Note: Descriptions are shown in the official language in which they were submitted.
CA 02931248 2016-05-26
WASTE AIR FLOW CAPTURE SYSTEM
FIELD OF THE INVENTION
[001] The present disclosure is in the field of passive energy capture
systems
pertaining to capturing wasted air flow.
BACKGROUND OF THE DISCLOSURE
[002] Air conditioning systems employ a condenser unit which is a necessary
component for air conditioning systems to produce cool air. During operation,
the
condenser unit produces exhaust air that is vented into the atmosphere. In
another aspect,
wind turbines passively produce electricity by being vertically deployed in
areas with high
winds.
[003] There is need for an efficient system or kit for capturing vented
waste
air that can be efficiently mounted to condenser units and heat pumps to
capture wasted
exhaust air vented during the operation air conditioning system, which
transfers to
mechanical energy into electrical power.
SUMMARY OF THE INVENTION
[004] Disclosed herein is a waste air flow capture system, comprising: a) a
cylindrical shroud configured to receive a waste air flow from a waste air
flow channel of
an HVAC compressor or a heat pump compressor and configured to vent the waste
air flow
received from the waste air flow channel of an HVAC compressor or a heat pump
compressor; b) a first electrical generator configured to generate electricity
when a first fan
blade assembly rotates relative to the cylindrical shroud and/or a second
electrical
generator configured to generate electricity when a first fan blade assembly
rotates relative
to the cylindrical shroud; d) a first fan blade assembly enclosed by the
cylindrical shroud
and coupled to the first electrical generator motor on a first side of the
first fan blade
assembly and coupled to the second electrical generator motor on a second side
of the first
fan blade assembly; and e) a second electrical generator bracket capable of
holding the
second electrical generator, wherein the first fan blade assembly is
configured to rotate the
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first electrical generator and/or the second electrical generator
simultaneously from
opposed sides of a hub of the first fan blade assembly.
[005] In another aspect, disclosed herein is a waste air flow capture
system
kit, comprising: a) a cylindrical shroud configured to receive a waste air
flow from a waste
air flow channel of an HVAC compressor or a heat pump compressor and
configured to
vent the waste air flow received from the waste air flow channel of an HVAC
compressor
or a heat pump compressor; b) a first electrical generator configured to
generate electricity
when a first fan blade assembly rotates relative to the cylindrical shroud
and/or a second
electrical generator configured to generate electricity when a first fan blade
assembly
rotates relative to the cylindrical shroud; c) a first fan blade assembly
enclosed by the
cylindrical shroud and coupled to the first electrical generator motor on a
first side of the
first fan blade assembly and coupled to the second electrical generator motor
on a second
side of the first fan blade assembly; d) a second fan blade assembly
configured to transmit
waste air flow from a waste air flow channel of an HVAC compressor or a heat
pump
compressor; and e) a second electrical generator bracket capable of holding
the second
electrical generator.
[006] In another aspect, disclosed herein is a method of passively
generating
electric power by recycling waste air flow received from a waste air flow
channel of an
HVAC compressor or a heat pump compressor with the waste air flow capture
system,
comprising the steps of: a) removing an HVAC compressor's or a heat pump
compressor's
fan shroud; b) replacing an HVAC compressor's or a heat pump compressor's fan
blade
assembly with a second fan blade assembly; c) installing a waste air flow
capture system
on a waste air flow channel of an HVAC compressor or a heat pump compressor,
wherein
a cylindrical shroud of the waste air flow capture system is facing away from
the HVAC
compressor or a heat pump compressor; d) using waste air flow from the channel
of the
HVAC compressor or the heat pump compressor to drive a first fan blade
assembly and
convert the wind energy into a mechanical energy which is converted further
into electrical
power; and e) converting the electric power with an electrical power converter
for
converting DC to AC and for outputting electric power output.
[007] In yet another aspect, disclosed herein is a method of passively
generating electric power by recycling waste air flow received from a waste
air flow
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channel of an HVAC compressor or a heat pump compressor with the waste air
flow
capture system, comprising the steps of: a) removing an HVAC compressor's or a
heat
pump compressor's fan shroud; b) installing a waste air flow capture system on
a waste air
flow channel of an HVAC compressor or a heat pump compressor, wherein a
cylindrical
shroud of the waste air flow capture system is facing away from the HVAC
compressor or
a heat pump compressor; c) using waste air flow from the channel of the HVAC
compressor
or the heat pump compressor to drive a first fan blade assembly and convert
the wind
energy into a mechanical energy which is converted further into electrical
power; and d)
converting the electric power with an electrical power converter for
converting DC to AC
and for outputting electric power output.
