U.S. patent application number 14/295812 was filed with the patent office on 2014-10-30 for modular thermal molecular adhesion turbine.
The applicant listed for this patent is Sol-Electrica, LLC. Invention is credited to Gary R. Kerns, Bret M. Lee.
Application Number | 20140321976 14/295812 |
Document ID | / |
Family ID | 51789382 |
Filed Date | 2014-10-30 |
United States Patent
Application |
20140321976 |
Kind Code |
A1 |
Kerns; Gary R. ; et
al. |
October 30, 2014 |
MODULAR THERMAL MOLECULAR ADHESION TURBINE
Abstract
A novel molecular adhesion turbine includes improved disc array,
flywheel, housing and nozzle structural designs each adapted to
exhibit molecularly repulsive and/or molecularly adhesive
properties depending upon the particular working fluid used with
the turbine. Backflow turbulence and drag forces are reduced, and
turbine operating efficiencies are improved as a result. The
invention includes an insulating enclosure, which provides added
noise cancellation and heat capture benefits. The new molecular
adhesion turbine is modular and thus capable of sealable
applications, including connecting the turbine to a bladed steam
turbine of the type typically used in power plants for heretofore
unrealized downstream energy efficiencies.
Inventors: |
Kerns; Gary R.;
(Worthington, IN) ; Lee; Bret M.; (Worthington,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sol-Electrica, LLC |
Worthington |
IN |
US |
|
|
Family ID: |
51789382 |
Appl. No.: |
14/295812 |
Filed: |
June 4, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13871365 |
Apr 26, 2013 |
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14295812 |
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14262773 |
Apr 27, 2014 |
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13871365 |
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Current U.S.
Class: |
415/90 ; 415/119;
415/182.1; 415/202 |
Current CPC
Class: |
F01D 1/36 20130101 |
Class at
Publication: |
415/90 ;
415/182.1; 415/202; 415/119 |
International
Class: |
F01D 1/36 20060101
F01D001/36 |
Claims
1. A turbine comprising: a hollow housing with walls adapted for
supporting a rotatable shaft inside the housing, said walls having
an inlet port and an outlet port formed therein so that flowable
fluid can pass in and out of the housing; a disc array mounted on
the shaft for capturing energy from the fluid to rotate the shaft;
and a pair of flywheels each mounted on the shaft in book end
fashion with respect to the disc array to form a barrier between an
interior wall of the housing and the disc array to prevent
frictional interaction of the flowable fluid between the flywheel
and the interior wall.
2. A turbine according to claim 1, wherein each flywheel includes,
with respect to the flowable fluid, an internal molecularly
adhesive surface and an external molecularly repulsive surface.
3. A turbine according to claim 1, wherein the disc array comprises
a plurality of equally spaced discs each having opposite sides that
converge to define a parabolic tip.
4. A turbine according to claim 3, wherein at least two of said
turbines are operatively connected together by a common shaft to
form a modular turbine system.
5. A turbine according to claim 3, wherein each side of each disc
has, with respect to the pressurized fluid, an outer molecularly
adhesive area and an inner molecularly repulsive area, the
parabolic tip is molecularly repulsive with respect to the
fluid.
6. A turbine according to claim 1, further comprising a tunable
outlet port device connected to the outlet port for adjusting the
rate the fluid flows out of the housing.
7. A turbine according to claim 6, wherein at least two of said
turbines are operatively connected together by a common shaft to
form a modular turbine system, and the tunable outlet port device
is adapted to be capable of adjusting the rate the fluid flows out
of at least one housing of said system.
8. A turbine according to claim 1, further comprising a nozzle
connected to the inlet port, the nozzle has an interior passage
with a convergent portion and a divergent portion.
9. A turbine according to claim 8, wherein the divergent portion of
the interior passage of the nozzle and a long axis of said passage
define at least two angles for canceling acoustic resonance
frequency peaks of a flowable fluid.
10. A turbine according to claim 8, wherein the interior passage of
the nozzle has a wall that is adapted to be molecularly repulsive
with respect to the flowable fluid.
11. A turbine according to claim 1, wherein at least two of said
turbines are operatively connected together by a common shaft to
form a modular turbine system.
12. A turbine according to claim 1, further comprising an insulated
enclosure, which includes an interior assembly that covers the
turbine for noise cancellation and an exterior assembly that covers
the interior assembly for heat capture.
13. A turbine according to claim 1, wherein at least two of said
turbines are operatively connected together by a common shaft to
form a modular turbine, and a working flowable fluid source is
operatively connected to an inlet port upstream of said modular
turbine.
14. A turbine according to claim 13, further comprising an exhaust
capture means operatively connected to the outlet port downstream
of said modular turbine.
15. A turbine comprising: a hollow housing with walls adapted for
supporting a rotatable shaft inside the housing, said walls having
an inlet port and an outlet port formed therein so that flowable
fluid can pass in and out of the housing; a nozzle connected to the
inlet port having an interior passage with a convergent portion and
a divergent portion; discs mounted on the shaft for capturing
energy from the fluid to rotate the shaft, each of the discs has
opposite sides that converge to define a parabolic tip, and a
central opening formed in each disc for the passage of flowable
fluid exiting said housing, spokes intersect each of the openings
and converge at a hub which receives the shaft, each of said spokes
has a tapered spoke edge for cutting through and directing the
flowable fluid passing through the openings; a pair of flywheels
each mounted on the shaft in book end fashion with respect to the
disc array, the discs and the flywheels are adapted for receiving
connection elements so as to rotate as a single unit on the shaft;
and a tunable outlet port device connected to the outlet port for
adjusting the rate the fluid flows out of the housing.
