WO2010007608A1

WO2010007608A1 - Foldable charger with two axial flux alternators

Info

Publication number: WO2010007608A1
Application number: PCT/IL2008/000882
Authority: WO
Inventors: Michael Freidhendler; Roman Lanzet; Alexander Sromin
Original assignee: Easy Energy Inc.
Priority date: 2008-06-29
Filing date: 2008-06-29
Publication date: 2010-01-21
Also published as: CA2638242A1

Abstract

Foldable high throughput charger for use in cooperation with power-hungry consumer electronics devices such as, but not limited to, laptop computers. The charger comprises two encased power generating units that are foldable over a central encased base. Each encased power generating unit comprises a functionally identical, and geometrically symmetrical set of elements arranged to convert reciprocating movement into direct current. Each set of element comprises a transmission unit, an axial-flux alternator and a power management unit. Additionally, each encased power generating unit is coupled to a pedal with a returning element attached to the encased base. The encased base may accommodate a rechargeable battery. In operational mode, the power generating units are unfolded such that they are substantially perpendicular with the central encased base. In the portable deployment, both encased power generating units are folded over the central base unit resulting in a flat space saving folded object.

Description

FOLDABLE CHARGER WITH TWO AXIAL FLUX ALTERNATORS

TECHNICAL FIELD

[0001] The present invention relates to the field of electricity chargers, and more particularly to high throughput portable chargers for consumer electronics device.

BACKGROUND

[0002] One of the main constraints imposed on portable computer electronics devices is their limited amount of electrical power stored in their independent power sources which directly affects their usability.

[0003] Many attempts are known in the art for providing portable battery chargers arranged to convert mechanical energy, usually human activity, into electrical power that is used in turn to recharge the independent power source of portable consumer electronics devices.

[0004] However, many of these solutions provide both inefficient and insufficient chargers that do not meet the power requirement of many power-hungry devices such as laptop computers and multimedia personal device accessories (PDA).

[0005] It would thus be advantageous to have an electrical power charger that combines efficiency, high throughput, portability and versatility.

BRIEF SUMMARY

[0006] Accordingly, in accordance with certain embodiments of the present invention, there is provided a portable foldable charger comprising two encased axial- flux alternators each coupled to an actuating pedal via a mechanical transmission unit and further comprising a power management module coupled to the output of the alternators.

[0007] In a preferred embodiment, there is provided a symmetrical configuration of elements arranged in two sets of standalone complementary elements. Each set is packed separately in a housing and comprises a transmission unit, an axial-flux alternator and power management unit, all used in cooperation with an actuating pedal in order to convert a reciprocating movement into a unidirectional rotary movement. The rotary movement is then converted into an alternating current which is in turn converted into direct current exhibiting a predefined voltage and current values. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings in which like numerals designate corresponding sections or elements throughout.

[0009] With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. In the accompanying drawings:

[0010] FIG. 1 is a schematic block diagram of the charger according to some embodiments of the present invention;

[0011] FIG. 2 A and FIG. 2B are isometric views of the charger in the operational configuration according to some embodiments of the present invention;

[0012] FIG. 3A and FIG. 3B are exploded views of the charger in the operational configuration according to some embodiments of the present invention;

[0013] FIG. 4 is an isometric view of the charger in the folded configuration according to some embodiments of the present invention;

[0014] FIG. 5 is an exploded view of the charger in the folded configuration according to some embodiments of the present invention;

[0015] FIG. 6A and FIG. 6B are exploded views of identical right and left electromechanical boxes according to some embodiments of the present invention;

[0016] FIG. 7A and FIG. 7B are transparent top and isometric views of the stator of one of the axial-flux alternator according to some embodiments of the present invention;

[0017] FIG. 8 is a developed view of the stator winding of one of the axial-flux alternators showing coils allocated on PCB layers according to some embodiments of the present invention; [0018] FIG. 9 is an exploded view of the rotor of one of the axial-flux alternator according to some embodiments of the present invention; and

[0019] FIG. 10 is an exploded view of one magnetic system of the double rotor of one of the axial-flux alternator according to some embodiments of the present invention.

[0020] The drawings, together with the description, make apparent to those skilled in the art how the invention may be embodied in practice.

[0021] Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.

DETAILED DESCRIPTION OF SOME EMBODIMENTS OF THE INVENTION [0022] Embodiments of the present invention provide a foldable high throughput charger for use in cooperation with power-hungry consumer electronics devices such as, but not limited to, laptop computers. The charger comprises two encased power generating units that are foldable over a central encased base. Each encased power generating unit comprises a functionally identical, and geometrically symmetrical set of elements arranged to convert reciprocating movement into direct current. Each set of element comprises a transmission unit, an axial-flux alternator and a power management unit as explained in detail hereinafter. Additionally, each encased power generating unit is coupled to a pedal with a returning element also attached to the encased base. The base may preferably accommodate a rechargeable battery. In operational mode, the power generating units are unfolded such that they are substantially perpendicular with the central encased base. In the portable deployment, both encased power generating units are folded over the central base unit resulting in a flat space-saving folded object.

[0023] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is applicable to other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. In other instances, well-known methods, procedures, components and circuits have not been described in detail so as not to obscure the teachings of the present disclosure. [0024] FIG. 1 is a schematic high level block diagram of the charger according to some embodiments of the present invention. The charger comprises two sets of identical elements that are operable in cooperation in order to achieve high power throughput of preferably over 60 W. Specifically, the charger comprises a first mechanical transmission unit 1110 and a second mechanical transmission unit 1210 sharing a common driving item. The charger comprises a first axial-flux alternator 1120 and a second axial-flux alternator 1220. The charger further comprises a first power management unit 1130 and a second power management unit 1230. First mechanical transmission unit 1110 is mechanically coupled and operatively associated with first axial-flux alternator 1120. First axial-flux alternator 1120 is electrically coupled to first power management unit 1130. Similarly, second mechanical transmission unit 1210 is mechanically coupled and operatively associated with second axial-flux alternator 1220. Second axial-flux alternator 1220 is electrically coupled to Second power management unit 1230.

[0025] The charger further comprises a pedal with a returning element 1300 mechanically coupled and operatively associated with first transmission unit 1110 and second transmission unit 1200. Further, the outputs of first power management unit 1130 and second power management unit 1130 may be electrically coupled to a rechargeable battery 1400 which is accommodated within a base housing 1410. [0026] In a preferred embodiment, first mechanical transmission unit 1110, first axial-flux alternator 1120 and first power management unit 1130 are accommodated within a first side housing 1100. Similarly, second mechanical transmission unit 1210, second axial-flux alternator 1220 and second power management unit 1230 are accommodated within a second side housing 1200.

[0027] In operation, each transmission unit 1110 and 1210 are arranged to convert a reciprocating movement of pedal 1300 into a unidirectional high-speed rotary movement transmitted into the first and second axial-flux alternators 1120 and 1220. First and second axial-flux alternators 1120 and 1220 are arranged to convert rotary movement into alternating current and power management units 1130 and 1230 are arranged to receive the alternating currents from the outputs of the first and the second axial-flux alternators and output in turn a direct current in accordance with predefined settings. The direct current may be then used to recharge a battery 1400 independently or in conjunction with another direct current source. [0028] FIG. 2A and FIG. 2B are isometric views of the charger in the operational configuration according to some embodiments of the present invention; The views show first side housing 1100 and second side housing 1200 with pedal 3200 and returning element 3100 located between them. Base housing is shown in accordance with the preferred embodiment according to which base housing 1400 is connected to first side housing 1100 and second side housing 1200 such that the connection enables first side housing 1100 and second side housing 1200 to be folded over base housing 1400.

[0029] FIG. 3A and FIG. 3B are exploded views of the charger in the operational configuration according to some embodiments of the present invention. The views show in particular a preferred structure in a non limiting manner. First and second side housing 1100 and 1200, pedal 3200 and returning element 3100, battery 1410, base housing 1410 and electric interface ports 2220.

[0030] FIG. 4 is an isometric view of the charger in the folded configuration according to some embodiments of the present invention. The view shows first side housing 1100 and second side , housing 1200 and base housing 1400 which is connected to first side housing 1100 and second side housing 1200. Specifically, first side housing 1100 and second side housing 1200 are folded over base housing 1400 resulting in a compact size.

[0031] FIG. 5 is an exploded view of the charger in the folded configuration according to some embodiments of the present invention. The views show in particular a preferred structure in a non limiting manner. First and second side housing 1100 and 1200, pedal 3200 and returning element 3100, battery 1410, base housing 1410 and electric interface ports 2220.

[0032] FIG. 6A and FIG. 6B are exploded views of identical right and left electromechanical boxes according to some embodiments of the present invention. The views show a preferred and non-limiting embodiment of the speed multiplication means comprising a set of three toothed wheels 1112, 1113 and 1114 operatively associated together and arranged to increase the speed of rotary movement of rotor 1215. The views also show stator 1290. There is also provided a clutch 1211 arranged to disengage toothed wheel 1212 in either downward or upward movement of pedal 3100. Thus, in operation, the transmission units are arranged to transform reciprocating upward and downward movements into unidirectional rotary movements. [0033] According to some embodiments of the invention, the reciprocating movement exhibits an upward movement and a downward movement of the pedal 3200 and wherein the mechanical transmission units are arranged to convert the downward movement into a rotary movement of both rotors of both axial-flux alternators on the same rotary direction and disconnect mechanically both rotors from the pedal during the upward movement and thus provide continuous rotors rotation on the first rotary direction.

[0034] According to some embodiments of the invention, the reciprocating movement exhibits an upward movement and a downward movement of the pedal and wherein the mechanical transmission units are arranged to convert the downward movement into a rotary movement of the rotor of the first axial-flux alternator while the rotor of the second axial-flux alternator is mechanically disconnected from the pedal, and the upward movement into a rotary movement of the rotor of the second axial-flux alternator while the rotor of the first axial-flux alternator is mechanically disconnected from the pedal..

[0035] FIG. 7A and FIG. 7B are transparent top and isometric views of the stator of the axial-flux alternators according to some embodiments of the present invention. The views show windings 1191/1291 of the stator which are, in a preferred embodiment, all integrated and implemented as a multilayer printed circuit board. The case 1195 is shaped to accommodate the stator in the PCB formation. [0036] FIG. 8 is a developed view of the stator winding 1192/1292 of the axial-flux alternators showing coils allocated on PCB layers according to some embodiments of the present invention;

[0037] FIG. 9 is an exploded view of the rotor 1215 of an axial-flux alternator according to some embodiments of the present invention. Rotor 1215 comprises heteropolar magnet pieces 1216.

[0038] FIG. 10 is an exploded view of one magnetic system of the rotor of an axial- flux alternator according to some embodiments of the present invention. Rotor 1215 comprises heteropolar magnet pieces 1216.

[0039] According to some embodiments of the invention, each rotor comprises a periodical heteropolar axially magnetized portion exhibiting a definite number of poles.

[0040] According to some embodiments of the invention, the heteropolar axially magnetized portion is implemented as one of: a plurality of permanent magnet pieces, a single-piece multi-pole permanent magnet disk, a planar thin soft magnetic disk affixed to the back of each rotor, closing the magnetic field.

[0041] According to some embodiments of the invention, the stator comprises planar windings implemented as a multilayered printed circuit board (PCB). [0042] According to some embodiments of the invention, the planar windings are made from one of: conductors produced by copper stamping and embedded within the central stator plate, conductors produced by etching technology and embedded within the central stator plate, planar spiral-like conductor loops in every layer interconnected throughout the layers to form a substantially multi-layered three- dimensional spiral inductor.

