a vacuum cleaner  930  which is located behind the fuel cell and closest to the operator in the present figure. Power may be applied in either alternating or direct current. A suction hose  940  is attached to the vacuum  930  and a handle extension  950  is attached to the hose for operator use. Port  960  is provided to allow the operator to attach a hose thereto for the option of blowing rather providing a vacuum.  
         [0052]    [0052]FIG. 9A shows a top view of the embodiment of the present invention shown in FIG. 9. In FIG. 9A two fuel storage units  920  are located on either side of the electrical appliance, in this case a vacuum cleaner  930 . Fuel cell  910  is located exterior to the vacuum relative to the operator.  
         [0053]    [0053]FIG. 10 shows a composite diagram of an embodiment of the present invention. Frame  1010  has shoulder straps  1015  attached thereto, in order for an operator to wear the frame. Electric power generator  1040  is vertically mounted to a support block  1045 . Fuel supply container  1050  and regulator  1055  are attached to the support block and located underneath the generator  1040  and appliance  1060 . Support block  1045  also contains certain electronics, which monitor the electrical fuel generation. Electric generator  1040  is attached to frame  1010  using clamps  1020  and steel plate  1030 . Clamps  1020  are attached to steel plate  1030  using screws  1023  which attach the plate to the generator at support units  1032 . Clamps  1020  are then attached to frame  1010  and tightened using screws  1022 .  
         [0054]    Electrical appliance  1060  is attached to frame  1010  using clamps  1070  which are similar to clamps  1020 . Screws similar to  1022  are used to clamp the electrical appliance  1060  to frame  1010 . In this case electrical appliance  1060  is a vacuum cleaner with hose  1075 , which is coupled to the electrical appliance  1060  using the suction hose port  1065 .  
         [0055]    [0055]FIG. 11 shows an electrical wiring schematic drawing for the electrical appliance, in this case a vacuum cleaner, utilized in an embodiment of the present invention. Electrical power supplied from the electrical power generating unit is supplied at connection point  1110 . Upon electrical power being supplied, the “plug in” light  1120  will illuminate to give the operator indication that electrical power is available to the appliance. Upon power being applied, motor  1134 , which can be wound in either AC or DC mode depending on the type of power being supplied from the power generator, is available for operation. Thermistor,  1132 , is provided to provide indication of an over temperature indication whereupon “over temperature” indicator  1138  will illuminate if thermister  1132  is closed.  
         [0056]    Additionally various switches are provided so that the user has an indication as to whether a bag present or the bag is full. Switch  1128  is closed when the bag is present. Switch  1124  will remain closed if the bag is not full. Switch  1122  is provided so that the operator can turn on or turn off the vacuum cleaner as desired. If the bag is full in the vacuum cleaner, switch  1124  will open thereby providing electrical current to “bag full” light  1126 , which will illuminate. Additionally if no bag is present, switch  1128  will remain open whereby “no bag” light  1130  will illuminate.  
         [0057]    [0057]FIG. 12 shows another embodiment of the present invention as worn by an operator. Frame  1202  is worn by the operator. Fuel storage container  1205  is attached to the frame and connected to the electrical generator  1212  through regulating system  1210 . Vacuum cleaner  1215  is electrically connected to the electrical fuel generator  1212  and to remote switches on hose  1225 , whereby the operator is able to turn on the vacuum cleaner and perform vacuum operations using the switches and hose  1225 . Blowhole/filter connection  1220  is provided to allow the operator to utilize the vacuum cleaner as a blower. In FIG. 12, the protective cover  1230  is provided over the top of electrical generator  1212 .  
         [0058]    [0058]FIG. 12A shows electrical generator  1212  without cover  1230 . Electrical generator  1212  is attached to frame  1202  via brackets  1203  and standoffs  1204 . Electrical generator  1212  is a hydrogen fuel cell capable of generating 20 amps at 48 volts DC, which is 960 watts of power. Additionally, the electrical generator is electrically connected to appliance  1215 , in this case a vacuum cleaner, via the electrical connections  1213 . This illustration shows the blowhole/air filter connection  1220 . Fuel supply container  1205  is not installed in this view of this embodiment of the invention.  
