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Patent Application Publication Apr. 3, 2014 Sheet 5 of 10 US 2014/009 1890 A1
Patent Application Publication Apr. 3, 2014 Sheet 6 of 10 US 2014/009 1890 A1
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current to the toroid windings 111 adds to its portion of the 0022 FIG. 4 is a drawing that depicts a preferred embodi
magnetic flux 103 received from primary magnetic path 100 ment of the invention;
yielding an increased net magnetic flux that approaches or 0023 FIG. 5 is a detail drawing an alternative reluctance
exceeds the knee of the materials magnetization curve Switch according to the invention implemented through split
thereby reducing its relative permeability and increasing its laminations;
reluctance. 0024 FIGS. 6A and 6B show the operation of an energy
generator according to the invention;
SUMMARY OF THE INVENTION (0025 FIG. 7A is an exploded view of a preferred energy
0014. This invention is directed to methods and apparatus generator construction;
wherein magnetic flux is Switched in direction and in inten 0026 FIG. 7B is a side view of the construction of FIG.
sity through a flux path to produce electricity. The apparatus 7A:
broadly comprises at least one permanent magnet generating 0027 FIG. 8 is a simplified schematic diagram of compo
flux, a magnetizable member forming the flux path, an elec nents used to simulate the apparatus of the invention;
trical conductor wound around the magnetizable member, 0028 FIG. 9A is a diagram that shows the current deliv
and a plurality of flux Switches operative to sequentially ered to one pair of flux switches in the simulation;
reverse the flux from the magnet through the member, thereby (0029 FIG.9B is a diagram that shows the current deliv
inducing electrical current in the coil. ered to the other set of flux switches in the simulation;
0015 The preferred embodiment includes first and second 0030 FIG.10 shows the output of the simulation disclosed
loops of magnetizable material. The first loop has four seg herein; and
ments in order A, 1, B, 2, and the second loop has four 0031 FIG. 11 is a block diagram of a controller applicable
to the invention.
segments in order C, 3, D, 4. The magnetizable member
couples segments 2 and 4, and the permanent magnet couples DETAILED DESCRIPTION OF THE INVENTION
segments 1 and 3. Such that the flux from the magnet flows
through segments A, B, C, D and the magnetizable member. 0032 FIG. 2 is a detail drawing of a reluctance switch
Four magnetic flux Switches are provided, each controlling according to the invention. The reluctance Switch includes the
the flux through a respective one of the segments A, B, C, D. following components: a closed magnetic path 110 com
A controller is operative to activate switches A-D and B-C in prised of a high performance magnetic material (preferably a
an alternating sequence, thereby reversing the flux through nonlinear material exhibiting a 'sharp knee' as Saturation is
the segment and inducing electricity in the electrical conduc approached), around which is wound a coil 111. The closed
tor. The flux flowing through each segment A, B, C, D is magnetic path 110 shares common segment 101 with a pri
substantially half of that flowing through the magnetizable mary magnetic path 100, in which magnetic flux 103 is
member prior to switch activation. induced by a permanent magnet (shown in Subsequent draw
0016. The loops and magnetizable member are preferably ings). Electric current is applied to windings 111 having a
composed of a nanocrystalline material exhibiting a Substan polarity and Sufficient amperage so that the magnetic flux
tially square BH intrinsic curve. Each magnetic flux switch generated in the path of switch 110 is additive to the magnetic
adds flux to the segment it controls, thereby magnetically flux 103 from the permanent magnet, such that the primary
saturating that segment when activated. To implement the path 110 approaches or reaches magnetic Saturation.
