BACKGROUND

[0001] The present invention relates generally to power generation systems and methods, and more specifically, to a safety structure for an electricity generation system used in an electrical vehicle.

[0002] Vehicles have been developed that use electric motors to convert stored electricity in batteries to rotational energy that provides the motive force to the vehicle. The batteries contain all of the energy available to the vehicle. Hybrid vehicles or those that combine the use of gasoline engines with electric motors have also been developed. One of the problems associated with electric motors is that the vehicle can have empty space at the front of the vehicle. Accordingly, in a head on collision the front of the vehicle can collapse on the driver and occupants of the vehicle.

SUMMARY

[0003] The present disclosure includes one or more of the features recited in the appended claims and/or the following features which, alone or in any combination, may comprise patentable subject matter.

[0004] According to a first aspect of the disclosed embodiments, a safety structure for a wind turbine chamber for an electric vehicle includes an outer housing formed from a first impact absorbing material. A cavity is defined by the outer housing and is configured to house at least one wind turbine. At least one airflow channel is configured to extend from a front of the outer housing to the at least one wind turbine and is configured to direct airflow downstream to the at least one wind turbine. The at least one airflow channel is formed from a second impact absorbing material.

[0005] In some embodiments of the first aspect, at least one of the first impact absorbing material and the second impact absorbing material can be formed from at least one of molded pulp, compressively-deformable foamed elastic resin, expanded polypropylene (EPP) and expanded polystyrene (EPS), organics, composites, ceramics, polymers, synthetic polymers, metals, plastics, rubbers, foams, endothermic reagents, exothermic reagents, decomposition reaction reagents. At least one reinforcement bar can extend between a front and a back of the outer housing. The at least one reinforcement bar can extend along at least one of the top of the outer housing or the bottom of the outer housing. A third impact absorbing material can be positioned in the cavity. The at least one wind turbine can be configured to be positioned upstream from the third impact absorbing material. A support bar can be configured to retain the at least one wind turbine. The support bar can be configured to deform upon an impact. A channel can be formed in a side wall of the outer housing. The channel can retain an end of the support bar so that the end of the support bar is moveable within the channel during an impact. The channel can be filled with a fourth impact absorbing material. The channel can narrow in the downstream direction to resist movement of the end of the support bar. The support bar can intersect a reinforcement bar extending between the front and a back of the outer housing.

[0006] According to a second aspect of the disclosed embodiments, a wind turbine assembly for an electric vehicle includes an outer housing formed from a first impact absorbing material. A cavity is defined by the outer housing. At least one wind turbine is positioned in the cavity. At least one airflow channel extends from a front of the outer housing to the at least one wind turbine to direct airflow downstream to the at least one wind turbine. The at least one airflow channel is formed from a second impact absorbing material.

[0007] In some embodiments of the second aspect, at least one of the first impact absorbing material and the second impact absorbing material can be formed from at least one of molded pulp, compressively-deformable foamed elastic resin, expanded polypropylene (EPP) and expanded polystyrene (EPS), organics, composites, ceramics, polymers, synthetic polymers, metals, plastics, rubbers, foams, endothermic reagents, exothermic reagents, decomposition reaction reagents. At least one reinforcement bar can extend between a front and a back of the outer housing. The at least one reinforcement bar can extend along at least one of the top of the outer housing or the bottom of the outer housing. A third impact absorbing material can be positioned in the cavity downstream from the at least one wind turbine. A support bar can retain the at least one wind turbine so that the at least one wind turbine rotates on the support bar. The support bar can be configured to deform upon an impact. A channel can be formed in a side wall of the outer housing. The channel can retain an end of the support bar so that the end of the support bar is moveable within the channel during an impact. The channel can be filled with a fourth impact absorbing material. The channel can narrow in the downstream direction to resist movement of the end of the support bar.

[0008] According to a third aspect of the disclosed embodiments, a wind turbine assembly for an electric vehicle includes an outer housing. A cavity is defined by the outer housing. At least one wind turbine is positioned in the cavity. A support bar retains the at least one wind turbine in the cavity. The support bar is configured to deform upon an impact. At least one airflow channel extends from a front of the outer housing to the at least one wind turbine to direct airflow downstream to the at least one wind turbine.

[0009] According to a third aspect of the disclosed embodiments, a wind turbine assembly for an electric vehicle includes an outer housing. A cavity is defined by the outer housing. At least one wind turbine is positioned in the cavity. A support bar- retains the at least one wind turbine in the cavity. A first reinforcement bar extends between the front and a back of the outer housing. The support bar intersects the first reinforcement bar. In some embodiments, a second reinforcement bar can extend perpendicular to and intersect the first reinforcement bar. [0010] Additional features, which alone or in combination with any other feature(s), such as those listed above and those listed in the claims, may comprise patentable subject matter and will become apparent to those skilled in the art upon consideration of the following detailed description of various embodiments exemplifying the best mode of carrying out the embodiments as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The detailed description particularly refers to the accompanying figures in which:

[0012] Fig. 1 is a side cross-sectional view of a safety structure for a wind turbine chamber for an electric vehicle taken about line 1-1 shown in Fig. 3;

[0013] Fig. 2 is a side cross-sectional view of another embodiment of a safety structure for a wind turbine chamber for an electric vehicle; [0014] Fig. 3 is a top plan view of the safety structure shown in Fig. 1, wherein the safety structure does not include a top;

[0015] Fig. 4 is a top plan view of the safety structure shown in Fig. 1 having reinforcement bars;

[0016] Fig. 5 is a top plan view of the safety structure shown in Fig. 1 having another embodiment of a reinforcement bar;

[0017] Fig. 6 is a top plan view of the safety structure shown in Fig. 1 having yet another embodiment of reinforcement bars;

[0018] Fig. 7 is a top plan view of the safety structure shown in Fig. 1 having an impact absorbing structure positioned in a cavity of the chamber;

[0019] Fig. 8 is a top plan view of the safety structure shown in Fig. 1 having another impact absorbing structure positioned in a cavity of the chamber;

[0020] Fig. 9 is a side elevation view of an embodiment of a side panel of the safety structure shown in Fig. 1;

[0021] Fig. 10 is a side elevation view of another embodiment of a side panel of the safety structure shown in Fig. 1;

[0022] Fig. 11 is a side elevation view of yet another embodiment of a side panel of the safety structure shown in Fig. 1; and

[0023] Fig. 12 is a schematic view of the safety structure positioned in a vehicle.

DETAILED DESCRIPTION

[0024] While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific exemplary embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. [0025] As used herein the term “impact absorbing material” can include any one of molded pulp, compressively-deformable foamed elastic resin, expanded polypropylene (EPP) and expanded polystyrene (EPS), organics, composites, ceramics, polymers, synthetic polymers, metals, plastics, rubbers, foams, endothermic reagents, exothermic reagents, decomposition reaction reagents. An endothermic reagent can be configured to retard deformation in certain areas. An exothermic reagent can be configured to facilitate deformation of certain components. [0026] Referring to Figs. 1-3, a safety structure 10 for a wind turbine chamber 12 of an electric vehicle 200 (as illustrated in Fig. 12) is provided with several components to absorb and dissipate energy from a vehicle collision, for example a head-on collision. The wind turbine chamber 12 includes an outer housing 14 having a bottom panel 16. A pair of opposite side panels 18 extend upward from the bottom panel 16. A front panel 20 and a rear panel 22 extend upward from the bottom panel 16 between the side panels 18. In some embodiments, a top panel 24 optionally encloses the outer housing 14, as indicated by the dashed line in Fig. 1. The top panel 24 can enable the chamber 12 to be utilized as a storage compartment. The outer housing 14 forms a cavity 28 that is configured to retain components of a wind turbine assembly 30. The outer housing 14 is formed from an impact absorbing material. In some embodiments, all of the bottom panel 16, the side panels 18, the front panel 20, the rear panel 22, and the optional top panel 24 are formed from the impact absorbing material. In some embodiments, at least one of the bottom panel 16, the side panels 18, the front panel 20, the rear panel 22, and the optional top panel 24 are formed from the impact absorbing material. In some embodiments, any combination of the bottom panel 16, the side panels 18, the front panel 20, the rear panel 22, and the optional top panel 24 are formed from the impact absorbing material. At least one of the bottom panel 16, the side panels 18, the front panel 20, the rear panel 22, and the optional top panel 24 can be arranged as a collapsible lattice structure. The outer housing 14 can be formed to absorb energy from a collision to create protection for the wind turbine assembly 30 and the vehicle passengers.