[0043] According to some embodiments of the invention, the charger is accommodated in a foldable construction. The foldable charger is arranged for converting reciprocating movement into electricity, the charger comprising: a pedal; transmission units connected to the pedal for converting reciprocating movement of the pedal into unidirectional rotary movements; two axial-flux alternators having a double rotor converting unidirectional rotary movement of their rotors into alternating currents; a power management unit connected to the alternators for converting alternating currents from the alternators into direct current; wherein the power management unit is accommodated within a base housing; and wherein the first and second axial-flux alternators are accommodated each with a side housing, wherein each side housing is connected to the base housing; and wherein the pedal is connected to the base housing and is further coupled to each side housing on each side such that when the pedal is pressed down over the base housing, the side housings are folded over the pedal and base housing.

[0044] According to some embodiments of the invention, the charger further comprises a returning element coupled to the pedal and arranged to return the pedal to a raised position after the pedal is pressed down.

[0045] According to some embodiments of the invention, the returning element comprises a limited angle torsion spring with one end fixed to the base housing and with the second end connected to the pedal.

[0046] According to some embodiments of the invention, each mechanical transmission unit comprises a clutch providing unidirectional transmission of torque to the axial-field alternators. [0047] According to some embodiments of the invention, each mechanical transmission unit comprises a speed multiplication unit arranged to increase outputted rotation speed.

[0048] According to some embodiments of the invention, means for speed multiplication comprises at least one gear couple.

[0049] According to some embodiments of the invention, each double rotor comprises two identical periodical heteropolar axially magnetized portions exhibiting a definite number of poles.

[0050] According to some embodiments of the invention, the heteropolar axially magnetized portion is implemented as one of: a plurality of permanent magnet pieces, a single-piece multi-pole permanent magnet disk, a planar thin soft magnetic disk affixed to the back of each rotor, closing the magnetic field. [0051] According to some embodiments of the invention, each axial-flux alternator comprises a stator comprising planar windings implemented as a multilayered printed circuit board (PCB).

[0052] According to some embodiments of the invention, the planar windings are made from one of: conductors produced by copper stamping and embedded within the central stator plate, conductors produced by etching technology and embedded within the central stator plate, planar spiral-like conductor loops in every layer interconnected throughout the layers to form a substantially multi- layered three-dimensional spiral inductor.

[0010] In the above description, an embodiment is an example or implementation of the inventions. The various appearances of "one embodiment," "an embodiment" or "some embodiments" do not necessarily all refer to the same embodiments.

[0011] Although various features of the invention may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the invention may be described herein in the context of separate embodiments for clarity, the invention may also be implemented in a single embodiment.

[0012] Reference in the specification to "some embodiments", "an embodiment", "one embodiment" or "other embodiments" means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the inventions. [0013] It is understood that the phraseology and terminology employed herein is not to be construed as limiting and are for descriptive purpose only.

[0014] The principles and uses of the teachings of the present invention may be better understood with reference to the accompanying description, figures and examples.

[0015] It is to be understood that the details set forth herein do not construe a limitation to an application of the invention.

[0016] Furthermore, it is to be understood that the invention can be carried out or practiced in various ways and that the invention can be implemented in embodiments other than the ones outlined in the description below.

[0017] It is to be understood that the terms "including", "comprising", "consisting" and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers or groups thereof and that the terms are to be construed as specifying components, features, steps or integers.

[0018] If the specification or claims refer to "an additional" element, that does not preclude there being more than one of the additional element.

[0019] It is to be understood that where the claims or specification refer to "a" or "an" element, such reference is not be construed that there is only one of that element.

[0020] It is to be understood that where the specification states that a component, feature, structure, or characteristic "may", "might", "can" or "could" be included, that particular component, feature, structure, or characteristic is not required to be included.

[0021] Where applicable, although state diagrams, flow diagrams or both may be used to describe embodiments, the invention is not limited to those diagrams or to the corresponding descriptions. For example, flow need not move through each illustrated box or state, or in exactly the same order as illustrated and described.

[0022] Methods of the present invention may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks.

[0023] The term "method" may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belongs.