Switches, each segment may have an aperture formed there 0033 FIGS. 3A and 3B are detail drawings of apparatus
through and a coil of wire wound around a portion of that that employs four reluctance Switches according to the inven
segment and through the aperture. The controller may be at tion in a manner similar to that disclosed in U.S. patent
least initially operative to drive the switchcoils with electrical application Ser. No. 11/735,746 entitled “Electricity Gener
current spikes. ating Apparatus Utilizing a Single Magnetic Flux Path, the
0017. The first and second loops may be toroidal in shape, entire content of which is incorporated herein by reference. In
and the loops may be spaced apart from one another, with A this and in all embodiments described herein, the geometry of
opposing C, 1 opposing 3, B opposing D and 2 opposing 4. the closed magnetic paths may be circular (toroidal), rectan
The magnetizable member in this case is preferably a separate gular, or any other closed-path shapes. A primary path 304
piece of material. Alternatively, the first and second loops unidirectionally carries the flux from permanent magnet 302.
may form a “Figure-8 shape, with the two loops intersecting Flux switch pairs 310A/E and 310 B/D are activated in alter
to form the magnetizable member. nating fashion to reverse the flux in magnetizable member
0018. The permanent magnet(s) and the material compris 304C, thereby inducing electrical current in winding 330.
ing the magnetic paths are preferably proportioned Such that FIG. 3A shows the flux flow in one direction, and FIG. 3B
the material through the common segment is at or slightly shows it reversed.
below its maximum relative permeability before the electri 0034. In FIG. 3A, switches 310A and 310E are activated
cally conducting output coil is energized. by controller 320 in electrical communication with the wind
ings on the Switches such as through conductor 322 to wind
BRIEF DESCRIPTION OF THE DRAWINGS ing 324. The additional flux in switches 310A and 310E are
additive with the flux that would otherwise be present in
0019 FIG. 1 is a drawing of prior art reluctance switch in segments 304A and 304E, thereby saturating these paths,
the form of an electrical toroid inserted into a primary mag causing the flux through segment 304C to be in the direction
netic path; shown. In FIG. 3B, Switches 310B and 310D are activated,
0020 FIG. 2 is a detail drawing of a reluctance switch saturating segments 304B and 304D, and reversing the flow.
according to the invention; 0035 FIG. 4 is a drawing that depicts an embodiment of
0021 FIGS. 3A and 3B are detail drawings showing the the invention using circular toroids 400, 401 and multiple
use of four reluctance Switches according to the invention; permanent magnets 402, 403 disposed in the primary path
US 2014/009 1890 A1 Apr. 3, 2014
404. The two toroids 400, 401 intersect, forming magnetiz with a block of material 704, preferably the same high-per
able member 404E. A coil 430 is wound around the member formance magnetic material used to construct loops 400, 401.
404E, as shown. Permanent magnet 702, shown at 702, preferably has the
0036. The primary magnetic path 404 interconnects the same length as block 704, enabling the various constituent
upper end of loop 400 and lower end of loop 401. One of the parts to be held together with compression, shown in FIG.7B.
magnets, 402, couples one end of the primary magnetic path 0044 FIG. 8 is a simplified schematic diagram of compo
404 to the first loop 400, and another, 403, couples the other nents used to simulate the apparatus of FIGS. 4, 6A and 6B.
end of the primary magnetic path 404 to the second loop 401. The circuit used to drive switches A-D (Lwinding 1, 2) is
0037. In this and all of the embodiments described herein, shown at 802. The circuit used to drive switches B-C (Lwind
the permanent magnets are strong, rare-earth magnets, and ing2, 3) is shown at 802, and the equivalent circuit associated
multiple magnets of any length (thickness) may be used in with the output is shown at 806. Lwinding pickup is the coil
each case. Further in all embodiments, the loops, primary wound around the magnetizable member. Note that the
magnetic path and/or magnetizable member are preferably Switches operated simultaneously are simply connected in
constructed from a high magnetic permeability material Such series, which is also possible with the various physical imple
as the FINEMETFT-3H nanocrystalline soft magnetic mate mentations. Each input circuit uses a current generator,
rial available from Hitachi. The invention is not limited in this whereas the output circuit uses an ammeter. All circuits
regard, however, as alternative materials, including laminated include a voltmeter.