[0027] At least one front vent 40 is formed in the front panel 20. The front vent 40 is configured to allow airflow into the cavity 28. The airflows from the front panel 20 downstream toward the rear panel 22. The front vent 40 can include a flap 42 that opens and closes depend on the driving conditions of the vehicle 200. In some embodiments, the flap 42 is positioned in the vehicle 200 upstream from the turbine chamber 12. In some embodiments, the flap 42 is opened during non-accelerating driving time to allow airflow into the wind turbine chamber 12. In embodiments including more than one flap 42, each flap 42 can open independently. At least one rear vent 44 is formed in the rear panel 22 to allow airflow to leave the wind turbine chamber 12. The rear vent 44 can be placed anywhere within the chamber 12, in some embodiments. The rear vent 44 can redirect airflow to cool lithium ion batteries or for other purposes. In some embodiments, the rear vent 44 can redirect airflow into a cabin of the vehicle 200 to condition the air in the cabin.

[0028] The wind turbine assembly 30 is positioned in the cavity 28. The wind turbine assembly 30 includes at least one wind turbine 50 coupled to the side panel 18 by a support bar 52. Each wind turbine 50 includes a rotor, a stator, copper wire, and magnets to produce energy from airflow through the chamber 12. There can be any number of wind turbines 50 in the chamber 12 to produce electricity and act as a collision absorbing device in the event of an accident. The wind turbines 50 can have different heights to maximize energy creation. The rotational friction can be minimized using magnets and/or other methods to allow for longer rotation time period, and therefore, the creation of more energy. In some embodiments, the wind turbines 50 are bladeless. The support bars 52 hold the wind turbines 50 in place within the cavity 28. The support bars 52 can be configured to deform, collapse, or disconnect upon an impact, thereby absorbing additional energy from the impact. As used herein “deform” is defined as altering the shape of by stress, such as bending or breaking. In some embodiments, only a portion of the wind turbines 50 are damaged during an impact. It is contemplated that intact wind turbines 50 can be salvaged and reused.

[0029] At least one airflow channel 60 extends from the front panel 20 to one of the wind turbines 50 of the wind turbine assembly 30. Each airflow channel 60 is in fluid communication with the front vent 40 and receives air that passes through the front vent 40. Each airflow channel 60 directs airflow downstream to one of the wind turbines 50. It will be appreciated that the airflow channels having varying lengths depending on which wind turbine 50 receives airflow from the respective airflow channel 60. In the embodiment illustrated in Fig. 1, the airflow channels 60 direct the airflow over a top 62 of each wind turbine 50. In the embodiment illustrated in Fig. 2, the airflow channels 60 direct the airflow along a bottom 64 of each wind turbine 50. The at least one airflow channel 60 can be formed from an impact absorbing material. In some embodiments, the at least on airflow channel 60 includes a collapsible lattice structure.

[0030] In some embodiments, the turbines 50 and/or the airflow channels 60 can include frangible materials designed to disintegrate upon a sufficient triggering force. Frangible materials are materials that tend to break up into fragments when subjected to a deforming force or impact, as compared with non-frangible materials that elastically deform and retain cohesion when subjected to comparable deforming forces. Some amorphous frangible materials are formed from a melt by cooling to rigidity without crystallization. Some frangible materials include a transparent or translucent material consisting typically of a mixture of silicates. Frangible structures (i.e. , structures formed using one or more frangible materials) are designed to undergo structural failure (break away) when struck by an externally applied impact force. Some frangible structures are designed to undergo structural failure in response to an externally generated command signal. The frangible material can store potential energy in the form of residual internal stress gradients such that, when the material is subjected to a relatively small initial fracture force, the stored potential energy is released in the form of a propagating fracture force that is quickly transferred throughout the material.

