COMBINED HEAT AND POWER ARCHITECTURES AND RELATED METHODS

RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application 63/400,327 filed August 23, 2022 (the “’327 Application”) and incorporates by reference the entire disclosures of the ‘327 Application, U.S. Non-Provisional Application 16/875,963, filed May 15, 2020 (the “’963 Application”), and Patent Co-operation T reaty Application US 23/24939 filed June 9, 2023 (the “’939 Application”), U.S. Pat. Nos. 7,004,120, 7,448,352, 8,113,164, 9,708,910, 9,708,976, 9,869,244, 10,337,452, 10,605,483, 11 ,352,930 and 11 ,598,243. Collectively, the above patents and applications may be referred to as “Related Applications” herein.

TECHNICAL FIELD

[0002] This disclosure relates to the field of combined heat and power (CHP) architectures and related methods.

INTRODUCTION

[0003] This section introduces aspects that may help facilitate a better understanding of the disclosure. Accordingly, the statements of this section are to be read in this light and are not to be understood as admissions about what is, or what is not, prior art.

[0004] To date, it has been challenging to produce CHP architectures that provide a wide range of heat and power requirements.

[0005] Accordingly, it is desirable to provide solutions to these challenges.

SUMMARY

[0006] The inventors describe various exemplary, inventive CHP architectures and related methods.

[0007] .In one embodiment a CHP architecture may comprise: a first CHP system, the first CHP system comprising a first energy generation module and a first energy

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SUBSTITUTE SHEET ( RULE 26) storage and transfer module; and at least one controller for controlling a flow of liquid between the first energy storage and transfer module and a second CHP system. The exemplary architecture may further comprise the second CHP system comprising a second energy generation module and a second energy storage and transfer module.

[0008] In an embodiment, each of the first and second CHPs may comprise components of a common platform.

[0009] The first energy generation module may comprise at least one, first inwardly-oriented opposed piston engine (OPE) and the .second energy generation module may comprise at least one, second inwardly-oriented OPE.

[0010] In an embodiment, the first energy storage and transfer module may comprise first thermal transfer coolant coils for transporting a coolant configured to surround an external surface of a first tank of the first CHP system, where the first coils may substantially extend a length of the first tank. Further, the second energy storage and transfer module may comprise second thermal transfer coolant coils for transporting a coolant configured to surround an external surface of a second tank of the second CHP system, where, similar to the first coils, the second coils substantially extend a length of the second tank.

[0011] In embodiments, the first and/or second coils may comprise D-shaped coils.

[0012] Still further, the exemplary CHP architecture may further comprise a first thermal transfer connection connected to a first internal tank of the first CHP system and to a second internal tank of the second CHP system to transport the liquid from the first tank to the second tank, and a second thermal transfer connection connected to the first tank of the first CHP system and to the second internal tank of the second CHP system to transport the liquid from the second tank to the first tank.

[0013] Yet further, the exemplary CHP architecture may comprise a buffer tank.

[0014] In addition to exemplary architectures, the disclosure also provides for related methods. One such exemplary method for operating a first CHP system independently of a second CHP system of an CHP architecture may comprise controlling a pump of the CHP architecture or components of the first and second

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SUBSTITUTE SHEET ( RULE 26) CHP system such that the first and second CHP systems operate independently. In an embodiment, the method may further comprise operating the first and second CHP systems at the same time, or, alternatively, operating one of the first CHP system or the second CHP system.

[0015] The inventive CHP architectures and methods described above are just some of the inventive architectures and methods that will be apparent from the discussion herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention is illustrated by way of example and is not limited by the accompanying figures in which like reference numerals indicate similar elements and in which:

[0017] Figure 1 depicts an external view of an inventive CHP architecture according to an embodiment of the disclosure.

[0018] Figure 2 depicts an internal view of an inventive CHP architecture according to an embodiment of the disclosure.

[0019] Figure 3 depicts a simplified illustration of an exemplary thermal interface between coolant connections (pipes) and a liquid storage tank according to an embodiment of the disclosure.

[0020] Figure 4 depicts another simplified illustration of the exemplary thermal interface between the coolant connections and a liquid storage tank according to an embodiment of the disclosure.

[0021] Figure 5 depicts an external view of another, inventive CHP architecture according to an embodiment of the disclosure.

[0022] Specific embodiments of the present disclosure are disclosed below with reference to various figures and sketches. Both the description and the illustrations have been drafted with the intent to enhance understanding. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements, and well-known elements that are beneficial or even necessary to a

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SUBSTITUTE SHEET ( RULE 26) commercially successful implementation may not be depicted so that a less obstructed and a clearer presentation of embodiments may be achieved.

[0023] Simplicity and clarity in both illustration and description are sought to effectively enable a person of skill in the art to make, use, and best practice the embodiments of the present disclosure in view of what is already known in the art. One of ordinary skill in the art will appreciate that various modifications and changes may be made to the specific embodiments described below without departing from the spirit and scope of the present disclosure. Thus, the specification and drawings are to be regarded as illustrative and exemplary rather than restrictive or all- encompassing, and all such modifications to the specific embodiments described below are intended to be included within the scope of the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0024] The detailed description that follows describes exemplary embodiments and is not intended to be limited to the expressly disclosed combination(s). Therefore, unless otherwise noted, features disclosed herein may be combined together to form additional combinations that were not otherwise shown for purposes of brevity.

[0025] The disclosure provided herein describes features in terms of preferred and exemplary embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure.

[0026] As used herein and in the appended claims, the term "comprises," "comprising," or variations thereof are intended to refer to a non-exclusive inclusion, such that a process, method, article of manufacture, apparatus or system (e.g., a CHP) that comprises a list of elements does not include only those elements in the list but may include other elements not expressly listed or inherent to such process, method, article of manufacture, or apparatus.

[0027] The terms “a” or “an”, as used herein, are defined as one, or more than one. The term “plurality”, as used herein, is defined as two, or more than two. The term “another”, as used herein, is defined as at least a second or more.

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SUBSTITUTE SHEET ( RULE 26) [0028] Unless otherwise indicated herein, the use of relational terms, if any, such as “first” and “second”, “top” and “bottom”, “back” and “front”, and “left” and “right” and the like are used solely to distinguish one view, entity or action from another view, entity or action without necessarily requiring or implying any actual such relationship, order or importance between such views, entities or actions.

[0029] The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language).

[0030] As used herein the phrase “operable to” means “functions to” unless the context or knowledge of one skilled in the art indicates otherwise.

[0031] As used herein the phrase “controller” means one or more electronic processors and at least one electronic memory that stores computer program code (e.g. , electronic signals representing instructions and data) where, upon execution of stored computer program code, the controller or apparatus (which includes the controller) may be caused to perform certain inventive functions and/or complete certain steps in an inventive method. The stored computer program code may be software or firmware, for example. Further the computer program code may be downloaded prior to being stored in the one or more electronic memories, for example.

[0032] As used herein the notation ”n” may indicate a last CHP or last component of a CHP.

[0033] It should be noted that similar reference characters/numbers denote similar features consistently throughout the attached drawings.

[0034] Referring now to Figure 1 , there is depicted an external view of an inventive CHP architecture 1 that may comprise two or more CHP systems 2, 3 (sometimes referred to hereafter as “first CHP” 2 and “second CHP” 3) that may be thermally connected via thermal transfer connections 4,5. In an embodiment, each of the connections 4,5 may comprise one or more energy transfer passageways (e.g., tubes, pipes) for transferring heated or cooled liquid between CHPs 2,3. In an embodiment connection 5 may comprise one or more energy transfer passageways for transferring heated liquid between CHPs 2,3 while connection 4 may comprise

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SUBSTITUTE SHEET ( RULE 26) one or more energy transfer passageways for transferring cooled liquid between CHPs 2,3.

[0035] Referring now to Figure 2, there is depicted a simplified, internal view of the inventive CHP architecture 1.

[0036] In an embodiment, each CHP system 2,3 may comprise an energy generation module 6,7 and an energy storage and transfer module 8,9.

[0037] For example, in an embodiment the first CHP 2 may comprise first energy generation module 6 and first energy storage and transfer module 8 while the second CHP 3 may comprise second energy generation module 7 and second energy storage and transfer module 9. For the sake of brevity, we will discuss the exemplary components of modules 6,8 of the first CHP 2, it being understood that second CHP 3 comprises similar (if not identical) components that may be referred to hereafter as “second” (component name) to distinguish them from components of the first CHP 2. In an embodiment, each CHP 2,3 (or if more are connected together, up to the last “n” CHP) may be comprised of a common “platform” of similar, if not identical, component types thus making the manufacture of each inventive CHP disclosed herein very efficient and cost-effective.

[0038] In an embodiment, the first energy generation module 6 may comprise one or more first, inwardly-oriented OPEs 14. As described in more detail in the Related Applications which are incorporated by reference herein, each of the inwardly oriented OPEs 14 may comprise a two or four-cycle or two or four-stroke engine, for example. In embodiments, each of the inventive inwardly oriented OPEs described herein may be configured to provide 0.5 kilowatt to 1 .0 megawatts of power (e.g., 10 kilowatts, 20 kilowatts, 30 kilowatts and 100 kilowatts) and be configured to have a displacement range of 24.8 cc to 500 liters, for example (e.g., 50 liters).

[0039] In embodiments, each OPE 14 may include one or more modular, removable intake and/or exhaust valve assemblies (e.g., throttle valves, spring loaded poppet valves, desmodromic valves (e.g., a valve that is closed by a camming mechanism, rather than by a spring mechanism)), for example. Further, one or more of the intake valve assemblies may be modified to include a hydraulic lash adjuster (HLA) configured to adjust the clearance of the intake valve as the intake valve

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SUBSTITUTE SHEET ( RULE 26) changes in temperature due to thermal expansion or contraction. The inventors believe that the incorporation of the hydraulic lash adjuster increases the durability of the intake valve and reduces the need for maintenance (i.e. , increases the time between maintenance). In an embodiment, exemplary timing for the exemplary intake valve assembly with the HLA may be 24/44 (center 460°), the timing for the exhaust valve assembly with an HLA may be 57/11 (center at 247°) with a valve lift of 10 millimeters for the intake and exhaust valves.

[0040] Because an inventive OPE may include removable intake and exhaust valve assemblies, such inventive OPEs do not include a typical cylinder head as in a traditional engine. This provides a number of advantages. For example, a cylinder head may function as a heat sink due to the fact that it typically comprises a large surface area and it is proximate to combustion events, thereby exposing the head to the entirety of the heart discharged by the combustion events. This typically leads to a loss of energy due to the conversion of energy from work into heat. However, because the inventive OPEs do not use a typical cylinder head, such losses are minimized (i.e., the inventive OPEs convert more fuel into work and less into heat than typical, traditional engines). Further, the inventive modular, removable valve assemblies (e.g., intake and exhaust assemblies) allow for ease of servicing and lowered production costs. In embodiments the modular intake and exhaust assemblies may be directly affixed (connected) to a cylinder, thus increasing the overall simplicity and practicality of the inventive OPE 14. That is to say, in general, because the inventive OPEs do not need to incorporate a cylinder head the intake and exhaust assemblies can be directly connected to the engine block, rather than be connected to the head. As a result, the inventive OPEs may be more compact and weigh less than traditional engines. It should be noted that intake and exhaust valve assemblies made a part of an inventive OPE need not necessarily be configured to be actuated in an overhead configuration. Alternatively, such valve assemblies may be actuated by a push-rod and camshaft combination, for example.

[0041] Still further, in an embodiment, first OPE 14 may comprise one or more oil supply jets for distributing pressurized oil to internal parts of the OPE 14, such as to the pistons and connecting rods. Pressurized oil to be distributed by the jet may first traverse through a passageway formed as a pipe or formed as an integral channel in

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SUBSTITUTE SHEET ( RULE 26) a housing, for example, which leads from an oil pump that applies pressure to oil) connected to a connector. In an embodiment the passageway may be 0.028 inches in diameter, for example. Upon receiving pressurized oil from the passageway each jet may be configured to distribute the pressurized oil in a spray pattern or jet pattern, to name just two of the many patterns that the jet(s) may use to distribute the oil onto internal parts of the OPE 14. In addition to oil supply jets, first OPE 14 may include an integrated oil pump according to an embodiment of the disclosure. The exemplary oil pump may be integrated into the first OPE 14 casting as opposed to be separately casted to improve durability and cost and may be driven by the exhaust cam shaft located at the rear of the pump.

[0042] As noted previously, second CHP system 3 may include one or more inwardly-oriented second OPEs 15 that may include similar features as noted above. For the reader’s benefit we will use the terms “first” with respect to CHP system 2 and OPE 14 and the word “second” with respect to CHP system 3 and OPE 15. Again, CHP 3 may share substantially the same type of components as CHP 2 (i.e., a common platform).

[0043] Turning now to the exemplary, first energy storage and transfer module 8, in an embodiment the exemplary module 8 may comprise a first, external enclosure 8a.

[0044] Referring to Figure 3, in an embodiment the enclosure 8a may be configured to enclose a first, internal thermal transfer storage tank 16 (“first tank”) for holding liquid 8b (e.g., water). Further, first, thermal transfer coolant coils 10 for transporting a coolant 10a (e.g., glycol) may be configured to surround the external surface or “skin” 16a of the first tank 16. The coils 10 may substantially extend the entire length (or height depending on the orientation) of the tank 16.