materials, may be used. 0045 While the applied current to the flux switches may
0038. The connections of the primary magnetic path 404 be AC, steady-state DC or pulsed DC, it has been found
to the two loops 400, 401 create four segments apart from through simulation that pulsed current achieves a vastly Supe
magnetizable member 404E, the four segments including two rior result. FIG.9A is a diagram that shows the current deliv
opposing segments A, B in the first loop on either side of ered to the flux switches in the simulation. Current is shown at
magnet 402, and two opposing segments C, D in the second 902,904,906,910, while voltage is shown at 920,921,922.
loop on either side of magnet 403. Note that the drive voltage settles down to approximately 1
0039 Four magnetic flux switches are provided, each Volt per cycle at a consistent peak Amperage of about 10
being operative to control the flux through a respective one of Amperes. FIG.9B is a diagram that shows the current deliv
the four segments. A controller 420 is operative to activate the ered to the other set of flux switches in the simulation. The
Switches associated with segments A and D, then Band C, in corresponding output from the simulation is graphed in FIG.
alternating fashion, thereby reversing the flux through the 10. Again, after initial variations, the output achieves a steady
member 404E, thereby inducing electrical current in coil 430. state of over +/-10 Amperes at over +/- 1.5 kilovolts. Such a
0040 Apertures may be formed through each of the four Substantial power gain leads to the conclusion that at least a
segments, with the Switches being implements with windings portion of the output may be used to drive the coils compris
410A-D through the apertures and around an outer (or inner) ing the flux Switches.
portion of each segment. As shown in FIG. 5, if the loops are 0046 FIG. 11 is a block diagram of a controller applicable
fabricated with laminated material 502, the laminations may to the invention. A waveform generator provides appropriate
be split at 506 to accommodate coil 504. The percentage of current drive to current drivers 1104, 1106. Waveform gen
the segment Surrounded by the coil may vary in accordance erator is preferable a programmable device allowing for
with the material used, the waveforms presented to the coils, variation in drive requirements. Each current driver 1104,
and other factors, with the goal being to magnetically saturate 1106 couples the waveforms from generator 1102 to a pair of
each segment through activation of the Switch associated flux Switch coils 1.4 and 2.3, energizing the coils with energy
therewith, thereby reversing the flux through path 404E. from high-current supply 1110. The current to each pair of
0041 FIGS. 6A and 6B show the operation of the appara coils is sensed by resistors 1112, 1114, facilitating feedback
tus of FIG. 4. The primary path 404 unidirectionally carries control via blocks 1120, 1122, thereby providing for a more
the flux from permanent magnets 402, 403. Reluctance stable operation.
switches 410A-410D are activated in alternating fashion to 0047. The following sections summarize some of the
reverse the flux in segment 404E which, in turn, induces important characteristics of the preferred embodiments.
electrical current in winding 430. FIG. 6A shows the flux flow 0048 Interms of materials, the apparatus benefits from the
in one direction, and FIG. 6B shows it reversed. use of nanocrystaline material with a “Square BH intrinsic
0042. In FIG. 6A, switches 410A and 410D are activated curve, a high Br (remanence) which is about 80% of its Bs
by controller 420 in electrical communication with the wind (saturation), a low He (coercivity), and a fast magnetic
ings on the Switches, such as through conductors 422 to response time to saturation. An example is FineMet FT-3H
switch 410B. The flux provided by switches 410A and 410D, from Hitachi of Japan, which has a Br of 1.0 Tesla, a Bs
thereby Saturating these paths, causing the flux through seg (saturation) of 1.21 Tesla, a time to saturation (Bs) of 2 usec,
ment 404C to be in the direction shown. In FIG. 6B, switches and an He of -0.6 amp-turns/meter.