10081 In yet another aspect, disclosed herein is a method of passively
generating electric power by recycling waste air flow received from a waste
air flow
channel of an HVAC compressor or a heat pump compressor with the waste air
flow
capture system, comprising the steps of: a) replacing an HVAC compressor's or
a heat
pump compressor's fan blade assembly with a second fan blade assembly; b)
installing a
fan shroud column configured to fit around a waste air flow channel of an HVAC
compressor or a heat pump compressor; c) installing a waste air flow capture
system on a
waste air flow channel of an HVAC compressor or a heat pump compressor,
wherein a
cylindrical shroud of the waste air flow capture system is facing away from
the HVAC
compressor or a heat pump compressor; d) using waste air flow from the channel
of the
HVAC compressor or the heat pump compressor to drive a first fan blade
assembly and
convert the wind energy into a mechanical energy which is converted further
into electrical
power; and e) converting the electric power with an electrical power converter
for
converting DC to AC and for outputting electric power output.
[009] In still another aspect, disclosed herein is a method of
passively
generating electric power by recycling waste air flow received from a waste
air flow
channel of an HVAC compressor or a heat pump compressor with the waste air
flow
capture system, comprising the steps of: a) installing a fan shroud column
configured to fit
around a waste air flow channel of an HVAC compressor or a heat pump
compressor; b)
installing a waste air flow capture system on a waste air flow channel of an
HVAC
compressor or a heat pump compressor, wherein a cylindrical shroud of the
waste air flow
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capture system is facing away from the HVAC compressor or a heat pump
compressor; c)
using waste air flow from the channel of the HVAC compressor or the heat pump
compressor to drive a first fan blade assembly and convert the wind energy
into a
mechanical energy which is converted further into electrical power; and d)
converting the
electric power with an electrical power converter for converting DC to AC and
for
outputting electric power output.
BRIEF DESCRIPTION OF THE DRAWINGS
100101 Figure 1 is a exploded view of an embodiment of a waste air flow
capture system 100 disclosed herein.
[0011] Figure 2 is an illustration of a bottom side view of a single
generator or
dual generator waste air flow capture system 500 disclosed herein.
[0012] Figure 3A is an illustration of a top side view of a dual
generator waste
air flow capture system 600 disclosed herein.
[0013] Figure 3B is an illustration of a top side view of a single
generator waste
air flow capture system 1200 disclosed herein.
[0014] Figure 4A is an illustration of a second side of a first fan
blade assembly
200 disclosed herein.
[0015] Figure 4B is an illustration of a first side of a first fan blade
assembly
300 disclosed herein.
[0016] Figure 5 is an illustration of a top side view of a second fan
blade
assembly 400 disclosed herein.
[0017] Figure 6A is an illustration of a top view of a fan shroud column
700
disclosed herein.
[0018] Figure 6B is an illustration of a side view of a fan shroud
column 800
disclosed herein.
[0019] Figure 7 is an isometric view of a waste air flow capture system
installation 900 with a heat pump 902.
[0020] Figure 8 is top side view of a waste air flow capture system
installation
1000 with an HVAC compressor 1006.
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[0021] Figure 9 is an isometric view of a waste air flow capture system
installation 1100 with an HVAC compressor 1102 and including a fan shroud
column 800
disclosed herein.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0022] The following is a detailed description of certain specific
embodiments
of the waste air flow capture systems and methods disclosed herein.
[0023] In one aspect, disclosed herein is a waste air flow capture
system,
comprising: a) a cylindrical shroud configured to receive a waste air flow
from a waste air
flow channel of an HVAC compressor or a heat pump compressor and configured to
vent
the waste air flow received from the waste air flow channel of an HVAC
compressor or a
heat pump compressor; b) a first electrical generator configured to generate
electricity
when a first fan blade assembly rotates relative to the cylindrical shroud
and/or a second
electrical generator configured to generate electricity when a first fan blade
assembly
rotates relative to the cylindrical shroud; d) a first fan blade assembly
enclosed by the
cylindrical shroud and coupled to the first electrical generator motor on a
first side of the
first fan blade assembly and coupled to the second electrical generator motor
on a second
side of the first fan blade assembly; and e) a second electrical generator
bracket capable of
holding the second electrical generator, wherein the first fan blade assembly
is configured
to rotate the first electrical generator and the second electrical generator
simultaneously
from opposed sides of a hub of the first fan blade assembly, and wherein the
HVAC
compressor or a heat pump compressor comprises a second fan blade assembly
configured
to transmit wasted air flow from a waste air flow channel of an HVAC
compressor or a
heat pump compressor.