16. A turbine according to claim 15, wherein each flywheel
includes, with respect to the flowable fluid, an internal
molecularly adhesive surface and an external molecularly repulsive
surface, the tapered spoke edge of each spoke is molecularly
repulsive with respect to the fluid.
17. A turbine according to claim 15, wherein at least two of said
turbines are operatively connected together by a common shaft to
form a modular turbine system.
18. A turbine according to claim 15, wherein each side of each disc
has, with respect to the pressurized fluid, an outer molecularly
adhesive area and an inner molecularly repulsive area, the
parabolic tip is molecularly repulsive with respect to the
fluid.
19. A turbine according to claim 15, Wherein the divergent portion
of the interior passage of the nozzle and a long axis of said
passage define at least two angles for canceling acoustic resonance
frequency peaks of a flowable fluid.
20. A turbine according to claim 18, wherein at least two of said
turbines are operatively connected together by a common shaft to
form a modular turbine system, and the tunable outlet port device
is adapted to be capable of adjusting the rate the fluid flows out
of at least one housing of said system.
21. A turbine according to claim 15, further comprising an
insulative enclosure, which includes an interior assembly that
covers the turbine for noise cancellation and an exterior assembly
that covers the interior assembly for heat capture.
22. A turbine according to claim 15, wherein at least two of said
turbines are operatively connected together by a common shaft to
form a modular turbine, and a working flowable fluid source is
operatively connected to the inlet port upstream of said modular
turbine.
23. A turbine according to claim 22, further comprising an exhaust
capture means operatively connected to the outlet port downstream
of said modular turbine.
24. A turbine according to claim 23, further comprising vacuum
means in fluid communication with the modular turbine for creating
at least a partial vacuum in a housing of the modular turbine.
Description
REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 14/262,773, filed Apr. 27, 2014, now pending,
which is a continuation-in-part of application Ser. No. 13/871,365,
filed Apr. 26, 2013, now pending.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to the field of
systems fir deriving power from moving fluids and, more
particularly, to a blade less turbine system.
[0003] Impeller systems for deriving mechanical power from moving
fluids are known. U.S. Pat. No. 1,061,206, which I hereby
incorporated by reference, describes an apparatus for converting
moving fluids to energy by adhesion to a central rotor comprising a
set of flat discs with spaces between each disc. As disclosed in
U.S. Pat. No. 1,061,206, such apparatus are also operable as fluid
pumps. The discs have flat edges and are secured for rotation on a
shaft. Working fluid enters an inlet passage tangentially aligned
with the discs. The fluid adheres to the discs transferring its
energy to the discs to rotate the shaft.
[0004] Each disc has a central opening for the moving fluid to
escape from the housing that contains the disc array and shaft. On
the other hand, when the discs are rotated by means of an external
motor, fluid is elected by the discs through a fluid outlet aligned
tangentially with the discs. The mechanical features of this
bladeless turbine system and their corresponding inefficiencies are
known. The discs are subject to erosion, wear and warping caused by
the extreme heat and supersonic rate of flow of the moving fluid
over time.
[0005] Turbulence is another problem. The moving fluid is typically
in a highly pressurized saturated gaseous state. Imperfections in
the surfaces of the discs, the housing and other fluid-directing
components, therefore, produce turbulence and hence drag on the
system. One example is the fluid intake passage. At
(sub/super)sonic flow rates, the working fluid often produces
harmonic wave patterns at the intake, which disrupts flow and
causes turbulence. The physical properties of the particular moving
fluid also impact overall system efficiency.
[0006] Fluid viscosity contributes to the fluid particle size that
manifests between the rotating discs. Fluid viscosity and adhesion
control the rate at which the fluid moves through the system as
well as system energy yields. The mechanical properties of the
system such as the shape of the disc, disc spacing and disc
mounting/connective structures, for example, should thus be
carefully engineered so that the system is optimally efficient
regardless of the particular moving fluid used. Another factor
influencing the efficiency of a bladeless turbine is the rate at
which the fluid exits the stator housing.
[0007] Upon start up of the turbine the moving fluid exits the
housing through the outlet ports at a slower rate and the disc
array functions at a slower RPM rate than when the turbine is fully
operational. Backflow issues are therefore common at start up as a
result. As the system picks up speed, the fluid exit rate
increases, backflow begins to subside and the pressure of the
system equalizes. Initial turbine function and backpressure,
however, often delay the time it takes to achieve system
equilibrium.
[0008] Other constant tormentors such as radiant heat escape and
system vibration constantly discount turbine system energy yields
as well.
[0009] There is, therefore, a need for a more efficient bladeless
turbine. The present invention is directed toward this need.
SUMMARY OF THE INVENTION
[0010] The invention is a modular thermal molecular adhesion
turbine for converting moving fluids into mechanical or electrical
energy. The new turbine includes an upper removable stator housing
with an open horizontally located chamber to accept various nozzle
designs and inserts. Various nozzle designs are interchangeable
depending upon the temperature, pressure, pounds per hour of
working fluid variations, or other factors requiring alternate
inlet nozzle designs. The lower stator housing is fastened to a
fixed platform and contains low fiction bearing assemblies at each
end of the housing to support the main rotor shaft, which is at a
horizontal plane in reference to the system configuration. Both
upper and lower stator housings have a half circular port at the
central exterior and when joined provide a full circular port to
exhaust the working fluid from the interior of the stator housing.
This fixed port size is maximized to match the full diameter of the
exit holes found in the central area of the discs.
[0011] Fitted to the main rotor shaft is a plurality of flat
polished discs, which have parabolic end edges instead of fiat and
which are coated in repel the incoming working fluid. This
modification prevents pitting and erosion of the disc edges while
channeling more working fluid into the gap spacing between each
disc. Each disc has a male notch that is inserted into the
longitudinal female notch running along the length of the central
shaft. During the turbine operation the main rotor shaft imparts
mechanical rotational power to the preferred electrical conversion
source. A spacing washer is positioned between each disc to provide
a uniformity of gaps between each. The discs are also coated on
both flat sides with greater working fluid adhesion properties near
the exterior working area of the disc and working fluid repulsion
coating on the surface area nearest the center of the disc.
[0012] These coatings increase the adhesion properties of the
working fluid and allow the working fluid to escape through the
center holes in each disc with no frictional losses. As mentioned,
each disc has openings located near the center with several central
spokes supporting the discs and ending in the center to slip onto
the main rotor shaft. Each disc spoke has at tapered edge which
prevents pitting and erosion when the rotor disc set is operational
at very high rotations per minute and working fluid is passing
through the internal exhaust channel created by the disc set. The
discs have openings near the center so that exhausting working
fluid can flow to either side of the internal disc set and exhaust
through the turbine stator housing at each end. At the end of each
disc set is a single flywheel, which is thicker than the interior
discs.
[0013] Each flywheel has a greater diameter than the discs and has
a male notch at the flywheel disc edge fitting into a recessed
matching female notch in the turbine stator housing inhibiting the
working fluid from coming in contact with the outer flywheel disc
surface and the turbine stator wall. The exterior of the flywheel
is coated with material to act as a repellent to the working fluid
preventing any frictional losses from the interaction of the
flywheels, working fluid and turbine stator walls.
[0014] The flywheels and discs have a series of small holes close
to half the radius length of the discs. Each disc has matching
holes in the flat surface area. A series of small diameter
stabilization rods fit through each series of disc holes, terminate
and attach at each exterior wall of both flywheels and thus, the
flywheels and discs rotate as a single unit on the shaft.
[0015] In another aspect of the invention, at the exterior of each
side of the turbine stator housing is mounted a tuned port
apparatus that can open fully to match the turbine stator exhaust
port or can incrementally restrict the exit exhaust hole size to
help with leveling internal back pressure during the beginning
start up time required by the turbine to reach operational
rotations per minute. The working fluid then travels into both
exterior exhaust port chambers and exits the system either into the
atmosphere, a closed-loop or a complementary condensing unit
providing a partial vacuum.
[0016] In another aspect, at least two of the turbines are
operatively connected together by a common shaft to form a modular
turbine system. A working flowable fluid source, such as a bladed
steam turbine, may be operatively connected to an inlet port
upstream of the modular turbine system, and an exhaust capture
means may be operatively connected to the outlet port downstream of
the modular turbine.
[0017] In yet another aspect, an insulative enclosure is provided,
which includes an interior assembly that covers the turbine for
noise cancellation and an exterior assembly that covers the
interior assembly for heat capture.
[0018] One object of the invention is to provide a more efficient
bladeless turbine. Related objects and advantages of the invention
will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a cutaway side view of the nozzle receptacle and
internal rotary discs.
[0020] FIG. 2 is a cutaway of an embodiment of the straight tube
nozzle insert.
[0021] FIG. 3 is a cutaway of an embodiment of a
convergent/divergent nozzle insert.
[0022] FIG. 4 is a cutaway view of an embodiment of the
convergent/anharmonic nozzle insert.
[0023] FIG. 5 is a front view of the nozzle connector flange ring,
connector holes and high-pressure o-ring.
[0024] FIG. 6 is a front view of a single internal rotating turbine
disc.
[0025] FIG. 7 is a front view of the inter-disc spacer.
[0026] FIG. 8 is a close up view of a disc spoke tapered edge.
[0027] FIG. 9 is a front view of a single side of an embodiment of
the rotor disc of the invention showing the molecular adhesion and
repulsion coating areas.
[0028] FIG. 10 is a diagrammatic enlarged cutaway view of a partial
internal rotor disc array showing disc gap and specialized disc
tip.
[0029] FIG. 11 is a front and partial side view of the end flywheel
disc with turbine housing notch and coating area facing the
internal disc array.
[0030] FIG. 12 is a cutaway view of a single complete modular
turbine assembly.
[0031] FIG. 13 is a cutaway view of a typical modular set of
turbines connected together.
[0032] FIG. 14 is a side view of the modular turbine enclosure
housing and mounting block.
[0033] FIG. 15 is a top cutaway view of a modular turbine set with
multiple inlet manifold connections from one working fluid input
port.
[0034] FIG. 16 is a side view of the external tunable exhaust port
from the turbine stator housing for disc exhaust.
[0035] FIG. 17 is an internal side view of the tunable exhaust
apparatus without the gear housing cover.
[0036] FIG. 18 is a cutaway front view of an embodiment of the
turbine noise cancellation and thermal heat capture enclosure
diagrammatically shown with a turbine.
[0037] FIG. 19 is a diagrammatic top cutaway view of half of the
two-stage modular turbine array working fluid pathway through the
complementary external exhaust capture apparatus.
[0038] FIG. 20 is a diagrammatic top cutaway view of a bladed steam
turbine connected to multiple condensing units.
[0039] FIG. 21 is a diagrammatic top cutaway view of a bladed steam
turbine connected upstream of the modular turbine showing the
modular turbine array stages one and two with complementary
condensing unit and additional modular condensing units connected
downstream of the modular turbine.
DETAILED DESCRIPTION OF INVENTION
[0040] For the purposes of promoting an understanding of the
principles of the invention, specific embodiments have been
described. It should nevertheless be understood that the
description is intended to be illustrative and not restrictive in
character, and that no limitation of the scope of the invention is
intended. Any alterations and further modifications in the
described components, elements, processes, or devices, and any
further applications of the principles of the invention as
described herein, are contemplated as would normally occur to one
skilled in the art to which the invention relates.
[0041] In this description the terms "working fluid," "flowable
fluid" and "moving fluid" shall have the same meaning, namely a
fluid or gas used with the invention to derive energy. Water in the
form of saturated steam has been used in this description as only
one such example.
[0042] The invention also contemplates the recovery of heat and
flowable fluids from both renewable and non-renewable sources where
they are otherwise wasted so the may be captured and used in
connection with the invention. Heat produced during manufacturing
processes and geothermal steam serve as examples.
[0043] With reference to FIGS. 1-4, the modular thermal molecular
adhesion turbine, herein known as `turbine` begins with the
introduction of a working fluid into a nozzle inlet opening 103. A
straight tube nozzle 205 is shown in a cutaway view showing the
working fluid flow direction upon entering nozzle inlet opening 103
and exiting through nozzle exit 203 to impart action through
working fluid adhesion upon the internal disc array 1203 (FIG. 12)
and each singular disc 106. The interior nozzle coating 204 is a
molecular repulsion material to reduce molecular adhesion drag and
frictional temperature increases. The area of initial working fluid
contact with the internal disc array 1203 occurs at the back-end
half of nozzle 203. The turbine stator housing 105 has a receptacle
104 or replaceable nozzle shaft cavity, which allows for easy
replacement of various nozzle types.
[0044] Each removable nozzle design attaches to the turbine stator
housing flange 102 with the corresponding nozzle flange 101 and is
fastened through a set of hardware with acceptable matching holes
503, as shown in FIG. 5. A high-pressure gasket 502 is inserted
between the turbine stator Range 102 and each replaceable nozzle
flange 101. In one embodiment, a high pressure saturated steam
gasket 502 made of inorganic fibers with a nitrite binder is used
to seal the nozzle flange 101 to the corresponding housing flange
102 using high strength threaded studs with steel washers and nuts
and barrier dielectric washers and bolt sleeves.
[0045] There are many nozzle designs that can be made adaptable to
the turbine stator nozzle shaft cavity 104. In one embodiment, a
straight tune nozzle is used. In a more preferred embodiment, a
convergent/divergent nozzle may be used, and most preferably, a
specially engineered convergent/anharmonic nozzle is applied. A
typical straight tube nozzle 205 is used when the working fluid has
sufficient fluid power and speed of movement to bring the internal
disc array 1203 to the desired operational rotations per minute.
The working fluid travels through the fluid flow path 201 of the
straight tube housing shell 202 and enters the turbine stator
housing 105 unimpeded.
[0046] In another embodiment, a convergent/divergent nozzle design,
as shown in FIG. 3, has a working fluid flow chamber 301 housed in
a rigid shell 302 that allows the working fluid to enter at nozzle
inlet opening 103 and travel through nozzle exit 301 into the
turbine stator housing 105. This design is for lower power and
fluid speeds imparted in the working fluid used. The
convergent/divergent nozzle design has an internal flow reduction
neck 303, which increases the speed of the working fluid from
subsonic to supersonic speeds. The convergent/divergent nozzle
design 304 is customized for constant working fluid speeds and does
not work at its most efficient with variable or intermittent
working fluid speeds.
[0047] In one embodiment, the working fluid is saturated steam. In
that embodiment, a convergent/anharmonic nozzle 406 is preferably
constructed using a solid rod stock of high temperature steel such
as 17-22-XX-grade steel. The solid rod stock may be CNC core
drilled in stages to provide the correct internal multiple-tapering
sections and end boring to produce a structurally sound replaceable
nozzle flange 101. The reduction neck compresses the incoming
working fluid at subsonic speeds and releases the working fluid at
supersonic speed prior to entering the stator housing 105. The
multiple stepped flow chambers 402, 403, and 404 do not allow the
working fluid to produce harmonic wave patterns inside the flow
chamber 401 and thus prevent turbulence.
[0048] The outer and inner diameters of the anharmonic rigid shell
405 are formed to compensate for the incoming steam pressure and
flow characteristics to ensure proper reduction of the internal
working fluid turbulence. A thicker shell with an increased outer
diameter is required to handle more highly pressurized working
fluid while the opposite is the case with lower pressure fluid. The
size of the inner diameter of the rigid shell therefore may be
predetermined accordingly. Referring to FIG. 4, a phantom line
depicts the portion of the long axis that extends the length of the
anharmonic extension chamber of the nozzle. In one embodiment the
divergent portion of the interior passage of the nozzle and the
long axis of the passage define at least two angles for canceling
acoustic resonance frequency peaks of the working fluid. Turbulence
typically produced by the resonance of pressurized fluid in turbine
applications cannot thus multiply exponentially. In another
embodiment, the divergent portion of interior passage of the nozzle
defines three angles. Referring to FIG. 4, the passage angles or
"steps" are defined according to the following.
[0049] Steps, 402 {S.sub.1}, 403 {S.sub.2}, & 404 {S.sub.3}
[0050] A.sub.x=total length 407, 2 decimal place percentages
represented in embodiment
[0050]
A.sub.x={S.sub.1}.about.A.sub.x/6.9686[R\Q]+{S.sub.2}.about.1.984-
6[R\Q].times.S.sub.1+{S.sub.3}.about.2.007[R\Q].times.S.sub.2
Angular degree, V.sub.1, V.sub.2 & V.sub.3, where I.sub.1 is
the length of the inner diameter of the passage at 408 and E.sub.1
is the length of the inner diameter of the passage at 409.