[0045] In an embodiment, upon starting (or re-starting) the operation of the first OPE 14 the coolant within coils 10 may be warmer than the atmosphere surrounding the first OPE 14 due to the fact the coolant may have been warmed by heated water that is present in the tank 16 remains. For example, the coolant on the tank 16 may be 120° F while the atmosphere may be 70° F. Accordingly, the warmed coolant functions to pre-warm the OPE 14 even before the OPE 14 operates. This feature

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SUBSTITUTE SHEET ( RULE 26) advantageously may provide the inventive OPEs (and the associated CHPs) with at least the following advantages: (i) allows lubricants (e.g., oil) to reach or maintain an optimal viscosity, ensuring better lubrication and reduced wear on OPE components; (ii) assist in the vaporization of fuel more effectively, resulting in smoother and more efficient combustion; (iii) allows the OPE to achieve its optimal operating temperature faster, leading to a reduction in unwanted emissions; and/or (iv) reduces the stress on OPE components, such as piston rings, bearings, and other moving parts, potentially extending the OPE’s lifespan.

[0046] Continuing, in an embodiment, the coils 10 may comprise one or more first D-shaped coils where the vertical elements 10b of the D-shaped coils may be configured to lie on the exterior surface 16a of the first interior tank 16 such that energy (e.g., heat) in the coolant 10a within the coils 10 that was originally generated by the energy generation module 6 may be efficiently transferred from the coolant 10a to the liquid 8b (e.g., water) within the first internal tank 16. Thereafter, the now heated liquid 8b within the tank 16 may be transported from the first internal tank 16 to the first thermal transfer connection 5 via pump 17 to the second CHP 3. In an embodiment, the first thermal transfer connection 5 may be connected to the first tank 16 of CHP 2 and a second internal tank of the second CHP 3 to transport liquid from the first tank 16 to a second tank (tank of CHP 3 not shown for simplicity).

[0047] As also depicted in Figures 1 , 2 and 4 cooled liquid may also be received by the CHP 2 via thermal transfer connection 4. In an embodiment, cooled liquid within the second internal tank of CHP 3 may be transported from the second CHP 3 to the first internal tank 16 of the first CHP 2 via second thermal transfer connection 4. Accordingly, in an embodiment the second thermal transfer connection 4 may be connected to the second tank of the second CHP 3 and to the first internal tank 16 of the first CHP 2.

[0048] Though the description above indicates that heated liquid flows from the first CHP 2 to the second CHP 3 and the cooled liquid flows from the second CHP 3 to the first CHP 2, this is merely exemplary. In yet another embodiment, the flows of heated and cooled liquid may be reversed. For example, cooled liquid within the first internal tank 16 of CHP 2 may be transported from the first CHP 2 to the second internal tank of the second CHP 3 via second thermal transfer connection 4 (and an

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SUBSTITUTE SHEET ( RULE 26) appropriately configured pump 17) while heated liquid within the second internal tank of CHP 3 may be transported from the second CHP 3 to the first internal tank 16 of the first CHP 2 via the first thermal transfer connection 5 (and an appropriately configured pump 17).

[0049] In an embodiment, the pump 17 may be configured to operate at a respective power level in order to transport liquid between CHP 2 and CHP 3 (or vice- versa) according to a range of flow rates (e.g., five to seven gallons per minute). As the liquid is transported from CHP 2 to CHP 3 the liquid may fill the tank within CHP 3 and then exit the tank through second thermal transfer connection 4 and then into CHP 2 (or vice-versa). In an embodiment the first and second thermal transfer connections 4, 5 may comprise separate pipes each having the same internal diameter such that liquid in each connection 4,5 may flow at the same rate of speed.

[0050] Still further, the pump 17 may be controlled by a controller 18a of the first CHP 2 (or by controller 18b of the second CHP 3) based on signals the controller 18a may receive form one or more flow meters or sensors and tank level sensors (meters and sensors not shown for simplicity). In an embodiment, the flow meters may detect the flow rate through connections 4, 5 and send associated electrical signals to the controller 18a (“sensed signals”) so that the controller 18a may then execute stored computer program code in order to generate control signals based on the received sensed signals (and its stored electronic instructions) to control the operation of the pump 17 and its flow rate via communications connection 19 (e.g., a wired or wireless connection, such as an Internet of Things (loT) connection). Though not shown in Figure 2, the controller 18b may be connected to the pump 17 via a communications connection that is similar to connection 19.