410B and 310C are activated, saturating segments 404B and 0049 Modern permanent magnets are used with a square
404D, thereby reversing the flux through path 404E. BH intrinsic curve, a Brin the range of 1.0 Tesla or more, and
0043 FIG. 7A depicts a preferred construction of the high. He in the range of -800,000 amp-turns/meter or more.
apparatus depicted in FIGS. 4, 6A and 6B. Loops 400, 401 are An example is the NdFeB magnet from the German company
implemented as complete toroids 700, 701. This is important, VAC, which has a Br of 1.427 Tesla and an He of -1,079,000
since preferred high-performance magnetic materials are cur amp-turns/meter.
rently available in regular shapes of this kind. Note that, in 0050. An important consideration is the matching of the
this case, curved slots such as 770 are formed through the magnet to the nanocrystaline material, both in Tesla rating
sides of each toroid to implement flux switches A-D. The and in cross-sectional area. The magnet’s Br should be below
magnetizable member in this embodiment is implemented the Bs of the nanocrystaline material. If the magnet is too
US 2014/009 1890 A1 Apr. 3, 2014
'strong for the nanocrystaline material, this may cause the 0056 We claim:
nanocrystaline material to Saturate at the area of contact with 1. A Switching power Supply, comprising:
the magnetic. first and second continuous loops of magnetizable mate
0051. The current driving the reluctance switches in the rial;
prescribed 2x2 sequence should have a sharp rise in the lead the first loop having four segments in order A, 1. B. 2;
ing edge (Tr) of each pulse with a pulse width (Pw) and the second loop having four segments in order C, 3, D, 4,
Amperage value that are Sustained until released at the end of the loops intersecting Such that segment 2 of the first loop
the pulse width (Tf). The table below shows the effects of and segment 3 of the second loop share the same mag
input current pulse rise times (Tr) on the output. These exists netizible material;
a narrow band of Tr, before which there is small power output, an electrical conductor wound round the region of inter
at which there are excellent power output and CoPs (coeffi section of the first and second loops;
cients of performance) in the range of 200 to 400 or greater, a length of magnetizable material coupling segment 1 of
and after which there is no major increase in power output. the first loop to segment 4 of the second loop:
The CoP of this device without the coupling circuit is defined at least one permanent magnet generating a unidirectional
as “Output power/Drive Power” for the switches. magnetic flux in the length of magnetizable material;
four magnetic flux Switches, each flux Switch controlling
the flux through a respective one of the segments A, B, C,
Tr Output Power Waveform Description D;
1.OE-4 secs SO Watts Spikes
an input electrical circuit including a waveform generator
7.5E-5 SO Watts- Spikes with intermittent 30 operative to activate switches A-D and B-C in an alter
Kilowatt Square waves nating sequence, thereby reversing the flux through the
S.OE-5 15 Kilowatts Square waves after 3 cycles region of intersection, thereby inducing electricity in the
1.OE-5 15 Kilowatts Square waves after 1 cycle electrical conductor; and
ote: an output electrical circuit interconnected to the electrical
The above data are for a dual toroid configuration using FinemetFT-3H, a permanentmagnet conductor.
of 1.2 Tesla, and a drive current of 7.0 Amps in the reluctance switches. The toroids have an 2. The Switching power Supply of claim 1, wherein:
D of 200mm, an OD of80mm, and a thickness of 30 mm. Each reluctance switch comprises
00 turns. The output has 40 Turns and feeds a 200 Ohm resistor, the flux switches are coils of wire wound around at least a
0052 To maximize output power, there should be a match portion of segments A, B, C, D,
flux switches A and D are connected in series with a first
between output coil turns and the resistive load. This relates to current driver between a high-current power source;
the L-R time constant.
flux switches Band Care connected in series with a second
0053. In the preferred embodiments, four circuits are used current driver between the high-current power source:
to operate and control the apparatus: 1) Input Switching Cir and
cuit, 2) Output Conversion Circuit, 3) Coupling Circuit, and
4) Startup Circuit. the waveform generator controls the first and second cur
0054 The invention may be used wherever there is a need rent drivers in an alternating sequence to reverse the flux
or use for electrical power. Further, the invention coupled to through the region of intersection.
an electric motor viaan intervening circuit and may be used in 3. The switching power supply of claim 1, further includ
place of engines powered by combustion, heat, wind, and ing:
water. The inventions innate ability to power a resistive load sense resistors in series with the flux switches; and
permits it to be used to generate heat directly. feedback control circuits between the waveform generator
0055. Uses of the invention include, and are not limited to, and the current drivers to providing for a more stable
providing electrical power for the following: operation.