[0024] The descriptions, examples, methods and materials presented in the claims and the specification are not to be construed as limiting but rather as illustrative only. [0025] Meanings of technical and scientific terms used herein are to be commonly understood as by one of ordinary skill in the art to which the invention belongs, unless otherwise defined.

[0026] The present invention can be implemented in the testing or practice with methods and materials equivalent or similar to those described herein.

[0027] Any publications, including patents, patent applications and articles, referenced or mentioned in this specification are herein incorporated in their entirety into the specification, to the same extent as if each individual publication was specifically and individually indicated to be incorporated herein. In addition, citation or identification of any reference in the description of some embodiments of the invention shall not be construed as an admission that such reference is available as prior art to the present invention.

[0028] While the invention has been described with respect to a limited number of embodiments, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of some of the embodiments. Those skilled in the art will envision other possible variations, modifications, and applications that are also within the scope of the invention. Accordingly, the scope of the invention should not be limited by what has thus far been described, but by the appended claims and their legal equivalents. Therefore, it is to be understood that alternatives, modifications, and variations of the present invention are to be construed as being within the scope and spirit of the appended claims.

Claims

CLAIMS What is claimed is:

1. A foldable portable high throughput charger comprising: a first housing and a second housing; a central base housing; a first axial-flux alternator and a second axial-flux alternator comprising each a stator and a rotor; a first mechanical transmission unit coupled to the first axial-flux alternator; a second mechanical transmission unit coupled to the second axial-flux alternator; a first power management unit coupled to the first alternator; a second power management unit coupled to the second alternator; and a pedal coupled to the first and second mechanical transmission unit and further attached to the central base housing, wherein the first housing comprises the first transmission unit, the first alternator and the first power management unit; and wherein the second housing comprises the second transmission unit, the second alternator and the second power management unit; and wherein the first housing and second housing are foldable over the central base housing; and wherein the mechanical transmission units are arranged to convent a reciprocating movement of the pedal into a unidirectional rotary movement transmitted into the rotors of the first and the second alternators; and wherein the first and second alternators are arranged to convert rotary movement of the rotors into alternating current; and wherein the power management units are arranged to receive the alternating currents and output a direct current in accordance with predefined settings.

2. The charger according to claim 1, wherein the two alternators are arranged to operate simultaneously enabling double throughput of power generation.

3. The charger according to claim 1, wherein the first and second housing are shaped and arranged to enable folding over the central base housing enabling minimal volume deployment to enhance portability.

4. The charger according to claim 1, wherein the reciprocating movement exhibits an upward movement and a downward movement and wherein the mechanical transmission unit is arranged to convert the downward movement into a rotary movement of the rotor of the first and the second axial-flux alternator.

5. The charger of claim 1 wherein each rotor comprises a periodical heteropolar axially magnetized portion exhibiting a definite number of poles.

6. The charger of claim 5, wherein the heteropolar axially magnetized portion is implemented as one of: a plurality of permanent magnet pieces, a single-piece multi- pole permanent magnet disk, a planar thin soft magnetic disk affixed to the back of each rotor, closing the magnetic field.

7. The charger of claim 1, wherein the stator comprises planar windings implemented as a multilayered printed circuit board (PCB).

8. The charger of claim 1, wherein the planar windings are made from one of: conductors produced by copper stamping and embedded within the central stator plate, conductors produced by etching technology and embedded within the central stator plate, planar spiral-like conductor loops in every layer interconnected throughout the layers to form a substantially multi-layered three-dimensional spiral inductor.

9. The charger of claim 6, further comprising a returning element coupled to the pedal and arranged to return the pedal to a raised position after the pedal is pressed down.

10. The charger according to claim 9, wherein the returning element comprises a limited angle torsion spring with one end fixed to the base housing and with the second end connected to the pedal.

11. The charger of claim 1, wherein the mechanical transmission comprises a clutch providing unidirectional transmission of torque to the alternators.

12. The charger of claim 1, wherein the mechanical transmission comprises speed multiplication unit arranged to increase outputted rotation speed.

13. The charger of claim 12, wherein the means for speed multiplication comprises at least one gear couple.