JP7690263B2 - Modular Active Response System - Google Patents

Description

CITED PATENTS The following documents and references are incorporated herein in their entirety: Erlston et al. (U.S. Patent Application No. 2008/0078631) and Bodenstein et al. (U.S. Patent Application No. 2012/0091724).

The present invention relates to the generation of supplemental energy from the motion of a vehicle, and more specifically to the generation of energy by combining a vehicle's disc brakes with a brushless motor-generator.

A large amount of energy is required to move a vehicle, and an approximately equal amount of energy (negative transmission losses) is released when the vehicle comes to a stop. In recent years, hybrids and other vehicles have used electric motors located in the wheels to regenerate energy during braking. Similarly, some of the energy used to move the vehicle can be recovered.

Vehicles with disc brakes (e.g., automobiles, rail vehicles, light aircraft, and other similar applications) employ a rotor located on the axle or wheel hub and a caliper mechanism that presses brake pads against either side of the rotor to create friction and braking force. Most civilian and military aircraft have multiple rotors connected together with ventilation slots between them. When using conventional disc brakes, the vehicle's kinetic energy is released as heat when the brakes are applied.

Such a feature would be advantageous because it could generate electricity from the braking motion, recharging the battery and eliminating the need to run the vehicle's alternator. What is needed is a simple mechanical method of coupling to the brake rotor.

The "SUMMARY OF THE PRESENT DISCLOSURE" section is intended to provide an overview of some aspects of the present invention and to provide a brief introduction to some embodiments. In order to avoid obscuring the purpose of this section, simplifications and omissions may be used. Such simplifications or omissions are not intended to limit the scope of the present invention.

All references cited herein, including any patents or patent applications, are hereby incorporated by reference. No reference is admitted to constitute prior art. The contents of the references state what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinence of the cited documents. Although this specification refers to a number of prior documents, it will be clearly understood that such reference is not an admission that any of the documents form part of the common general knowledge in the prior art.

It is recognized that the word "comprise" may be interpreted in various jurisdictions in either an exclusive or an inclusive sense. For purposes of this specification, unless otherwise specified, the word "comprise" shall have an inclusive meaning, i.e., meaning to include not only the listed parts that are directly referenced, but also other parts or components not specifically shown. This principle also applies when the words "comprised" or "comprising" are used in connection with one or more steps of a method or process.

In one aspect, the present invention relates to an energy device for a vehicle that includes a generator coupled to a shaft having mechanical components for coupling with a disk ventilation slot and electronic components for connecting the generator to the vehicle's electrical system.

Other features and advantages of the present invention will become apparent from the following detailed description of the embodiments thereof, taken in conjunction with the accompanying drawings.

FIG. 1 is a front perspective view showing components of a prior art disc brake system. FIG. 2 is a perspective view of a coupled disc brake and generator according to one embodiment of the present invention. FIG. 3 is a rear view of a coupled disc brake and generator according to one embodiment of the present invention. FIG. 4 is a perspective view of a combined disc brake/generator including a vehicle tire, according to one embodiment of the present invention. FIG. 5 is a top view of a combined disc brake/generator according to one embodiment of the present invention. FIG. 6 is a top view of a combined disc brake/generator according to one embodiment of the present invention. FIG. 7 is a side view of a disc brake and bracket according to one embodiment of the present invention. FIG. 8 is a side view of a disc brake and bracket according to one embodiment of the present invention. FIG. 9 is a perspective view of a disc brake and generator components according to one embodiment of the present invention. FIG. 10 is a perspective view of a disc brake and generator components according to one embodiment of the present invention. FIG. 11 is a perspective view of a chain-linked disc brake/generator including a wheel hub according to one embodiment of the present invention. FIG. 12 is a perspective view of a disc brake/generator linked using a chain according to one embodiment of the present invention. FIG. 13 is a front view of a disc brake/generator linked using a chain according to one embodiment of the present invention. FIG. 14 is a side view of a disc brake/generator linked using a chain according to one embodiment of the present invention. FIG. 15 is a top view of a disc brake/generator linked using a chain according to one embodiment of the present invention. FIG. 16 is a partially exploded perspective view of a disk brake/generator linked using a chain according to one embodiment of the present invention. FIG. 17 is a side cross-sectional view taken along line BB of FIG. 18 showing a disc brake/generator linked using a chain according to one embodiment of the present invention. FIG. 18 is a front view of a disc brake/generator linked using a chain according to one embodiment of the present invention. FIG. 19 is a partial cross-sectional view of a disc brake coupled with a chain according to one embodiment of the present invention. FIG. 20 is a partial cross-sectional view of a sprocket coupled with a chain in accordance with one embodiment of the present invention. FIG. 21 is a top view of a sprocket in accordance with one embodiment of the present invention. FIG. 22 is a side view of a sprocket in accordance with one embodiment of the present invention. FIG. 23 is a plan view of the jaw members and axle of the clutch; FIG. 24 is a side view of the jaw members and axle of the clutch; FIG. 25 is a plan view of the driven member or generator shaft of the clutch. FIG. 26 is a side view of the driven member or generator shaft of the clutch. FIG. 27 is a plan view of the jaw members of the clutch; FIG. 28 is a side view of a jaw member of the clutch; FIG. 29A shows a diagram of a sprocket according to one embodiment of the present invention. FIG. 29B shows a diagram of a sprocket according to one embodiment of the present invention. FIG. 29C shows a diagram of a sprocket according to one embodiment of the present invention. FIG. 30A shows a diagram of the disk assembly parts according to one embodiment of the present invention. FIG. 30B shows a diagram of the disk assembly parts according to one embodiment of the present invention. FIG. 30C shows a diagram of the disk assembly parts according to one embodiment of the present invention. FIG. 30D shows a diagram of the disk assembly parts according to one embodiment of the present invention. FIG. 30E shows a diagram of the disk assembly parts according to one embodiment of the present invention. FIG. 31 shows a diagram of an axle and clutch according to one embodiment of the present invention. FIG. 32 shows a diagram of an axle and clutch according to one embodiment of the present invention. FIG. 33 is a perspective view of a combined disc brake/generator according to another embodiment of the present invention. FIG. 34 is a front perspective view of a combined disc brake/generator according to another embodiment of the present invention. FIG. 35 is a cross-sectional side view of a combined disc brake/generator according to another embodiment of the present invention. FIG. 36 is a partial perspective view of a coupler that engages a chain around a disc brake rotor according to one embodiment of the present invention. 37 is a partial perspective view of a coupler engaging a chain around a disc brake rotor and showing a clutch according to one embodiment of the present invention. The above-discussed features and other features will be appreciated and understood by those skilled in the art from the following detailed description, the drawings and the appended claims.