[0051] In addition, the tank level sensors in the first tank 16 and the second tank may detect the level of liquid in their respective internal tanks. In a further embodiment, upon receiving one or more electrical signals from tank level sensors associated with each internal tank representing the respective liquid level within each internal tank at controller 18a, the controller 18a may execute stored computer program code in order to compare the levels to one another and then generate a computed difference between the levels. For example, the comparison may generate the difference (in gallons) between the sensed level in the first tank 16 and the sensed

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SUBSTITUTE SHEET ( RULE 26) level in the second tank. If the generated difference exceeds a pre-determined (or adjustable) amount (e.g., an amount that indicates one level is at least 10% or more above the other level or an amount that indicates one level is 10% or more below the other level) then the controller 18a may to execute stored computer program code in order to generate and send control signals to the pump 17 via connection 19 to cause liquid to flow from first tank 16 of CHP 2 to the second tank of CHP 3 (or vice-versa) to, for example, maintain a balance of liquid (an associated thermal energy stored in the liquid) between CHP 2 and CHP 3.

[0052] In embodiments, controller 18a and/or 18b may be further operable to execute stored computer program code in order to control the pump 17 of the architecture 1 and/or components of its respective CHP 2,3 such that both CHPs 2,3 operate at the same time, or, alternatively, such that only one of the CHPs 2,3 operates while the other CHP 2,3 does not operate. Still further, when more than two CHPs are connected together (“n” CHPs), the controller of each CHP may be operable to control the associated pump of the architecture and/or components of its respective CHP such that its’ respective CHP operates at the same time as one or more of the other CHPs, or, alternatively, such that only its’ respective CHP operates while the other CHPs do not operate.

[0053] The ability to operate one CHP system independently of another CHP system provides a user of architecture 1 with added flexibility. For example, maintenance may be completed on one CHP system (while it is inoperative) while the other CHP system remains in operation. Said another way, the first CHP system 2 may operate while the second CHP system 3 is inoperative ( or “n” CHP systems are inoperative).

[0054] In addition, the first energy storage and transfer module 8 may comprise fuel exhaust and treatment components 12. For example, components 12 may include a turbo-generator, muffler and catalytic converter unit. In embodiments, the muffler that is part of components 12 may be operable to reduce a level of sound generated by the OPE 14 and exhaust gases, for example, to less than 60 dB. Such sound reduction is desirable in order to place the system 1 within a house or other enclosure (e.g., warehouse, factory, apartment building).

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SUBSTITUTE SHEET ( RULE 26) [0055] Referring now to Figure 5, there is depicted an external view of another inventive CHP architecture 100 that may comprise two or more CHP systems 200, 300, one or more buffer tanks 400 and one or more electrical storage units 700 (e.g., batteries). In an embodiment, the CHPs 200, 300 may be thermally connected via one or more thermal transfer connections 500a, 600a, while one (or more) of the CHPs (e.g., CHP 300) may be thermally connected via ternal transfer connections 500b, 600b. Yet further, the storage unit 700 may comprise a battery pack which may be connect to CHP 200,300 via electrical conductors (not shown in figures).

[0056] In an embodiment, the connections 500a, 600a and 500b, 600b may comprise one or more energy transfer passageways (e.g., tubes, pipes) for transferring heated or cooled liquid between CHPs 200,300 or between CHP 300 and buffer storage tank 400. In an embodiment connections 600a may comprise one or more energy transfer passageways for transferring heated liquid between CHPs 200,300 via pump 800a and controller 900a (or controller 900b) while connection 500a may comprise one or more energy transfer passageways for transferring cooled liquid between CHPs 200,300 via pump 800a and controller 900a (or controller 900b) while connections 600b may comprise one or more energy transfer passageways for transferring heated liquid between CHP 300 and buffer storage tank 400 via pump 800b and controller 900b (or controller 900c) and connection 500b may comprise one or more energy transfer passageways for transferring cooled liquid between buffer tank 400 and CHP 300 via pump 800b and controller 900b (or controller 900c), for example.

[0057] By providing the additional buffer tank to store additional heated liquid (e.g., water), the architecture 100 may store more energy in the form of heated liquid for those instances that require additional energy.

[0058] Each of the CHPs 200,300 may include respective energy generation modules and an energy storage and transfer modules that have elements or components as described above with respect to CHP 2 (i.e. , a common platform of components as CHP 2). For the sake of brevity, the reader is suggested to review the discussion above to understand such components and elements. Further, the buffer storage tank 400 may include an energy storage and transfer module similar to the module discussed previously above.

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SUBSTITUTE SHEET ( RULE 26) [0059] While benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments of the present invention. However, the benefits, advantages, solutions to problems, and any element(s) that may cause or result in such benefits, advantages, or solutions, or cause such benefits, advantages, or solutions to become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the claims.

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SUBSTITUTE SHEET ( RULE 26)