         [0059]    [0059]FIG. 13A shows theis embodiment of the present invention in a modified form. In the present invention, straps  1305  are attached to frame  1310 . Straps  1305  are worn by the operator to allow the operator to carry the present invention. On strap  1305  is control unit  1340  which allows the operator remotely to turn on or turn off the vacuum cleaner and the fuel cell. The base of frame  1310  provides two legs  1395  which are used to support the unit in an upright position, and allow the unit to stand upright on a level surface. Brackets  1330  and  1332  are provided to attach various components to the frame  1310 . Electrical generating unit  1315  is attached to bracket  1332 , and fuel container  1320  is attached to frame  1330 .  
         [0060]    Regulating unit  1325  is provided to regulate fuel flow to the electrical generating unit. Additionally, appliance  1334  is attached to the frame to complete this embodiment of the present invention. Strap  1335  is used to hold fuel container  1320  in place.  
         [0061]    [0061]FIG. 13B shows a fuel container bracket used in this embodiment of the present invention. Bracket  1330  includes straps  1335 , which hold the fuel container into the bracket. Elastic piece  1328  is provided to is allow the fuel container to sit within the bracket and to absorb mechanical shocks to the system, minimizing those shocks that are transferred to the fuel container. Bolt  1326  attaches bracket  1330  to frame  1310  in order to secure the fuel container holding device.  
         [0062]    [0062]FIG. 13C shows a rear view of the present invention. Frame  1310  is provided for support of electric fuel generator  1315 , fuel supply container  1320 , and electric appliance  1340 , in this case a vacuum cleaner. Fuel container support bracket  1330  supports fuel container  1320  which is secured by strap  1335 .  
         [0063]    Elastic support  1328  reduces shock to fuel supply container  1320 . Fuel gauge  1334 , which is attached to fuel regulating system  1325 , provides the operator with an indication of the pressure and thus the amount of fuel remaining. Electrical generating unit  1315 , which receives fuel from fuel container  1320  via fuel regulator  1325 , is attached to brackets  1332  and electrically connected to appliance  1340  through electrical connections  1380 . Blowhole connection/air filter holder  1370  is provided for the operator to use the appliance as a blower. The base of frame  1310  provides two legs  1395  and a third leg  1390  so that the unit will stand on a level surface.  
         [0064]    Referring to FIGS.  13 A through FIG. 13C, in order to start the system the operator should proceed as follows. The operator should check that the red power switch on unit  1340  on strap  1305  is in the off position. Next, the operator should open the shut off valve at the pressure regulating unit  1325  completely. This will take several complete counter clockwise rotations of the black plastic knob which is shown in FIG. 14A as knob  1408 . The operator will typically will need to open the main enclosure door to gain access to the shut off valve.  
         [0065]    Upon closing the enclosure doors, the operator should put the backpack on the operator&#39;s shoulders. This is most easily accomplished by placing the backpack on the edge of the table and stepping backwards into the backpack. By adjusting shoulder straps  1305  for comfort and securing the raised harness  1306 , the operator is able to help reduce the load on the operator&#39;s shoulders. Next the operator should attach any vacuum accessories that the operator will be using, such as a suction hose.  
         [0066]    For normal vacuum operation, the operator should attach the accessory hose to the vacuum port at the bottom of the backpack. If the operator chooses to use the backpack as a blower, the operator needs to remove the filter from the exhaust port  1370  and connect the hose thereto. Next the operator shall turn on the red power switch located on the strap mounted control panel  1340 . The operator should hear certain pneumatic valves opening and hydrogen gas being purged while the electrical fuel generating unit is slowly ramping up to full power. Shortly thereafter, power will reach to the vacuum system and the operator can use the vacuum normally. After the system has been warmed up, approximately 30 seconds after systems start, the fuel cell cooling fans  1560  as shown in FIG. 15A will speed up and the operator will notice a significant increase in fan and vacuum sound.  
         [0067]    In order to stop the system the following steps should be used. First, the operator should turn off the red power switch located on unit  1340 . The fuel cell will power down and the voltage at the fuel cell clamps will fall to 0 volts DC within a few minutes. Next the operator should detach all vacuum cleaner accessories from the vacuum unit  1340 . Next the operator should remove the backpack from the operator&#39;s shoulder, and finally close off the shut off valve at the pressure regulating unit by turning it clockwise until it stops.  