[0024] Referring to Figures 1-4 depict views of a waste air flow
capture system
100 configured to receive a waste air flow from a waste air flow channel of an
HVAC
compressor or a heat pump compressor. The systems and methods disclosed
pertain to
generating electricity using unused exhaust air from heat dissipating
equipment or
ventilation from air conditioning equipment. In some embodiments, the system
is
configured to be bolted to a waste air flow channel of an HVAC compressor or
the heat
pump compressor. The components and design comprise a first electrical
generator motor
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138 and a second electrical generator motor 116 coupled to opposed sides of a
first fan
assembly comprising a plurality of first fan blades 122, a first fan assembly
housing 144,
a hub 142 affixed to the first fan assembly housing 144 with a plurality of
bolts 140. In
some embodiments, the first electrical generator and the second electrical
generator each
independently have a rated voltage in a range between about 12 volts and 48
volts. In some
embodiments, the first electrical generator and the second electrical
generator each
independently have an output between about 100 W/h to 500 W/h. In some
embodiments,
the first electrical generator and the second electrical generator each
comprises an
alternating current, magnet, drive shaft, bearings, insulators and power wire
terminals.
[0025] As illustrated, the first electrical generator motor 138 and the
second
electrical generator motor 116 comprise electrical generator motor feet 114,
whereby the
first electrical generator motor 138 and the second electrical generator motor
116 are
affixed to L-brackets 132 and 108 respectively via bolts 150 and bracket holes
110. In some
embodiments, the first electrical generator is affixed to a first electrical
generator bracket
with a plurality of welds, nuts and/or bolts. In some embodiments, the first
electrical
generator is affixed to a first electrical generator bracket with a plurality
of welds, nuts
and/or bolts, wherein the first electrical generator bracket is affixed to the
cylindrical
shroud with a plurality of welds, nuts and/or bolts. Moreover, L-bracket 132
may be bolted
on a second side 152 to a top side of a cylindrical shroud 128 via nuts and
bolts 130 and
134 and bracket holes 150, respectively.
[0026] In some embodiments, a second electrical generator bracket
comprises
an L-bracket 108, a center ring portion 112 and a plurality of support arms
106 affixed to
an outer portion of the center ring thereby forming an X-shape as illustrated
with Figures
1 and 2. In some embodiments, the second electrical generator is affixed to a
second
electrical generator bracket with a plurality of welds, nuts and/or bolts. In
some
embodiments, the second electrical generator bracket comprises a center ring
portion with
a plurality of support arms affixed to an outer portion of the center ring
thereby forming an
X-shape. In some embodiments, the second electrical generator bracket
comprises a center
ring portion with a plurality of support arms affixed to the outer portion of
the center ring,
wherein a terminal end of one or more of the support arms comprises a support
arm
mounting aperture 104. In some embodiments, the second electrical generator
bracket
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comprises a center ring portion with a plurality of support arms affixed to
the outer portion
of the center ring, wherein a terminal end of one or more of the support arms
comprises a
support arm mounting aperture, and wherein the cylindrical shroud comprises a
plurality
of cylindrical shroud mounting apertures each independently aligned a support
arm
mounting aperture. L-bracket 108 may be affixed to the center ring portion 112
whereby
the second electrical generator motor 116 is affixed to a first side 120 of L-
bracket 108
which positions the second electrical generator motor drive shaft 118 to be
rotateably
coupled with a hub channel 146. In some embodiments, wherein the waste air
flow capture
system further comprises that the second electrical generator drive shaft 136
is coupled to
a second side of a hub 200 of the first fan blade assembly at an axial center
position 146 of
the hub 142.
[0027] As discussed, the first electrical generator motor 138 is affixed
to a top
side and an axial center position 158 of the cylindrical shroud 128 to be
aligned with the
hub channel 146. In some embodiments, wherein the waste air flow capture
system further
comprises that the first electrical generator drive shaft is coupled to a
first side of a hub
300 of the first fan blade assembly at an axial center position 146 of the hub
142. In some
embodiments, wherein the waste air flow capture system further comprises a
first electrical
generator drive shaft 118 and a second electrical generator drive shaft 136
are adjoined
through hub channel 146 via a threaded coupling 148. In some embodiments, the
second
electrical generator drive shaft is adjoined to the hub through a hub channel
via at least one
threaded coupling 148 on a first side of the hub and/or a second side of the
hub.