[0031] Referring now to Fig. 4, in some embodiments, the chamber 12 includes at least one reinforcement bar 70. The at least one reinforcement bar 70 extends between the front panel 20 and the rear panel 22. In the illustrated embodiments, the at least one reinforcement bar 70 extend along a top of the outer housing 14. It will be appreciated that, in some embodiments, the at least one reinforcement bar 70 extends along a bottom of the housing 14. In some embodiments, at least one reinforcement bar 70 extends along both the top and the bottom of the housing 14. The at least one reinforcement bar 70 can be formed from an impact absorbing material. In some embodiments, the at least one reinforcement bar 70 can extend within the cavity 28 from the front 20 to the back 22, and between the wind turbine 50 with the support bar 52 going through the reinforcement bar 70 or attached to the reinforcement bar 70 within an opening 72, as illustrated in Fig. 5. In some embodiments, at least one reinforcement bar 74 extends perpendicular to at least one reinforcement bar 70 and between adjacent turbines 50, as illustrated in Fig. 6. The reinforcement bar 74 can intersect and couple to the reinforcement bar 70. In some embodiments, the reinforcement bar 70 includes a collapsible lattice structure.

[0032] Referring to Fig. 7, the cavity 28 includes a space 80 formed downstream of the wind turbine assembly 30. In some embodiments, the space 80 can be used for storage. In some embodiments, the wind turbine chamber 12 can be positioned below a storage compartment in the vehicle 200. In such embodiments, the wind turbine chamber 12 can be accessible through the storage compartment. In other embodiments, the space 80 can be used to house additional wind turbines 50. In the illustrated embodiment, the space 80 is filled with a block 82 of impact absorbing material. The block 82 is configured to operate as an additional bumper for the vehicle 200. The block 82 can have a lattice configuration, in some embodiments. In some embodiments, the block 82 can be replaced with at least on spring 84 having a high compressive strength, as illustrated in Fig. 8, to absorb energy from an impact.

[0033] Referring now to Figs. 9-11, an interior surface 90 of each side panel 18 includes a slot 92. The slot 92 is configured to receive an end of a support bar 52 to retain the support bar 52 in the chamber 18 so that the wind turbines 50 can rotated on the support bar 52. The end of the support bar 52 is configured to slide downstream along the slot 92 during a collision. In the embodiment illustrated in Fig. 9, the slot 92 is filled with an impact absorbing material 94. The impact absorbing material 94 can have a lattice configuration, in some embodiments. The impact absorbing material 94 absorbs energy from the collision as the end of the support bar 52 slides along the slot 92. In the embodiment, shown in Fig. 10, a spring 96 having a high compressive strength is positioned in the slot 92 to absorb the energy from the impact.

[0034] Referring to Fig. 11, the slot 92 include a top edge 98 and a bottom edge 100. As the slot 92 extends from a front end 102 to a back end 104, the top edge 98 and the bottom edge 100 angle toward each other so that the slot 92 narrows. That is, the slot 92 narrows from the front end 102 to the back end 104. During a collision, the end of the support bar 52 slides downstream from the front end 102 toward the back end 104 and the top edge 98 and the bottom edge 100 absorb the energy from the impact as the slot 92 narrows. [0035] Referring now to Fig. 12, any of the embodiments of the structure 10 described above can be utilized with the vehicle 200. In the illustrative embodiment, the structure 10 is positioned at a front 202 of the vehicle 200 upstream of a passenger compartment 204. The structure 10 can be positioned near a hood 206 of the vehicle 200 or, alternatively, the structure 10 can be positioned closer to the wheels 208 of the vehicle 200. In some embodiments, the structure 10 is aligned with the bumper 210 of the vehicle 200. It will be appreciated that the structure 10 can be positioned anywhere between the hood 206 and a bottom 212 of the vehicle 200. In some embodiments, the structure 10 is positioned adjacent the front 202 of the vehicle 200. Alternatively, the structure 10 is positioned adjacent the passenger compartment 204. It will be noted that the structure 10 can extend any distance between the front 202 of the vehicle 200 and the passenger compartment 204. The structure 10 can also extend any distance between the sides of the vehicle 200. In some embodiments, the largest wind turbine 50 is positioned near the front 202 of the vehicle 200, as shown in the embodiment of Fig. 2, so that the largest wind turbine 50 absorbs an initial impact of a collision. In other embodiments, the smallest wind turbine 50 is positioned near the front 202 of the vehicle 200, as shown in the embodiment of Fig. 1, so that the smallest wind turbine 50 absorbs an initial impact of a collision.

