INVENTORS Jesse Antoine Marcel Jeffrey Scott Chimenti

PRIORITY CLAIM

This application claims the benefit of US provisional patent application number 63/224,319, filed July 21, 2021, the contents of which are incorporated by reference.

FIELD OF THE INVENTION

This invention relates to the field of air handlers. More specifically, the invention comprises a high flow air handler system which optionally replaces conventional air handlers used in everything from home air conditioners to mining ventilation. The invention creates a powerful, compact, and efficient system with the added benefits of gyroscopic inertia created by the rotating assembly, which helps to dampen errant vibrations and lessen the impact of incoming turbulent air. BACKGROUND OF THE INVENTION

There are many known devices used for air handlers. Most of these use a standard AC motor connected to a large metal fan. One good example is an air handler used in a heat pump. Air from the air handler blows over evaporator coils circulating the heat energy into the refrigerant.

Air handler systems have been refined over time while still relying on industrial motors to rotate their pressed metal fans. The present invention provides a new, powerful, compact and efficient means to move air that creates inertia lessening pressure on bearings and related structures decreasing maintenance.

SUMMARY OF THE INVENTION

The present invention comprises a gyroscopic air handler for an air conditioning system. The invention is configured to be mounted/retrofitted in a similar position to existing air handlers, typically in the upper most section of evaporator coils/air filtration. Power is preferably provided through a breaker box/power panel.

The invention includes a hubless rotating magnetic chamber that houses rotors for air flow. The entire chamber is located by external thrust bearings that place the magnetic chamber within an electromagnetic duct. The duct itself creates electromagnetic energy in phases causing rotation of the magnetic chamber. The duct is created from a composite matrix that aligns iron sheathed magnetic wire in the desired location within its fabric. The fabric is laid up with an epoxy resin to take on almost any shape in the vertical plane. The magnetic chamber, when rotating, causes a strong vibration dampening gyroscopic effect while producing the desired air flow. A motor controller creates the phasing of the magnetic fields. BRIEF DESCRIPTION OF THE DRAWINGS

Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings:

FIGURE 1 is a cross section view, showing the present invention.

FIGURE 2 is a cross section view, showing the electromagnetic duct and the position of electromagnetic elements.

FIGURE 3 is a cross section view, depicting a magnetic chamber with integrated permanent magnets and location of rotors.

FIGURE 4 is a cross section view, of a thrust bearing assembly.

FIGURE 5 is a top view, showing the layers of the composite structure of the electromagnetic duct section.

FIGURE 6 is a top view of the duct and rotor.

FIGURE 7 is a cross section view showing composite electromagnetic wire assembly.

FIGURE 8 is a diagram showing a motor controllers connection to the electromagnetic wire assembly.

FIGURE 9 is a cross section of an alternate embodiment of the current invention replacing the composite electromagnetic components with magnetic wire and iron stator stack.

Reference Numerals in the Drawings

• 10 electromagnetic duct

• 10a inlet duct section

• 10b composite electromagnetic duct section

• 10c tail duct section

• 20a composite electromagnetic wire assembly

• 20b iron sheath

• 20c copper wire with enamel coating

• 30 gyroscopic magnetic thrust chamber • 40 permanent magnets

• 50a upper rotor

• 50b lower rotor

• 60 thrust bearings assembly

• 62 races or channels

• 70 bonding epoxies in void

• 80 composite electromagnetic wire locations

• 90 iron composite section

• 100 bonding epoxies in void

• 110 field coils

• 120 stator stacks

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” when used in this specification, specify the presence of stated features, steps operations, elements, and/or components, but do not preclude the presence of addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which the invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the one context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combination are entirely within the scope of the invention and the claims.

New gyroscopic air handler apparatuses are discussed herein. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.

The present disclosure is to be considered as an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated by the figures or description below.