         [0068]    [0068]FIG. 14A shows a close up of a fuel regulating unit for an embodiment of the present invention. Fuel container  1410  is connected to regulating unit  1400 . A fill cap  1402  is provided in order to fill the fuel storage container without removing the storage container from the regulating unit. Pressure gauge  1404  is provided in order to provide an indication of the amount of fuel remaining in fuel container  1410 . Shut off valve  1408  is provided in order to cut the flow of fuel to the electrical generator, either to secure the electrical generation unit or to store the present invention for long periods of time and retain the fuel contents within the container. Fuel outlet valve  1406  is provided in order to connect the fuel regulator to the electrical generation unit.  
         [0069]    [0069]FIG. 14B shows a schematic of this embodiment of the present invention with fuel outlet hose connected thereto to provide fuel to the electrical generation unit. Pressure gauge  1404  is provided to indicate the pressure within the fuel container. Fuel outlet valve  1406  is provided as the male end for fuel tube  1412  which has female end  1414 . Fuel tube  1412  has enough length to connect to the power generation unit via the female end  1416 .  
         [0070]    [0070]FIG. 14C is provided to show fuel tube  1414  connected to the fuel container via the regulating system. Fuel tube  1412  is connected to the pressure regulating unit via connection  1414 . Fuel tube  1412  runs the entire length of the fuel container to reach the electrical generation unit.  
         [0071]    [0071]FIG. 15A shows a side view of the electrical generation unit. Fuel cell  1570  provides for various electrical connections to the appliance and batteries as will be explained below. Fan  1560  is provided to ensure smooth airflow over the fuel cells. Battery charging ports  1530  and  1540  are provided to recharge the fuel cell batteries as necessary. Female connections  1560  and  1550  are provided to connect to an electrical appliance. Additional female connections are provided in connections  1530  and  1540  for an external battery charging of the fuel cell battery. The fuel cell will contain microprocessors for more efficient operations. Connector  1510  is provided to provide a switched input to start the microprocessor. Jack  1505  provides battery voltage to the remote operating device  1340  which is located on the strap. Electrical jack  1515  is provided to provide switched power to the electronics of the fuel cell during starting. Finally, an additional lead for the LED battery indicating unit is provided at wire  1520 . FIG. 15B shows the on/off switch connected to electrical generating unit.  
         [0072]    Refer now to FIG. 16, which shows the perforated cover for the fuel cell along with the location of the battery charging jacks for recharging the fuel cell batteries. The fuel cell batteries should last for at least 25 starting procedures. If the system fails to start up, this could be a sign that the batteries need to be recharged. In order to recharge the batteries, the system must be off. Next the operator should attach an external DC power supply to the positive and negative charging jacks  1602  and  1604  on the fuel cell system. Next the operator should adjust the supply to an output voltage of 11.5 volts DC and a maximum current of 0.5 amps. Next the operator should allow the batteries to charge until the current drops to about 0.2 amps. This should take less than 2 hours. Upon completion of the charge, the operator should disconnect the external power supply.  
         [0073]    If the operator decides to store this embodiment of the present invention, the following guidelines are provided. The operator should evacuate the fuel container bottles  1320  by using the discharge tube. Next the operator should keep the system locked in its protective shipping container when not in use. Next the operator should use tape to secure the red power switch in the off position. If the power switch is actually switched on while in storage, the LED indicators will discharge the onboard control batteries and the operator will need to recharge the batteries prior to use.  
         [0074]    [0074]FIG. 17A shows a front view of the electrical power generating unit  1570 . Fuel inlet port  1702  is provided to connect the fuel tube to the electric power generating unit. This allows fuel to be carried from the fuel container to the power generating unit. FIG. 17B provides a back view of the electrical power generating unit. In FIG. 16B two hydrogen outlet ports,  1704  and  1706 , are provided for periodic purging. Rechargeable batteries  1505  can be seen in both Figures. Rechargeable batteries  1505  are connected at various locations on the underneath portion of the electrical generating unit to provide for power during start up.  
         [0075]    Having thus described our invention, what we claim as new and desire to secure by Letters Patent is set forth in the following claims.

Technology Category: h