((E.sub.1-I.sub.1)/2).times.15.45%=
((S.sub.1).sup.2-(cosV.sub.1.times.S.sub.1).sup.2)
((E.sub.1-I.sub.1)/2).times.27.48%=
((S.sub.2).sup.2-(cosV.sub.2.times.S.sub.2).sup.2)
((E.sub.1-I.sub.1)/2).times.27.51%=
((S.sub.3).sup.2-(cosV.sub.3.times.S.sub.3).sup.2)
[0051] When using saturated steam as the working fluid, the three
"steps" of the chambers 402, 403 and 404, as a percentage of the
total length 407, along with their corresponding angles are,
approximately: 14.35% and 8.1 degrees; 28.48% and 6.2 degrees; and
57.17% and 4.3 degrees.
[0052] With respect to this embodiment of the nozzle, the term
"steps" is used for convenience in understanding the transition in
the interior diameter of the chamber wall and is not intended to
necessarily suggest the interior wall of the chamber is not
consistently sloped or includes non-smooth annular surfaces.
Additionally, each of the aforementioned angles are defined by
extrapolating the appropriate portion of the inner chamber wall and
the long axis (shown in phantom) until they meet to define an
angle. The dissimilar non-integer related angles and corresponding
wall lengths prevent flowing fluid harmonics from being produced at
any fluid flow speed or pressure. Values, including those
corresponding to E.sub.1 and I.sub.1, are dependent upon the
particular working fluid used.
[0053] With saturated steam as the working fluid, a hydrophobic
coating is applied to the internal surfaces of the anharmonic fluid
flow chamber 401. An amorphous carbon film about 3 microns in
thickness is coated on the high temperature steel by close field
unbalanced magnetron sputter ion plating. This coating will provide
the hydrophobic properties needed to repel steam particles from
adhering to the surface of the convergent/anharmonic fluid flow
chamber 401 and provide heat and wear resistance needed for
extended operations. As the working fluid exits the selected nozzle
design it enters the interior turbine stator housing 105 and begins
imparting force on the internal disc array 1203 along the interior
disc fiat surface 601 (FIG. 6).
[0054] The disc material will be of high tensile strength metal,
plastic, alloy or composite. Internal disc material selection will
be based on compatibility with the particular working fluid type.
In the exemplary embodiment, the working fluid is saturated steam,
which interacts with the disc flat surface 601. The disc material
may be Inconel Alloy 718 which is a precipitation hardenable
nickel-based alloy designed to display exceptionally high yield,
tensile and creep-rupture properties at temperatures up to
1300.degree. F. This material is preferable when using saturated
steam as the working fluid. Based on the extremely high tensile
strength of Inconel Alloy 718 the internal disc array 1201 can be
operated at RPMs of over 100,000. Discs can be cut from flat stock
using high-speed CNC milling practices, electropolished and
mechanically buffed for an ultra smooth surface needed for higher
hydrophilic properties of the metal alloy surface.
[0055] Each internal rotating disc 601 is comprised of a polished
flat surface, interconnected multi-disc stabilization holes 602,
center disc opening for internal rotating main shaft 603, center
disc male notch 604 for main rotating shaft 1205, multiple disc
openings 606 for spent working fluid exhaust, supporting multiple
internal disc spokes 607 and tapered disc spoke edge 608. The
working fluid comes in contact With the exterior disc surface 601
and during disc rotation follows a decreasing circular path until
it reaches the disc openings 606 and exits the center of the
rotating disc array 1203 through the stator housing exhaust ports
1605 (FIG. 16). Disc opening 606 in another embodiment can be of
various disc openings 609 shapes and sizes so that a wide variety
of working fluids can exit the disc openings 606 more efficiently
traveling through the decreasing circular flow path ensuring that
low adhesion working fluids exit the disc opening 606 prior to the
point at which the working fluid causes frictional drag without
imparting additional energy to the modular thermal molecular
adhesion turbine system. This variable opening area will match the
molecular adhesion properties of the working fluid used and allow
for weaker adhesion working fluids to exit the system without the
spent working fluid causing frictional drag. The tapered disc spoke
edges 608 decrease erosion and pitting that flat surface spoke
edges would have by cutting through the internal working fluid flow
exiting the disc openings 606 instead of hitting the working fluid
at a perpendicular angle. In (FIG. 8) it is shown the parabolic tip
801 and a close up view of the spoke taper 608 in relation to the
working fluid flow path.
[0056] A specific parabolic formula generates the characteristic
tapered angle and distance from the beginning of the disc taper to
the center point of the parabolic disc tip 801 that is ideal for
the physical properties of said working fluid. Following on with
the saturated steam example, the formulaic example uses the average
steam particle size of 0.015625'' diameter and the fixed disc
thickness of 0.03125''. As the steam particle adheres to the
Inconel disc surface with a hydrophilic coating of magnesium
zirconate the wetted steam particle is pressed down and the
distance from the disc surface to the quadrant of the outer
circumference of the steam particle decreases to 0.0078125''. By
adding the thickness of both the adhered disc sides and free steam
particles flowing through the medial disc gap the sum would be
0.03125''. This gap distance, therefore, is ideal for the given
estimated average saturated steam particle size to both adhere and
impact causing rotational movement in the disc array 1203.
[0057] The preferred parabolic shape of the disc end tip for a
saturated steam application is thus obtained using formula
Y=0.6.times.(1/2X).sup.2 where Y is the thickness of the disc (in
inches) and X is the distance for the perpendicular point Y to the
center point of the parabolic disc tip. Thus, using a disc
thickness of 0.03125'' and the average water (steam) particle
diameter 0.015625 yields a tip height of 0.0375'' and a taper angle
of 4.75 degrees for a disc width of 0.03125'' and saturated steam
used as the working fluid. If compressed pressurized air were being
used as the working fluid the tip height would be greater and the
taper angle would decrease due to smaller average working fluid
particle size.