[0036] The disclosed embodiments provide a wind turbine for an electric vehicle 200 that allows the driving range of the vehicle 200 to be increased. The disclosed embodiments can increase the driving range a minimum of 35%, in some embodiments. By increasing the range of the electrical vehicle 200, manufacturers can use fewer batteries. The typical electrical vehicle has 4000 pounds (2 tons) of rechargeable lithium ion batteries that increase weight added to the roads and bridges compared to gas powered vehicles. By increasing the range of the electrical vehicle by a minimum of 35%, the amount of batteries can be reduced by approximately 25%, or 1000 pounds per vehicle, thereby saving roads and bridges from wear and tear due to the increased weight. Additionally, reducing the size of the batteries can save the rare earth minerals required to make lithium ion batteries.

[0037] The disclosed embodiments also create additional safety for passengers in the vehicle 200. Many electric vehicles have nothing under the hood except storage space, i.e. a front trunk. Other electric vehicles have components under the hood that may provide some level of protection, but have no engine upfront to protect the passengers. The disclosed embodiments provide a large component under the hood of the vehicle 200 that can absorb head on collisions.

[0038] The following clauses enumerated consecutively from 1 through 23 provide for various aspects of the present invention. In one embodiment, in a first clause (1), the present invention provides an apparatus comprising:

[0039] A safety structure for a wind turbine chamber for an electric vehicle, the structure comprising: an outer housing formed from a first impact absorbing material, a cavity defined by the outer housing and configured to house at least one wind turbine, and at least one airflow channel configured to extend from a front of the outer housing to the at least one wind turbine and configured to direct airflow downstream to the at least one wind turbine, the at least one airflow channel formed from a second impact absorbing material.

[0040] 2. The structure of clause 1, wherein at least one of the first impact absorbing material and the second impact absorbing material are formed from at least one of molded pulp, compressively-deformable foamed elastic resin, expanded polypropylene (EPP) and expanded polystyrene (EPS), organics, composites, ceramics, polymers, synthetic polymers, metals, plastics, rubbers, foams, endothermic reagents, exothermic reagents, decomposition reaction reagents.

[0041] 3. The structure of clause 1, further comprising at least one reinforcement bar extending between the front and a back of the outer housing.

[0042] 4. The structure of clause 3, wherein the at least one reinforcement bar extends along at least one of the top of the outer housing or the bottom of the outer housing.

[0043] 5. The structure of clause 1, wherein a third impact absorbing material is positioned in the cavity, wherein the at least one wind turbine is configured to be positioned upstream from the third impact absorbing material.

[0044] 6. The structure of clause 1 , further comprising a support bar configured to retain the at least one wind turbine. [0045] 7. The structure of clause 6, wherein the support bar is configured to deform upon an impact.

[0046] 8. The structure of clause 6, further comprising a channel formed in a side wall of the outer housing, wherein the channel retains an end of the support bar so that the end of the support bar is moveable within the channel during an impact.

[0047] 9. The structure of clause 8, wherein the channel is filled with a fourth impact absorbing material.

[0048] 10. The structure of clause 8, wherein the channel narrows in the downstream direction to resist movement of the end of the support bar.

[0049] 11. The structure of clause 6, wherein the support bar intersects a reinforcement bar extending between the front and a back of the outer housing.