[0028] As depicted with Figures 1, 2, 3A and 3B, the cylindrical shroud
128
comprises a plurality of cylindrical shroud mounting apertures 124. In some
embodiments,
the system is configured to be bolted to a waste air flow channel of an HVAC
compressor
or the heat pump compressor. As depicted with Figure 1, bolts 102 are aligned
with
cylindrical shroud mounting apertures 124 and support arm mounting apertures
104. In
some embodiments, the cylindrical shroud 128 has a diameter 154 that is about
0.5 inches
to about 6 inches larger than the waste air flow channel of the HVAC
compressor or the
heat pump compressor. In some embodiments, the cylindrical shroud 128 has a
diameter
154 between about 24 inches and 30 inches and a height 156 between about 2
inches and
8 inches. In some embodiments, the cylindrical shroud mounting apertures 124
are
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separated by a distance between about 18 inches and 30 inches. In some
embodiments, the
cylindrical shroud 128 has a diameter 154 of about 27.5 inches and a height
156 of about
4.5 inches. In some embodiments, the cylindrical shroud mounting apertures 124
are
separated by a distance of about 21 inches.
[0029] Turning to drawings, Figure 2 is an illustration of a bottom side
view of
a single generator or dual generator waste air flow capture system 500
disclosed herein. As
illustrated the assembled waste air flow capture system 500 depicts a serial
wire 502 which
connects the second electrical generator motor 138 and the second electrical
generator
motor 116 in series. Moreover, the positive and negative power wires 504 and
606 may be
connected to a charge controller or rectifier, etc. In some embodiments, the
first electrical
generator and the second electrical generator are connected in series or in
parallel. The
bottom side of a waste air flow capture system 100 as depicted with Figure 2
illustrates the
second electrical generator bracket comprises an L-bracket 108, a center ring
portion 112
and a plurality of support arms 106. The motor is centrally affixed to the
bracket within the
center ring portion 112 and coupled to the hub 142. In some embodiments, the
first
electrical generator and the second electrical generator each have a diameter
less than a
diameter of the first fan blade assembly. The plurality of support arms 106
are capable of
supporting the waste air flow capture system 100 over a waste air flow channel
of an HVAC
compressor or a heat pump compressor while exposing the first fan assembly
comprising
a plurality of first fan blades 122 the waste air flow exiting the waste air
flow channel of
an HVAC compressor.
100301 Turning to drawings, Figure 3A is an illustration of a top side
view of
an assembled dual generator waste air flow capture system 600 disclosed
herein. As
illustrated the assembled waste air flow capture system 600 depicts a
generator wire 604
which may be used to connect the generators in series and/or connect to a
charge controller
or rectifier, etc. The top side of a waste air flow capture system 100 as
depicted with Figure
3A illustrates the first electrical generator bracket comprises an L-bracket
132, bolts 150
and a nuts and/or bolts 134 which affix the L-bracket 132 to the axial center
position 158
of the cylindrical shroud 128. The motor is centrally affixed to the bracket
within the center
ring portion 112 and coupled to the hub 142. The plurality of support arms 106
are capable
of supporting the waste air flow capture system 100 over a waste air flow
channel of an
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HVAC compressor or a heat pump compressor while exposing the first fan
assembly
comprising a plurality of first fan blades 122 the waste air flow channel.
[0031] Figure 3B depicts a top side of a single generator waste air flow
capture
system 1200 disclosed herein. In this view, the cylindrical shroud 128 is not
shown to show
the first electrical generator drive shaft 118 coupled to the hub 142 on a
first side of a first
fan blade assembly 300 via the hub channel 146 and the threaded coupling 148
being
engaged with the threads of first electrical generator drive shaft 118. In
this arrangement,
the cylindrical shroud mounting apertures 124 of the cylindrical shroud 128
and support
arm mounting apertures 104 are aligned for installation with bolts 102.
Moreover, in this
arrangement the single generator waste air flow capture system 1200 utilizes
rectifier 602
and wires 504 and 606 of Figure 2 as the positive and negative power wires
from the
rectifier.
[0032] Turning to Figure 4A is an illustration of a second side of a
first fan
blade assembly 200 disclosed herein. As depicted, the second side of a first
fan blade
assembly 200 depicts the hub 142, a backside of the first fan blade assembly
housing 144.