[0058] Beginning at the midpoint of the disc array 1203 each disc
601 to the left of center has the spoke taper 608 facing from the
left exiting working fluid flow likewise each disc 601 to the right
of center has the spoke taper 608 facing from the right exiting
working fluid flow. This directional taper design acts as an
additional motive force aiding the working fluids exhaust path from
the internal center disc openings 606 to the turbine stator
external exhaust ports 1605. A central disc spacer 605 is placed
in-between each disc 601 to provide uniform gap spacing 1002 (FIG.
10) between each disc 601.
[0059] When the working fluid is saturated steam, the gap spacing
1002, central disc spacer 605, gap spacing between the discs 601
and flywheels 1107 (FIG. 11), and the disc thickness should all be
0.03125''. This spacing allows for the saturated steam particles to
adhere to the disc surfaces and allow enough room for non-adhering
steam particles which are just above the planar surface of the
discs to impact the adhering steam particles thus providing contact
movement to the rotating discs 601. If compressed pressurized air
were to be used as the working fluid then the gap spacing would
decrease to 0.006125 due to the decreased molecular size of the
working fluid particles.
[0060] The gap spacing 1002 is variable in size depending on the
type of working fluid to be used. Each disc spacer 605 has a
central hole 701 (FIG. 7) which fits on the main rotor shaft 1205
to separate each disc 601 and also in-between discs next to the
flywheels 1107 (FIG. 11). Each disc 601 side has specialized
molecular adhesion and repulsion coating areas (FIG. 9) increasing
the energy imparted by the working fluid and aids in the spent
working fluid exhaust speed into the central disc openings 606. The
molecular adhesion and repulsion coatings are matched to the type
of working fluid that is used in the turbine system. The adhesion
coating area 901 is applied to the outer disc 601 so that the
maximum conversion of energy from the working fluid is
realized.
[0061] The molecular repulsion coating area 902 is applied to the
outer disc 601 so that the working fluid does not incur unneeded
frictional resistance as it exits the central disc openings 606.
The phantom line 903 of FIG. 9 identifies the barrier between the
molecular adhesion coating 901 and molecular repulsion coating 902.
The parabolic disc edges 1001 are coated with molecular repulsion
material, which directs working fluid into the disc nap spacing
1002 without frictional losses and prevents pitting and
erosion.
[0062] In one embodiment, the molecular repulsion coating for
saturated steam can be an amorphous carbon film about 3 microns in
thickness coated on the high temperature steel by close field
unbalanced magnetron sputter ion plating. For this application,
areas that may require this coating are the inner disc area 902,
disc spokes 607, disc spoke tapered edges 608, parabolic disc tips
801, 1001, interior flywheel area 1108 and the internal flywheel
inner diameter. The internal aluminum stator housing will be also
coated with a hydrophobic polymer, polytetrafluoroethylene, which
is heat resistant up to 536 degrees F. and highly wear resistant.
Areas needing hydrophilic coatings, when saturated steam is used as
the working fluid, are the inner disc area 901 and the internal
flywheel area 1104. One type of coating for high hydrophilic
properties can be plasma sprayed magnesium zirconate which also
provides a very good heat and abrasion resistant permanent
layer.
[0063] Disc array 1203 has two end flywheels 1107 that are slightly
greater in diameter than the discs 601 and are notched 1101 and
1102 at the end to fit into the female notch in the internal
turbine stator housing 105. The flywheel notch 1103 provides a
nearly complete barrier to the working fluid front entering the
area in-between the turbine stator housing 105 and the exterior of
the flywheel disc surface 1108. Frictional interaction of the
working fluid between the rotating external flywheel surface 1108
and the turbine stator housing 105 is further reduced by coating
the external flywheel surface 1108 and coating the internal turbine
stator housing walls 1003 with molecular repulsion material. The
near total reduction of frictional losses improves the overall
turbine efficiency. The molecular adhesion coating is applied to
the flywheel interior surface 1109 at area 1104 and the molecular
repulsion coating is applied to the flywheel interior surface 1109
at area 1105 and to both the flywheel spokes 1111 and flywheel
spoke tapers 1110. There is a boundary line 1106 between the two
coating areas that will vary with changes in disc diameter and the
type of working fluid used in the turbine system.
[0064] With reference to FIG. 12, a cutaway view of the entire
modular turbine assembly 1213 shows the upper half of the turbine
disc assembly housing 1201, lower half of the turbine disc assembly
housing 1202, internal rotor disc array 1203, working fluid exhaust
shell 1204, internal main rotor shaft 1205, single shaft connection
1206, rotor Shaft extension 1207 for reduction gear attachment,
then to generator/alternator 1212, external exhaust port for
working fluid 1208, external exhaust port connector flange 1209,
internal cavity of the main exhaust chamber 1210 and modular rotor
shaft interconnect dual shaft connection 1211. The working fluid
enters the upper turbine stator housing 1201 from the nozzle exit
203 and imparts energy to the disc array 1203. The working fluid
exits the central disc array 1203 through the multiple disc
openings 606 and exhausts through the turbine stator housing side
ports 1605. The working fluid then travels through the internal
cavity of the main exhaust chamber 1210 and exits the external
exhaust port 1208 into a closed-loop system, the front end expander
area of at complementary external exhaust capture apparatus unit
1914 (FIG. 19) or into the atmosphere. The modular rotor shaft
interconnect single shaft connection 1206 can be replaced with the
modular rotor shah interconnect dual shaft connection 1211 joining
another modular turbine to the system.