[0050] 12. A wind turbine assembly for an electric vehicle, the assembly comprising: an outer housing formed from a first impact absorbing material, a cavity defined by the outer housing, at least one wind turbine positioned in the cavity, and at least one airflow channel extending from a front of the outer housing to the at least one wind turbine to direct airflow downstream to the at least one wind turbine, the at least one airflow channel formed from a second impact absorbing material.

[0051] 13. The assembly of clause 12, wherein at least one of the first impact absorbing material and the second impact absorbing material are formed from at least one of molded pulp, compressively-deformable foamed elastic resin, expanded polypropylene (EPP) and expanded polystyrene (EPS), organics, composites, ceramics, polymers, synthetic polymers, metals, plastics, rubbers, foams, endothermic reagents, exothermic reagents, decomposition reaction reagents.

[0052] 14. The assembly of clause 12, further comprising at least one reinforcement bar extending between the front and a back of the outer housing.

[0053] 15. The assembly of clause 14, wherein the at least one reinforcement bar extends along at least one of the top of the outer housing or the bottom of the outer housing. [0054] 16. The assembly of clause 12, wherein a third impact absorbing material is positioned in the cavity downstream from the at least one wind turbine.

[0055] 17. The assembly of clause 12, further comprising a support bar that retains the at least one wind turbine in the cavity.

[0056] 18. The assembly of clause 17, wherein the support bar is configured to deform upon an impact.

[0057] 19. The assembly of clause 17, further comprising a channel formed in a side wall of the outer housing, wherein the channel retains an end of the support bar so that the end of the support bar is moveable within the channel during an impact, wherein the channel is filled with a fourth impact absorbing material.

[0058] 20. The assembly of clause 17, further comprising a channel formed in a side wall of the outer housing, wherein the channel retains an end of the support bar so that the end of the support bar- is moveable within the channel during an impact, wherein the channel narrows in the downstream direction to resist movement of the end of the support bar.

[0059] 21. A wind turbine assembly for an electric vehicle, the assembly comprising: an outer housing, a cavity defined by the outer housing, at least one wind turbine positioned in the cavity, a support bar that retains the at least one wind turbine in the cavity, wherein the support bar is configured to deform upon an impact, and at least one airflow channel extending from a front of the outer housing to the at least one wind turbine to direct airflow downstream to the at least one wind turbine.

[0060] 22. A wind turbine assembly for an electric vehicle, the assembly comprising: an outer housing, a cavity defined by the outer housing, at least one wind turbine positioned in the cavity, a support bar that retains the at least one wind turbine in the cavity, and a first reinforcement bar extending between the front and a back of the outer housing, wherein the support bar intersects the first reinforcement bar.

[0061] 23. The assembly of clause 22, further comprising a second reinforcement bar extending perpendicular to and intersecting the first reinforcement bar.

[0062] It will be appreciated that any of the features described above can be reasonably combined to form other embodiments of a safety structure.

[0063] Any theory, mechanism of operation, proof, or finding stated herein is meant to further enhance understanding of principles of the present disclosure and is not intended to make the present disclosure in any way dependent upon such theory, mechanism of operation, illustrative embodiment, proof, or finding. It should be understood that while the use of the word preferable, preferably or preferred in the description above indicates that the feature so described can be more desirable, it nonetheless cannot be necessary and embodiments lacking the same can be contemplated as within the scope of the disclosure, that scope being defined by the claims that follow.

[0064] In reading the claims it is intended that when words such as "a," "an," "at least one," "at least a portion" are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language "at least a portion" and/or "a portion" is used, the item can include a portion and/or the entire item unless specifically stated to the contrary.

[0065] It should be understood that only selected embodiments have been shown and described and that all possible alternatives, modifications, aspects, combinations, principles, variations, and equivalents that come within the spirit of the disclosure as defined herein or by any of the following claims are desired to be protected. While embodiments of the disclosure have been illustrated and described in detail in the drawings and foregoing description, the same are to be considered as illustrative and not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Additional alternatives, modifications and variations can be apparent to those skilled in the art. Also, while multiple inventive aspects and principles have been presented, they need not be utilized in combination, and many combinations of aspects and principles arc possible in light of the various embodiments provided above.