The illustration shows a first side 202 of the hub channel 146 positioned in
an axial center
of the second side of a first fan blade assembly 200. Figure 4B illustrates a
first side of a
first fan blade assembly 300 comprising the hub 142, hub channel 146, and a
plurality of
nuts and/ bolts which affix the hub 142 to the first fan blade assembly
housing 144. In some
embodiments, the first fan blade assembly housing 144 has an inner diameter
308 of about
6 inches. In some embodiments, the first fan blade assembly housing 144 has an
inner
diameter 308 between about 4 inches and 8 inches. In some embodiments, a fan
hub has a
diameter 306 of about 11 inches. In some embodiments, a fan hub has a diameter
306
between about 8 inches and 20 inches. In some embodiments, the first fan blade
assembly
has a diameter less than the cylindrical shroud inner diameter of between
about 0.1 inches
to about 1 inch. In some embodiments, the width 314 of the plurality of first
fan blades 122
is about 57/8 inches. In some embodiments, the width 314 of the plurality of
first fan blades
122 is between about 4 inches 10 inches. In some embodiments, the first fan
blade assembly
300 has a diameter 312 of about 23 inches. In some embodiments, the first fan
blade
assembly 300 has a diameter 312 between about 18 inches and 24 inches. As
illustrated,
the first side of a first fan blade assembly 300 has a clockwise rotation of
310, and each
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first fan blades 122 has a first fan blade tailing edge 302 and a first fan
blade leading edge
304 with a pitch angle of about 40 degrees and 9 first fan blades. In some
embodiments,
each first fan blades 122 has a first fan blade tailing edge 302 and a first
fan blade leading
edge 304 with a pitch angle between about 20 degrees and 60 degrees and
between about
4 and 20 first fan blades. In some embodiments, the vertical between the first
fan blade
tailing edge 302 and the first fan blade leading edge 304 is about 21/4
inches. In some
embodiments, the vertical between the first fan blade tailing edge 302 and the
first fan
blade leading edge 304 is between about 11/2 inches and 10 inches. In some
embodiments,
the first fan blade assembly 300 is an automotive radiator cooling fan. In
this aspect,
automotive radiator cooling fans like the first fan blade assembly 300 are
designed to pull
air through a radiator, which is utilized with the waste air flow capture
system 100 disclosed
herein to maximize the second fan blade assembly's 400 venting of waste air
flow. The
first fan blade assembly 300 pulls air from the second fan blade assembly's
400 venting of
waste air flow. The first fan blade assembly 300 is also weighted and balanced
very
precisely when manufactured in order to handle high rpm.
[0033] Turning to
the drawings, Figure 5 is an illustration of a top side view of
a second fan blade assembly 400 disclosed herein. The second fan blade
assembly 400
comprises a hub 404, a plurality of second fan blade assembly blades 402. In
some
embodiments, the second fan blade assembly hub 404 has a diameter 408 of about
6 inches.
In some embodiments, the second fan blade assembly hub 404 has a diameter 408
between
about 4 inches and 8 inches. In some embodiments, the width 410 of the
plurality of second
fan blades 402 is about 18 inches. In some embodiments, the width 410 of the
plurality of
second fan blades 402 is between about 8 inches and 22 inches. In some
embodiments, the
second fan blade assembly 400 has a diameter 412 of about 213/4 inches. In
some
embodiments, the second fan blade assembly 400 has a diameter 412 between
about 18
inches and 22 inches. As illustrated, the first side of a second fan blade
assembly 400 has
a rotation of 406, and each second fan blades 402 has a second fan blade
leading edge 414
and a second fan blade tailing edge 416 with a pitch angle of about 40 degrees
and 4 first
fan blades. In some embodiments, the pitch angle is between about 20 degrees
and 60
degrees and between about 4 and 10 first fan blades. In some embodiments, the
vertical
between the second fan blade tailing edge 416 and the second fan blade leading
edge 414
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is about 61/2 inches. In some embodiments, the vertical between the second fan
blade
tailing edge 416 and the second fan blade leading edge 414 is between about 2
inches and
8 inches. In operation, the top side view second fan blade assembly 400
represents the side
of the fan blade that is facing the exiting air flow towards the waste air
flow capture system
100 disclosed herein. The second fan blade assembly 400 is a wind propulsion
style fan
and pushes air away from the Air conditioning unit or heat pump. This second
fan blade
assembly 400 comprises four blades pitched for clockwise revolutions. The
combination
of pushing by the second fan blade assembly 400 and pulling of the first fan
blade assembly
300 while facing each other creates the power generated as a result of these
revolutions
more than cancels the power needed to run the second fan blade assembly 400.
[0034] Figure 6A illustrates a top view of a fan shroud column 700
disclosed
herein. The fan shroud column 700 has a diameter 704 of about 26 inches. In
some
embodiments, the fan shroud column 700 has a height 802 as depicted with
Figure 6B as a
side view of the fan shroud column of about 7 inches. Installation of the
waste air flow
capture system 100 in some instances is requires utilizing the fan shroud
column 700 is
installed between the waste air flow capture system 100 and the HVAC
compressor or a
heat pump compressor. The fan shroud column depicted with Figures 6A and 6B
comprise
a plurality of fan column notches 702 spaced around the circumference to mate
with the
support arms 106 of the second electrical generator bracket.