[0065] An example of the modularity of the turbine is shown in
(FIG. 13) with a single unit modular turbine 1301 operatively
connected to three additional single unit modular turbine 1301
assemblies to form a final group of four turbine units 1302. Any
number of single unit modular turbine 1301 assemblies can be
connected together for use with any expanded working fluid
system.
[0066] Side view of the exterior of the modular turbine enclosure
housing including both locking bracket and mounting block are shown
in FIG. 14. This drawing identifies the assembly parts for the
exterior turbine housing, which includes the upper locking bracket
for multiple modular turbines in tandem 1401, lower turbine stator
housing flange connector 1402, upper turbine stator housing flange
connector 1403, frictionless bearing assembly 1404, mounting
bracket for bearing assembly and interconnect for base mounting
plate and upper locking bracket 1405, base mounting plate for
modular turbine array 1406 and upper turbine stator chamber
receiver for interchangeable nozzle types 1407. To connect more
than one modular turbine together, the mounting bracket for bearing
assembly and interconnect for base mounting plate and upper locking
bracket 1405 is removed then additional modular single turbine
units 1301 are added. Also, the base mourning plate for modular
turbine array 1406 will be customized to it additional modular
single turbine units 1301 when added. The frictionless bearing
assembly 1404 reduces shaft friction and improves efficiency.
[0067] When multiple modular single turbine units 1301 are
connected together to form a group, for example a four unit modular
turbine set 1302, a custom manifold 1507 (FIG. 15) is required.
This drawing comprises the interconnects for the manifold 1507,
upper housing 1201 and the lower housing 1202 all being joined
together by the upper locking bracket 1401 through the upper
locking bracket holes 1501 for connection to the upper turbine
stator housing flange 1403 and manifold 1507, external exhaust port
chamber 1502, multiple exhaust manifold connector flange 1503 which
interconnects with nozzle insert connector flange 101 and turbine
stator housing nozzle chamber flange 102, multiple exhaust manifold
chamber shell 1504, working fluid path prior to turbine nozzle
inlet 1505, working fluid input port 1506 and the final customized
manifold 1507. The manifold 1507 is connected by the manifold
flange 1503 to both the nozzle flange 101 and the turbine stator
housing flange 102 by through-hole fasteners and each flange has an
inserted high pressure o-ring 502 between each flange connection.
Working fluid enters the manifold 1507 through the manifold input
port 1506 and is distributed evenly to each working fluid path 1505
prior to each turbine nozzle inlet 103.
[0068] The upper exterior turbine stator housing 1204 allows for
mounting the tunable exhaust base plate 1703 (FIG. 17) which holds
in place the nine tuning blades and provides fastening points for
the minor rotating tuning gear 1701, the main gear 1705, rotational
expander channels 1706 for tuning blades 1602 and slider pegs 1708.
The main gear 1705 has matching sprocket teeth 1704 interacting
with the minor rotation tuning gear sprocket teeth 1702 to adjust
the rotational blades 1602 for varied exhaust port 1604 diameter.
This tunable exhaust port assembly 1709 allows the working fluid
exhaust pressure to be adjusted to prevent excess backpressure in
the turbine system.
[0069] This embodiment shows the invisible view of the edge of the
tuning blades 1707 which are expanded and contracted through the
fixed slider pegs 1708 moving through the expander channels 1706.
The tunable port gear housing cover 1601 is fastened to the upper
turbine stator housing 1201 and the lower turbine stator housing
1202 and provides an opening for the rotor shaft 1205 to exit
through the main exhaust port 1605. An end view of the main shaft
1603 can be seen in relation to the rotational blades 1602 inside
the tunable port gear housing cover 1601.
[0070] At the beginning of the introduction of saturated steam into
the turbine the tunable exhaust apparatus 1709 would be completely
constricted making the exhaust port diameter 1604 small preventing
the internal pressure and temperature of the saturated steam from
decreasing during start up conditions. During start up the RPM of
the internal disc array 1203 increases as does the exhaust port
diameter to prevent backpressure from building inside the stator
turbine housing 105. At operational RPM the exhaust port diameter
1604 is fully open allowing free flowing spent saturated steam to
exit the system as hot condensed water.
[0071] Heat loss from the modular single turbine assembly 1301 will
be prevented through the installation of a noise cancellation and
thermal heat capture enclosure 1809 (FIG. 18). This three-piece
enclosure drawing shows the final enclosure cover for the matched
triple-insulated turbine noise cancellation and thermal heat
capture side coupling assembly 1801, hollow interior of the final
enclosure 1802, low density thermal insulating foam and noise
canceling material 1803, rigid structural box frame material 1804,
vacuum impregnated panel (VIP) matched pair sub assembly 1804,
flexible double ply steel mesh to absorb minimal vibrational impact
from normal turbine operation 1805, matched set of VIP, thermal
insulating foam and noise canceling sub assemblies 1806, final
enclosure opening which slips over and encloses the matching sub
assembly shells when applied against the turbine 1807 and turbine
outline 1808. Preventing heat from escaping the turbine through the
exterior sides increases the efficiency of the heat engine and also
cancels out unwanted noise.
[0072] As a follow on to the saturated steam example, the modular
thermal molecular adhesion turbine 1213 is shown in a modular
stacked two-phase grouping 1913 (FIG. 19) with a complementary
external exhaust capture apparatus 1914 attached. The modular
stacked two phase grouping 1913 and complementary external exhaust
capture apparatus 1914 will replace the common Condenser unit 2013
(FIG. 20) at the backend of a typical bladed steam turbine 2012.