The "Description of the Invention" section is intended to provide an overview of some aspects of the invention and to provide a brief introduction to some embodiments. In order to avoid obscuring the purpose of this section, some simplifications and omissions may be used. Such simplifications or omissions are not intended to limit the scope of the invention.

In order to provide a general understanding of the present invention, several exemplary embodiments and examples are described below. However, those skilled in the art will recognize that the same or equivalent functions and sequences may be accomplished by different embodiments that are intended to fall within the spirit and scope of the present disclosure. The compositions, devices, systems, and/or methods described herein may be modified and altered to suit the application at hand, and those described herein may be used in other suitable applications. Such other additions and modifications do not depart from the scope of the present disclosure.

Simplifications and omissions may be made to avoid obscuring the purpose of this section. Such simplifications or omissions are not intended to limit the scope of the invention. All references cited herein, including any patents or patent applications, are hereby incorporated by reference. No reference is admitted to constitute prior art. The contents of the references state what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinence of the cited documents. Although prior documents are referenced herein, it will be clearly understood that such reference is not an admission that any of the documents form part of the common general knowledge in the prior art.

As used herein and in the claims, the singular "a," "an," and "the" include the plural unless the context clearly indicates otherwise. For example, the term "a transaction" may include a plurality of transactions unless the context clearly indicates otherwise. As used herein and in the claims, a name or type referred to in the singular includes variations that are subsumed by that name unless the context clearly indicates otherwise.

In the following description, some terms are used for convenience only and are not limiting. The words "lower," "upper," "bottom," "top," "front," "back," "left," "right," and "sides" indicate directions as referenced in the figures but do not limit the orientation in which the modules or any assemblies thereof may be used.

It is recognized that the word "comprise" may be interpreted in various jurisdictions in either an exclusive or an inclusive sense. For purposes of this specification, unless otherwise specified, the word "comprise" shall have an inclusive meaning, i.e., meaning to include not only the listed parts that are directly referenced, but also other parts or components not specifically shown. This principle also applies when the words "comprised" or "comprising" are used in connection with one or more steps of a method or process.

1, a disc brake system currently practiced in the prior art is shown with a disc brake rotor 100. The disc brake rotor 100 has ventilation slots 102 arranged circumferentially about its center. Positioned astride the disc brake rotor 100 is a brake caliper 104 having a hollow interior defined by a pair of sides 106, 108. Positioned within the hollow interior within the sides 106, 108 are a pair of brake pads 110 sized to engage a portion of the outer surface of the disc brake rotor 100. A guide pin 112 located at one end of the brake caliper 104 can squeeze the brake caliper 104, thereby moving the brake pads 110 so that they engage the disc brake rotor 100. An inspection hole 114 at the top of the brake caliper 104 allows the brake pads 110 to be visually inspected to determine their relative wear. The disc brake rotor 100 is connected to a wheel via a wheel hub 116 and wheel studs 118. Although a disc brake rotor is shown and disclosed herein, it will be understood that the energy generating system of the present invention may be used with other components that can be attached or coupled to a vehicle axle (i.e., rotate with the tire), including, but not limited to, drum brakes. It will be understood that if other components are used, a chain or other rotating conveyor can be customized to wrap around and engage the components to achieve energy generation as disclosed herein.

With reference to Figures 2-37, various embodiments of an energy generation system 200 are shown having a generator 204, a mechanical coupler 206, a connecting member 208, and an energy storage system 210. In both front and rear wheel configurations, the system 200 fits within the wheel area, with the forward location allowing it to rotate with the movement of the wheel.

2, 3, 21, and 29A-C, the mechanical coupler 206 is shown as a sprocket or gear having a plurality of circumferentially spaced teeth 212 that are sized and shaped to mesh with corresponding ventilation slots 102 of the disc brake rotor 100. In another embodiment (FIGS. 33-37), the coupler 206 meshes with openings in a roller chain 300 located around the edge of the disc brake rotor 100 to facilitate rotation. With reference to FIG. 19, to facilitate mechanical connection of the chain 300 to the disc brake rotor 100, the spokes or elongated members 214 that form the ventilation slots 102 are provided with tapered ends 216 for meshing with openings in the links of the chain 300. Also, while a chain is shown and disclosed herein, it will be understood that other rotating conveyors may be used, such as, but not limited to, timing belts and pulleys. Additionally, although tapered ends are shown and disclosed herein, it will be appreciated that a chain or other rotating conveyor may be engaged with the disc brake rotor 100 by friction or other known connectors 336 or connection methods. With particular reference to FIG. 30A, various connectors may be secured or positioned in channels 340 provided around the periphery of the disc brake rotor 100.

The mechanical coupler 206 is connected to a shaft or axle 208 that passes through its center. A bracket 202 may be used to maintain the coupler 206 in the proper position relative to the disc brake rotor 100. As with the disc caliper 104 in operation, the bracket 202 is maintained parallel to the surface of the disc brake. To avoid interfering with the operation of the disc brake, the coupler 206 and bracket 202 are positioned away from the caliper 104 around the circumference of the disc brake rotor 100.

Referring again to FIG. 2, a hollow bracket 202 defined by a pair of side walls 220 is positioned to straddle the disc brake rotor 100. To allow the coupler 206 to be aligned with the ventilation slots 102, the side walls 220 are provided with opposed holes 222 therethrough for receiving portions of the axle or shaft 208. As shown in FIG. 16, a bushing 224 may be inserted into the hole 222 to facilitate rotation of the axle 208.

The axles 208 are connected to a generator 204 for generating energy in the form of either alternating current ("AC") or direct current ("DC"). This energy is transmitted to and/or stored in an energy storage or system. The energy storage or system may be located locally with the generator or may be part of the vehicle's energy system. This may include powering an alternator/battery bus and/or separate vehicle electronics. For example, energy may be stored in one or more batteries located on the vehicle and/or in a trailer or their accessories.

Now referring to Figures 13, 23, 24, 27, 28, 31-33, the energy generation system 200 may include a clutch 230 to generate energy only when desired or required. The illustrated positive clutch 230 includes a jaw member 232 at the end of the axle 208 and a corresponding jaw member 234 disposed on a driven shaft 236 for the generator 204. When the clutch 230 is engaged, the corresponding jaw members 232, 234 engage and allow rotational motion to be transferred to the generator 204. When disengaged, the axle 208 rotates without transferring energy to the generator 204. Similarly, the energy generation can be electronically shunted so that the load is minimal when no energy is being generated.

In operation, one or more teeth 212 of the sprocket 206 mesh with respective slots of the ventilation slots 102 of the disc brake rotor 100. As the disc brake rotor 100 rotates, the teeth 212 of the sprocket 206 move out of and into the slots 102, causing the sprocket 206 and axle 208 to rotate. Thus, as the wheel moves, the disc brake rotor 100 moves, causing the axle 208 to move towards the generator, generating energy that is stored on the vehicle. If desired, a clutch 230 may be utilized to selectively allow control of the transfer of energy to the generator 204.

FIGS. 11-20 show another embodiment of the invention in which a chain 300 is used to transfer rotational energy from the disc brake rotor 100 to a coupler or sprocket 206. In this embodiment, the sprocket 206 is offset from the disc brake rotor 100. As shown in FIGS. 19 and 20, the ventilation slots 102 are formed by a plurality of spokes or elongated members 214 having tapered ends 216. The chain 300 spans both a substantial portion of the circumference of the disc brake rotor 100 that meshes with the tapered ends 216 and a portion of the sprocket 206, thereby meshing with the sprocket teeth 212. Referring to FIG. 14, a clutch 230 as disclosed above may be used to selectively control the transfer of energy to the generator 204.