[0035] The installation depicted with Figure 7 is an isometric view of a
waste
air flow capture system installation 900 with a heat pump 902. In this
example, the waste
air flow capture system 100 has been installed on the waste air flow channel
916 of a heat
pump compressor 902, whereby a second fan blade assembly 400 is original
equipment
and therefore replacement it not needed. In some embodiments, wherein the
waste air flow
capture system further comprises that the HVAC compressor or a heat pump
compressor
comprises a second fan blade assembly configured to transmit wasted air flow
from a waste
air flow channel of an HVAC compressor or a heat pump compressor, wherein the
second
fan blade assembly is either original equipment with the HVAC compressor or
the heat
pump compressor or the second fan blade assembly replaces an original HVAC
compressor's or heat pump compressor's exhaust fan. The air flow direction
918, which is
derived from the exhaust air flow being pushed out via the gas flow channel
916 and
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subsequently pulled via the automotive radiator style cooling fan used as the
first fan blade
assembly 200 disclosed herein. In this aspect, the first side of a first fan
blade assembly
300 has a clockwise rotation of 310. As illustrated, the waste air flow
capture system
installation 900 comprises serial wire 502, positive and negative power wires
504 and 606,
rectifiers 506 and 602, battery bank 906, inverter wire 908, inverter 910 and
the grid 914.
In some embodiments, the first electrical generator and the second electrical
generator are
connected to a charge controller, rectifier, power grid, battery storage bank
and/or an
inverter. In some embodiments, wherein the waste air flow capture system
further
comprises a controller coupled to the each generator for receiving a current
from each
generator in parallel or in series. In some embodiments, wherein the waste air
flow capture
system further comprises an electrical power converter for converting DC to AC
and for
outputting electric power output.
[0036] In another
example the installation depicted with Figure 8 is top side
view of a waste air flow capture system installation 1000 with an HVAC
compressor 1006.
In this instance the installation begins with removing 1008 the HVAC
compressor's
original exhaust fan shroud 1004 via bolts 1018 and removing and replacing
1010 exhaust
fan 1002 via the original fan motor bracket 1020 by removing 1014 one or more
fan blade
bolts 1016 and the exhaust fan 1002 is replaced with the second fan blade
assembly 400
disclosed herein. In some embodiments, wherein the waste air flow capture
system further
comprises that an HVAC compressor's or heat pump compressor's original fan
shroud is
removed. Next, as depicted waste air flow capture system 100 is then mounted
on the waste
air flow channel 1012 of the HVAC compressor with bolts 102 engaged are
aligned with
cylindrical shroud mounting apertures 124 and support arm mounting apertures
104 and
tightened within threaded compressor apertures 1022. Moreover, the waste air
flow capture
system 100 may be installed in series over multiple waste air flow channels
1012. In some
installations, the original compressor's fan motor 1024 is removed 1026 and
replaced with
a replacement fan motor 1028 for greater efficiency operating with the second
fan blade
assembly 400. The replacement fan motor 1028 may be an efficient 1/4 hp
electric motor
rated between about 1100 rpm and 1725 rpm. The second fan blade assembly 400
is lighter
and more efficient than the exhaust fan 1002 and therefore the original
compressor's fan
motor 1024 rated at about 1/2 hp to 3/4 hp is no longer needed to efficiently
rotate the second
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fan blade assembly 400. This raises the efficiency by reducing the amount of
power needed
to rotate the second fan blade assembly 400. Moreover, this also allows for an
increase
speed of the wasted air flow from the compressor, which results in more power
being
generated by the single generator or dual generator waste air flow capture
system 500.
[0037] Figure 9 is
an isometric view of a waste air flow capture system
installation 1100 with an HVAC compressor 1102 and including a fan shroud
column 800
disclosed herein. The direction of the airflow 1104 is shown with this
installation of a
HVAC compressor 1102, whereby the original compressor's fan motor 1024 and the
compressor's original fan motor bracket 1020 is replaced with the second
electrical
generator bracket comprises an L-bracket 108, a center ring portion 112 and a
plurality of
support arms 106 with replacement fan motor 1028. The original exhaust fan is
replaced
with the second fan blade assembly 400. Then, the fan shroud column 800
disclosed herein
is engaged with the outer perimeter of waste air flow channel of an HVAC
compressor and
held in place between via bolts 102 tightened against the assembly and engaged
and aligned
with cylindrical shroud mounting apertures 124 and support arm mounting
apertures 104.