Bladed steam turbines are used in power plants and serve here as an
example of an upstream working flowable fluid source that is
operatively connected to the inlet port of the modular turbine. The
bladed turbines produce waste exhaust comprised of high pressure
and temperature saturated steam. This drawing shows a top cutaway
view of the modular stacked two phase grouping 1913 and a saturated
steam flow pathway through the system ending with its exit into the
complementary external exhaust capture apparatus 1914. In this
embodiment, the external exhaust capture apparatus 1914 is a common
cold water tube condensing unit with an external vacuum pump to
provide positive flow of the hot condensate exiting the modular
stacked two phase grouping 1913.
[0073] The assembly parts of the modular stacked two phase grouping
1913 consist of a modular turbine array connector flange 1901,
common industrial steam turbine exhaust flange 2014, top tier inlet
1920, modular turbine array manifold 1507, mid tier exhaust inlet
1903, sub tier exhaust inlet 1902, two stage modular turbine arrays
1907, 1908, exterior housing 1904, main rotor shaft extension 1905,
minor rotor shaft extension 1906, expander exhaust tube 1909,
capillary expander joint inlet 1910, external partial vacuum pump
piping 1911, modular turbine array separation housing 1912, and
complementary external exhaust capture apparatus unit 1914. In this
embodiment, the modular turbine array 1913 and complementary
external exhaust capture apparatus unit 1914 connects to the waste
exhaust from a common bladed steam turbine 2012 (FIG. 20) and
converts the waste exhaust into mechanical or electrical energy.
The modular turbine array 1913 has a complementary external exhaust
capture apparatus 1914 which uses the exiting working fluid energy
and external vacuum pump system to create a partial vacuum
assisting in forward flow of the working fluid throughout the
entire modular turbine array 1913 system increasing overall
mechanical or electrical output. Other embodiments call for vacuum
means also in fluid communication with the modular turbine for
creating at least a partial vacuum in a housing of the modular
turbine. A nonexclusive list of vacuum means includes inert means,
ambient heat differentials, condenser means, a vacuum pump and
vacuum produced by the rotary action of the heat engine/turbine
itself.
[0074] In the example illustrated, waste saturated steam exhaust
leaves the common bladed steam turbine 2012 from exhaust chamber
2005 and enters multiple exhaust inlets of type 1902, 1903 and
1920. There are four levels of the modular stacked two-phase
grouping 1913 which are not shown on this drawing (FIG. 19) but are
also fed by the bladed steam turbine exhaust 2005. Saturated steam
enters each individual modular turbine assembly 1213 and produces
mechanical energy that is transferred to the main rotor shaft
extension 1905, which runs an external generator 1212. As saturated
steam exits the first stage modular turbine array 1907 it enters
the second singe modular turbine array 1908 through the exhaust to
inlet array connector 1917 to produce additional mechanical energy
Which is transferred to the minor rotor shaft extension 1906 which
runs an external generator 1212. In this example, a vacuum is
pulled by an external vacuum pump tube 1911 which aids the exiting
hot water from the second stage modular turbine array 1908 exhaust
into the expander exhaust tube 1909 array and then into a common
cold water tube condensing unit 2105 (FIG. 21) with an external
vacuum pump to provide positive flow of the hot condensate exiting
the modular stacked two phase grouping 1913. Other embodiments
employ any one or a combination of vacuum means described
above.
[0075] A common bladed steam turbine 2012 and a joined modular
condenser unit 2013 are shown coupled (FIG. 20). This is just one
type of waste exhaust system producing saturated steam waste gas
that can be used by the modular stacked two phase grouping 1913 to
produce mechanical to electrical energy without additional
fuel.
[0076] The main assembly parts, interconnects and waste gas flow
path include inlet for high-pressure, high temperature superheated
steam working fluid 2001, stage one expander steam turbine blades
2002, stage two expander steam turbine blades 2003, stage three
expander steam turbine blades 2004, common bladed steam turbine
high pressure saturated steam exhaust chamber 2005, common bladed
steam turbine 2012 high pressure saturated steam exhaust chamber
diverted downward flow 2006, multi condenser unit chiller tube
matrix 2007, common condenser expander area typical in all modular
condenser additions 2008, area for additional modular condenser
units based on increased exhaust from common steam turbine base
unit enlargement 2009, common condenser expander housing shell 2010
and the flow path of high pressure saturated steam from common
steam turbine final exhaust port 2011. A great deal of waste energy
is lost through the practice of using a common bladed steam turbine
2012 to produce energy from fossil fuels and other non-renewable
energy sources worldwide.
[0077] When the two-phase turbine array 2101 is placed at the end
exhaust of a common bladed steam turbine 2012 the exiting waste gas
will be converted into usable mechanical or electrical energy
without additional fuel. A typical cold water tube condensing unit
2105 is connected to the exhaust end of the two-phase turbine array
2101 which allows the exiting hot condensate to enter the
condensing chamber 2102 flow over the cold water tube array 2103
and exit the condenser through dry bulb temperature condensate port
2104.
[0078] While the invention has been illustrated and described in
detail in the drawings and foregoing description, the same is to be
considered illustrative and not restrictive in character. It is
understood that the embodiments have been shown and described in
the foregoing specification in satisfaction of the be mode and
enablement requirements. It is understood that one of ordinary
skill in the art could readily make a nearly infinite number of
insubstantial changes and modifications to the above-described
embodiments and that it would be impractical to attempt to describe
all such embodiment variations in the present specification. Thus,
it is understood that it is desirable to protect all the changes
and modifications that come within the spirit of the invention.
* * * * *