In concluding the detailed description, it should be noted that it will be obvious to those skilled in the art that many changes and modifications can be made to the embodiments without substantially departing from the principles of the present invention. Such changes and modifications are intended to be included within the scope of the present invention as set forth in the appended claims. Furthermore, in the following claims, the structures, materials, acts and equivalents of all means or step-plus-function elements are intended to include any structures, materials or acts for performing their recited functions.

It should be emphasized that the above-described embodiments of the present invention, particularly the "proposed embodiments," are merely possible examples of implementations, set forth solely for a clear understanding of the principles of the present invention. Any changes and modifications may be made to the above-described embodiments of the present invention without substantially departing from the spirit of the principles of the present invention. All such modifications and changes are intended to be included within the scope of this disclosure and the present invention, and to be protected by the following claims.

The present invention has been described in sufficient detail above, to a certain extent, and its usefulness is understood by those skilled in the art. Those skilled in the art will appreciate that the present disclosure of these embodiments is by way of example only, and that various changes in the arrangement and combination of parts may be employed without departing from the spirit and scope of the invention as claimed. Accordingly, the scope of the invention is defined by the appended claims, and not by the description of the embodiments set forth above.

Claims (19)

1. A system for generating energy in a vehicle having a disc brake including a disc having a circumferential surface provided with a plurality of ventilation slots, comprising:
A generator,
a coupler having a plurality of teeth for mechanically connecting the generator to the ventilation slot of the disk;
a bracket for holding the coupler in a position where the teeth engage the ventilation slots of the disk;
The rotation of the disk rotates the coupler to provide rotational energy to the generator to generate energy for storage. The system of claim 1, wherein the generator includes a connection member that mechanically connects the generator to the coupler. The system of claim 2, wherein the connecting member is an axle. The system of claim 2, wherein the coupler includes a coupler member having a plurality of teeth for engaging with the ventilation slot. The system of claim 2, further comprising a bracket that maintains the coupler in position relative to the ventilation slot of the disk. The system of claim 1, wherein the coupler includes a coupler member having a plurality of teeth for engaging with the ventilation slot. The system of claim 1, wherein the coupler includes a chain disposed around at least a portion of the circumference of the disk, and a coupler member having a plurality of teeth for engaging with the chain. The system of claim 7, wherein the ventilation slots in the disk are defined by an elongated member having a tapered end, and the chain meshes with the tapered end of the elongated member. The system of claim 1, further comprising a bracket that maintains the coupler in position relative to the ventilation slot of the disk. The system of claim 1, wherein the coupler includes a chain. The system of claim 1, further comprising a clutch that selectively controls the generation of energy by the generator. The system of claim 1, further comprising an energy storage system electrically connected to the generator for storing energy generated by rotation of the disk. 1. A system for generating energy in a vehicle having a disc brake including a disc having a circumferential surface provided with a plurality of ventilation slots, comprising :
A generator,
a chain having a plurality of links, each having an opening therethrough, disposed about at least a portion of a circumference of the disk;
a coupler having a plurality of members for engaging the openings in the plurality of links of the chain;
at least one connection member mechanically coupling the generator to the coupler;
The rotation of the disk rotates the coupler and the connecting member to provide rotational energy to the generator to generate energy for storage. The system of claim 13, wherein the plurality of members are teeth. The system of claim 13, further comprising a bracket that maintains the coupler in position relative to the disc brake of the disc. The system of claim 13, further comprising a clutch that selectively controls the generation of energy by the generator. The system of claim 13, wherein the coupler includes a chain disposed around at least a portion of the circumference of the disk, and a coupler member having a plurality of teeth for engaging with the chain. 1. A system for generating energy in a vehicle having a disc brake including a disc having a circumferential surface provided with a plurality of ventilation slots, comprising:
A generator,
a chain having a plurality of links, each having an opening therethrough, disposed about at least a portion of a circumference of the disk;
a coupler having a plurality of members for engaging the openings in the plurality of links of the chain;
at least one connection member mechanically coupling the generator to the coupler;
rotation of the disk rotates the coupler and the connecting member to provide rotational energy to the generator to generate energy for storage;
the coupler including a chain disposed about at least a portion of a circumferential surface of the disk, and a coupler member having a plurality of teeth for engaging with the chain;
The ventilation slots in the disk are defined by an elongated member having a tapered end, and the chain meshes with the tapered end of the elongated member. The system of claim 13, further comprising an energy storage system electrically connected to the generator for storing energy generated by rotation of the disk.

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