In some embodiments, wherein the waste air flow capture system further
comprises a fan
shroud column configured to fit around a fan shroud of waste air flow channel
of an HVAC
compressor or a heat pump compressor. In some embodiments, wherein the waste
air flow
capture system further comprises a fan shroud column configured to fit around
a fan shroud
of waste air flow channel of an HVAC compressor or a heat pump compressor,
wherein
the fan shroud column comprises a plurality of notches for engaging with a
plurality of
support arms affixed to an outer portion of a center ring of the second
electrical generator
bracket. Next, with the fan column notches 702 engage with the support arms
106 of the
second electrical generator bracket. During operation the exhaust air 1104 is
pushed by the
second fan blade assembly 400 towards the first fan blade assembly 300 thereby
rotating
the first electrical generator motor 138 and the second electrical generator
motor 116
simultaneously. Thus, the design affords the use of electrical generator
motors on opposing
sides of the hub of the first fan blade assembly 300, and subsequently turning
this
mechanical energy into electrical power during operation of the HVAC
compressor 1102.
Employing twin generators which can generate power either clockwise or counter
clockwise places twin generators facing each other with the first fan blade
assembly 300
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(i.e., automotive radiator cooling fan blade) in the middle creating a single
shaft turning in
parallel with the two drive shafts coupled at the central axis of the hub.
[0038] With the systems and methods disclosed herein, the waste wind
energy
of an air conditioner compressor and heat pump compressor is used and
converted into
electric power and to conserve energy. In addition, the present disclosure is
applicable for
various types of heat dissipating or ventilating air conditioners such as air
conditioners,
square water cooling type water towers, erected or aslant water cooling type
water towers,
which can be used for the air cooling type outdoor air conditioner or air
cooling type ice
water cooler, etc. In some embodiments, the system is configured to be bolted
onto the
HVAC compressor or the heat pump compressor. The waste air flow capture system
100
is also universally sized for residential and commercial air conditioning
units and heat
pumps.
[0039] In another aspect, disclosed herein is a waste air flow capture
system
kit, comprising: a) a cylindrical shroud configured to receive a waste air
flow from a waste
air flow channel of an HVAC compressor or a heat pump compressor and
configured to
vent the waste air flow received from the waste air flow channel of an HVAC
compressor
or a heat pump compressor; b) a first electrical generator configured to
generate electricity
when a first fan blade assembly rotates relative to the cylindrical shroud; c)
a second
electrical generator configured to generate electricity when a first fan blade
assembly
rotates relative to the cylindrical shroud; d) a first fan blade assembly
enclosed by the
cylindrical shroud and coupled to the first electrical generator motor on a
first side of the
first fan blade assembly and coupled to the second electrical generator motor
on a second
side of the first fan blade assembly; e) a second fan blade assembly
configured to transmit
wasted air flow from a waste air flow channel of an HVAC compressor or a heat
pump
compressor; and f) a second electrical generator bracket capable of holding
the second
electrical generator. In some embodiments, the kit comprises the fan shroud
column 800.
In some embodiments, the kit comprises the second electrical generator bracket
comprises
an L-bracket 108, a center ring portion 112 and a plurality of support arms
106 and the
replacement fan motor 1028.
[0040] In another aspect, disclosed herein is a method of passively
generating
electric power by recycling waste air flow received from a waste air flow
channel of an
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HVAC compressor or a heat pump compressor with the system of claim 1,
comprising the
steps of: a) removing an HVAC compressor's or a heat pump compressor's fan
shroud; b)
replacing an HVAC compressor's or a heat pump compressor's fan blade assembly
with a
second fan blade assembly; c) installing a waste air flow capture system on a
waste air flow
channel of an HVAC compressor or a heat pump compressor, wherein a cylindrical
shroud
of the waste air flow capture system is facing away from the HVAC compressor
or a heat
pump compressor; d) using waste air flow from the channel of the HVAC
compressor or
the heat pump compressor to drive a first fan blade assembly and convert the
wind energy
into a mechanical energy which is converted further into electrical power; and
e) converting
the electric power with an electrical power converter for converting DC to AC
and for
outputting electric power output.
[0041] In another aspect, disclosed herein is a method of passively
generating
electric power by recycling waste air flow received from a waste air flow
channel of an
HVAC compressor or a heat pump compressor with the system of claim 1,
comprising the
steps of: a) removing an HVAC compressor's or a heat pump compressor's fan
shroud; b)
installing a waste air flow capture system on a waste air flow channel of an
HVAC
compressor or a heat pump compressor, wherein a cylindrical shroud of the
waste air flow
capture system is facing away from the HVAC compressor or a heat pump
compressor; c)
using waste air flow from the channel of the HVAC compressor or the heat pump
compressor to drive a first fan blade assembly and convert the wind energy
into a
mechanical energy which is converted further into electrical power; and d)
converting the
electric power with an electrical power converter for converting DC to AC and
for
outputting electric power output.
[0042] In another aspect, disclosed herein is a method of passively
generating
electric power by recycling waste air flow received from a waste air flow
channel of an
HVAC compressor or a heat pump compressor with the system of claim 1,
comprising the
steps of: a) replacing an HVAC compressor's or a heat pump compressor's fan
blade
assembly with a second fan blade assembly; b) installing a fan shroud column
configured
to fit around a fan shroud of waste air flow channel of an HVAC compressor or
a heat
pump compressor; c) installing a waste air flow capture system on a waste air
flow channel
of an HVAC compressor or a heat pump compressor, wherein a cylindrical shroud
of the
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CA 02931248 2016-05-26
waste air flow capture system is facing away from the HVAC compressor or a
heat pump
compressor; d) using waste air flow from the channel of the HVAC compressor or
the heat
pump compressor to drive a first fan blade assembly and convert the wind
energy into a
mechanical energy which is converted further into electrical power; and e)
converting the
electric power with an electrical power converter for converting DC to AC and
for
outputting electric power output.
[0043] In another aspect, disclosed herein is a method of passively
generating
electric power by recycling waste air flow received from a waste air flow
channel of an
HVAC compressor or a heat pump compressor with the system of claim 1,
comprising the
steps of: a) installing a fan shroud column configured to fit around a fan
shroud of waste
air flow channel of an HVAC compressor or a heat pump compressor; b)
installing a waste
air flow capture system on a waste air flow channel of an HVAC compressor or a
heat
pump compressor, wherein a cylindrical shroud of the waste air flow capture
system is
facing away from the HVAC compressor or a heat pump compressor; c) using waste
air
flow from the channel of the HVAC compressor or the heat pump compressor to
drive a
first fan blade assembly and convert the wind energy into a mechanical energy
which is
converted further into electrical power; and d) converting the electric power
with an
electrical power converter for converting DC to AC and for outputting electric
power
output.
DEFINITIONS
[0044] For the purposes of this specification and appended claims,
unless
otherwise indicated, all numbers expressing quantities, percentages or
proportions, and
other numerical values used in the specification and claims, are to be
understood as being
modified in all instances by the term "about." Accordingly, unless indicated
to the contrary,
the numerical parameters set forth in the following specification and attached
claims are
approximations that can vary depending upon the desired properties sought to
be obtained.
It is noted that, as used in this specification and the appended claims, the
singular forms
"a," "an," and "the," include plural references unless expressly and
unequivocally limited
to one referent. As used herein, the term "include" and its grammatical
variants are intended
to be non-limiting, such that recitation of items in a list is not to the
exclusion of other like
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items that can be substituted or added to the listed items. As used herein,
the term
"comprising" means including elements or steps that are identified following
that term, but
any such elements or steps are not exhaustive, and an embodiment can include
other
elements or steps.
[0045] As will be understood by one skilled in the art, for any and all
purposes,
particularly in terms of providing a written description, all ranges disclosed
herein also
encompass any and all possible subranges and combinations of subranges
thereof. Any
listed range can be easily recognized as sufficiently describing and enabling
the same range
being broken down into at least equal halves, thirds, quarters, fifths,
tenths, etc. As a non-
limiting example, each range discussed herein can be readily broken down into
a lower
third, middle third and upper third, etc. As will also be understood by one
skilled in the art
all language such as "up to," "at least," "greater than," "less than," and the
like, include the
number recited and refer to ranges which can be subsequently broken down into
subranges
as discussed above. Finally, as will be understood by one skilled in the art,
a range includes
each individual member.
[0046] While certain embodiments have been illustrated and described, it
should be understood that changes and modifications can be made therein in
accordance
with ordinary skill in the art without departing from the technology in its
broader aspects
as defined in the following claims.
[0047] The present disclosure is not to be limited in terms of the
particular
embodiments described in this application. Many modifications and variations
can be made
without departing from its spirit and scope, as will be apparent to those
skilled in the art.
Functionally equivalent methods and devices within the scope of the
disclosure, in addition
to those enumerated herein, will be apparent to those skilled in the art from
the foregoing
descriptions. Such modifications and variations are intended to fall within
the scope of the
appended claims. The present disclosure is to be limited only by the terms of
the appended
claims, along with the full scope of equivalents to which such claims are
entitled. It is to
be understood that this disclosure is not limited to particular methods or
devices, which
can of course vary. It is also to be understood that the terminology used
herein is for the
purpose of describing particular embodiments only, and is not intended to be
limiting.
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[0048] All
publications, patent applications, issued patents, and other
documents referred to in this specification are herein incorporated by
reference as if each
individual publication, patent application, issued patent, or other document
was
specifically and individually indicated to be incorporated by reference in its
entirety.
Definitions that are contained in text incorporated by reference are excluded
to the extent
that they contradict any definitions in this disclosure.
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