The present invention is described by referencing the appended figures representing preferred embodiments. FIGURE 1 shows a cross section view of the present invention. Gyroscopic air handler assembly 200 is shown with hubless magnetic thrust chamber 30 that creates air flow when rotated and a strong gyroscopic force that helps to dampen vibration harmonics of the assembly. A plurality of permanent magnets 40 are integrated into the exterior of a magnetic thrust chamber 30 that cause rotation of the chamber when acted upon by phasing magnetic fields created in one or more electromagnetic ducts. A plurality of hubless rotors 50a upper and 50b lower are atached to the inner diameter of the magnetic chamber 30. The design and number of rotors may be optimized for the desired results. The magnetic chamber 30 is supported by a plurality of thrust bearing assemblies 60 that allows free rotation.

FIGURE 2 depicts the elements of an electromagnetic duct 10. The duct 10 surrounds the magnetic chamber 30 and is composed of three sections: 10a inlet section that optimizes incoming airflow; 10b composite electromagnetic section that integrates a plurality of composite field coils 20a; and 10c tail section that guides air into the desired location. The duct 10 may be composed of carbon fiber, Kevlar, aluminum or any appropriate material. A plurality of races or channels 62 accepts a plurality of thrust bearings to support the magnetic chamber, and are sized to accept the appropriate bearing for the desired application.

FIGURE 3 shows a cross section of one design for a magnetic chamber 30 which may be made from lightweight composites, carbon fiber, aluminum or any material that will support the forces created by the chamber. A plurality of hubless rotors 50a and 50b are atached to the inside surface of the chamber. The rotor design, blade/screw is adapted to the desired air flow, size, and efficiency of the air handler. A plurality of permanent magnets 40 are atached to races 62 in the exterior of the chamber and atached with adhesive or any appropriate mechanical device.

FIGURE 4 shows a cross section of an example of a thrust bearing assembly that may be used in the present invention.

FIGURE 5 shows a cross section of the composite electromagnetic duct 10b generally containing a ferrous structural element 10a, a plurality of composite electromagnetic coils 80, ferrous magnetic focusing sections 90, and voids 70,80 that are filled with a nonferrous adhesive. The duct 10c is to be constructed from Kevlar cloth or similar nonconductive material containing these elements that can be laid up as a composite with adhesive binder. The cloth are preferably laid up in such a manner that the electromagnetic composite coils are of the correct number and position to optimize the rotation of the magnetic chamber and its permanent magnets. Because of the composite nature of the duct, not only could the duct be made into almost any shape that is desired, but cooling is also greatly enhanced due to the airflow over its surfaces.

FIGURE 6 depicts a top view of the assembly with 10a inlet duct and 50a hubless rotor. As shown with reference to FIGURE 1, the thrust bearings 60 are located so that they do not interfere with airflow.

FIGURE 7 shows the makeup of the composite electromagnetic coils 20a generally made from a copper core with enamel coating 20c sheathed in a flexible ferrous layer containing iron particles within an adhesive 20b. The length of each coil is configured to match the requirements necessary for efficient motor operation.

FIGURE 8 shows a diagram of how the composite field coils 20a are attached to a motor controller.

As shown with reference to FIGURE 8, when the composite coils 20a are energized in phases through a motor controller, the electromagnetic fields act upon the permanent magnets in the magnetic chamber causing rotation. The number and orientation of the composite field coils are optimized to match the orientation and number of magnets in the magnetic chamber 30. This allows for design freedom in the shape of the duct in its vertical plane. The gyroscopic air handler is preferably positioned to optimize airflow for the desired use.

As shown with reference to FIGURE 9, an alternate embodiment of the invention 240 is described where the composite electromagnetic section 10b of the duct is replaced with a more conventional iron stator stack and field coils in a housing that correctly orients the stator to the magnets in the magnetic chamber.

In an alternate embodiment the rotors 50a, 50b, integrate a central hub and bearings that allow for the magnetic chamber to be supported from its center and a plurality of cross members integrated into the duct, to locate the hub assembly (not shown).

While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention.