1. Field of The Invention
This invention pertains to wind mill blades that are for mounting onto an axle to turn in a wind and produce a power output for doing work, with the combination of the blade design and a nose cone directing an air flow into the blades providing a very efficient conversion of the wind energy into blade turning.
2. Prior Art
The present invention is in a new and substantially more efficient wind powered blade structure than any presently available wind mill blade or blades arrangement. Specifically, the present invention is an improvement over an earlier wind sail receptor that the inventor is a joint inventor of, set out in U.S. Pat. No. 7,309,213. Unique to the invention, the blades of the improved wind sail receptor are formed separately as flat segments for mounting between rear and forward hubs, forming a wind sail receptor having three to five blades, depending upon the diameter of the hub the blades are mounted to. The individual blades are each bent between forward and rear hubs to have a leading edge from the forward hub that faces into the wind, and are curved across a cylinder whose ends the forward and rear hubs are mounted to, forming a blade trailing edge. The blades are bent between the leading and trailing edges in a uniform arc and provides a smooth turbulence free wind transition where the wind flow exits off the blades trailing edges at approximately a forty five degree angle downwardly to the direction the entering wind. Which wind flow redirection turns the wind sail receptor blades that are mounted on an axle that turns a generator.
The spacing of the blades around the hub and the bend angle of each blade provides, in practice, for a maximum utilization of the force of the entering wind to translate that wind force into wind sail receptor turning. Further, to provide a maximum efficiency in the utilization of the energy of the wind flow into the wind sail receptor, the invention includes a nose cone, that is fitted over a forward end of a wind sail receptor housing. Which nose cone has a cylindrical shape and slopes outwardly from a rounded dome end to an open base end that mounts across the front or wind facing end of the housing and contains a generator that is axially connected to be turned by wind sail receptor turning, with the wind sail receptor journaled to turn freely on the housing rear end. Which nose cone slope and the radius of the rounded dome end are selected to provide for a translation of wind striking the nose cone and direct it over the rounded top end and along a nose cone cylindrical section, and along the housing surface and into the wind sail receptor blades to turn the wind sail receptor blades, without a creation of turbulence in the wind flow entering the wind sail receptor.
A wind flow passing over the nose cone travels along the housing, that is pivot mounted to the top of a vertical pole, and into the wind sail receptor blades that are thereby turned into that wind flow, without a necessity for a rudder, or like device to turn the wind sail receptor into the wind, causing the wind sail blades to always face directly into the wind flow.
So arranged, the combination of the unique blade design and arrangement of the nose cone provide for an essentially turbulence free passage of a wind flow through the wind sail receptor to capture most, if not all of that wind flow energy, and convert it into torque turning the wind sail receptor blades that are axially connected to turn the generator contained in the housing.
Heretofore, wind mill blade configurations have generally lack efficiency, particularly the blades as are turned in a wind farm operation, that operate at only an efficiency of approximately twenty (20), and thereby utilize only a small percentage of the energy of a wind energy passing through the blades. Which wind farm blades, therefore, have to be large to produce a worthwhile energy output. In fact, even the wind sail receptor of applicant's prior patent could only obtain an efficiency of approximately ninety (90) per cent utilization of wind energy at winds of from eight (8) to ten (10) miles per hour and greater.
The wind sail receptor blades arrangement, because of its size, manner of construction and assembly is far less expensive to construct and maintain over earlier and present wind mills, and is therefore a significant improvement over earlier wind powered systems.
It is a principal object of the present invention to provide a wind sail receptor for converting wind power into torque that is applied through an axle of the wind sail receptor to turn a generator for producing electrical energy, whose design provides for a very efficient use of wind energy for turning of the wind sail receptor blades that nears a one hundred percent efficiency.
Another object of the present invention is to provide a wind sail receptor having three to five blades, dependent upon the diameter of the blades hubs, and can be arranged to form six, twelve and up to twenty five foot diameter assemblies that will be significantly smaller in diameter than other wind mill arrangements that produce a like or lesser power output, as compared to the invention.
Still another object of the present invention is to provide a wind sail receptor where the blades are preferably formed and shipped flat for later installation onto a hub arrangement that, accordingly, are inexpensive to manufacture and ship, and can be easily installed and repaired on site.
The present invention is in a wind sail receptor for converting wind energy into electrical power that has three to five blades, depending upon the diameter of forward and rear blade hubs, that can be formed into six, twelve and up to twenty five foot diameter assemblies. In which assemblies, the blades are equally spaced around a rear hub, and are each bent from attachment points at the front face of the rear hub to a forward location on a cylinder, that is proximate to the forward hub, where the rear and a forward hub are connected to opposite faces of the cylinder. Which blade to rear hub connection is at spaced points around the rear hub front face, and the connection to the cylinder is to at least one, and may be to several aligned spaced attachment tabs, that extend outwardly from the cylinder surface, with a forward most connection point being adjacent to the forward hub. In which blade mounting the blade is bent in a uniform curve from leading to trailing edges. Which bend has a uniform curved surface that a wind flow entering the wind sail receptor will travel over from the blade leading to trailing edges, without a creation of turbulence in that wind passage. Which wind flow will exit off of each blade trailing edge at approximately a forty five degree angle to the entering wind flow, without a creation of wind flow separation or turbulence in that exhaust flow as it passes off the blade trailing edge.
The wind sail receptor of the invention includes a nose cone that is secured across a forward end of a housing that has the forward hub mounted to turn freely on the cylinder rear end. Which nose cone has a dome shaped outer end surface and a cylindrical body that connects at a rear surface of the forward end of the housing. The nose cone is formed to provide an even distribution of a wind flow that strikes and travels along the housing, to pass to the forward hub, and travels into the blades. Which wind flow, absent the nose cone, would strike a blunt forward end of the housing and spread outwardly into the wind flow entering the wind sail receptor, negatively affecting wind sail receptor turning efficiency.
The blades of the wind sail receptor are preferably formed individually and each has an inner end attached at forward spaced points to a front surface of the rear hub, and is bent therefrom forward along the outer surface of a cylinder to a point thereof that is proximate to the forward hub. From the rear hub attachment, each blade cylinder mounting end is bent along the cylinder outer surface to a forward attachment tab that is adjacent to the forward hub for attaching the blade to butt against the cylinder outer surface. In which blade to cylinder mounting the blade is bent into an arc of from seventy to seventy eight degrees that provides for a smooth redirection of the entering wind flow that has passed across the nose cone and traveled along the housing, to turn the wind sail receptor blades, translating wind energy into wind sail receptor turning.
Each blade from a second connection to the rear hub has an outwardly curved edge that is the blade trailing edge and is curved from its first inner end connection to fit closely to the cylinder surface and ends in a connection end that couples to a tab that extends outwardly from the cylinder surface, proximate to the front hub and the cylinder end of the blade leading edge. Which blade forward trailing and leading edges, respectively, extend outwardly from the cylinder, and each connects to an opposite end of a straight blade outer end. The blade leading edge, before mounting, is essentially straight. However, when bent, appears to have a curved leading edge, and the trailing edge that is curved outwardly adjacent to the rear hub mounting to a point therealong wherefrom it is essentially straight to is end connection to the blade outer end.
In operation, a wind flow entering the wind sail receptor from the nose cone and across the housing travels over blade essentially straight sloping leading, and is redirected by the blade trailing edge curved section as a smooth non turbulent flow to the blade trailing edge. Which wind flow has passed off of the nose cone and along the housing as a smooth air flow that then travels across the blades leading edge, around the curve of the blades, and exits off of the blades trailing edges as a turbulence free air flow. Which exhaust wind flow is directed downwardly by the blades trailing edges of each blade at approximately a forty five degree angle to the entering wind flow. Which exhaust air flow is turbulence free and provides nearly a one hundred percent efficiency in the conversion of the entering wind flow energy into turning of the wind sail receptor. With the redirection of the entering air flow redirection acting on each blade to translate the wind flow energy into blade movement that turns an axle that is axially connected to the hubs to turn a generator mounted in the housing, converting the energy of the wind flowing into the wind sail receptor into axial torque.
The blade themselves and the other components of the wind sail receptor of the invention are simple and economical to produce, with the blades, preferably manufactured by casting methods, from a polyurethane material and are connected to the rear hub to be equally spaced there around.
In operation, the wind directed across the nose cone and along the housing acts on the wind sail receptor blades to pivot the housing with wind direction changes such that the wind sail receptor will always face into the wind.
The invention may take physical form in certain parts and arrangement of parts, and a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof:
The present invention is in a wind sail receptor 10, shown in
The blade 11 is thereby connected to the rear hub 12 forward face at its arc section 15 by fitting fasteners, such as screws, through the first and second rear hub connection holes 15a and 15b, respectively, into selected rear hub holes 12a. With the blade 11 connected to the rear hub 12, a trailing blade edge 23 is adjacent to the second connecting hole 15b and extends outwardly therefrom. The blade 11 has a curved section 16 that extends from adjacent to the first connecting hole that is for fitting closely to the surface of a cylinder 26, as shown in
The curve of the blade inner surface 16 is, of course, dependant upon the diameter of the rear and front hubs, 12 and 18, respectively, and the cylinder 26, and that curve is dependent upon the number of blades 11, whether three to five blades 11 are employed, and the diameter the wind sail receptor 10 across the blades. Also, as shown in
The blade 11 is bent between the front face of the rear hub 12 to its end connection point 17a and it's coupling at a hole 28 in an end of tab 27, that extends outward from the cylinder 26 surface, into an arc of from seventy to seventy six degrees, whereby a wind striking the blade 11 leading edge 19 will travel, without turbulence, around the blade arc to exit, without turbulence, off of the blade trailing edge 23.
Where a blade 11 single end connection point 17a is shown for connection to the coupling to the single tab 27, it should be understood that additional spaced coupling tabs 27 can be installed onto the cylinder 26 surface, and appropriately spaced holes can be formed along the blade inner surface section 16 that align with to connect to the spaced tabs 27, to provide a reinforcement of the connection of the blade inner surface 16 to the cylinder 26 surface. Such reinforcement, while not required, is useful for adding strength to the blade to cylinder connection, particularly for the twelve and twenty five foot diameter wind sail receptors. Which tab 27 and blade 17 end connection, as shown in
Shown in
For mounting each blade 11, to the rear hub 12, the rear hub 12 includes spaced holes 12a formed around the rear hub edge that are spaced equidistantly apart and are for alignment with the blade arc section 15 first and second connection holes 15a and 15b to receive fasteners fitted through the blade arc section 15 first and second connection 15a and 15b, respectively, that are turned into the rear hub 12 holes 12a, as shown in
The configuration of the blades 11 provides, as shown in
Shown in
In
In practice, the arrangement of the wind sail receptor 10 blades 11 mounted around the rear hub 12, where the blades 11 arc sections 15 are attached to the front face of the rear hub at equal intervals, provides for a secure and durable mounting to the blades 11. So arranged, the combined wind flows A and B enter the blades 11 across the blade leading edge 19 accumulates at the blade trailing edge at curved section 24 to flow outwardly therefrom to where the curve is reversed at 24a and then to the essentially straight section 25, and off from the blade end 22. Which curved section 24 has a greater length of edge to accommodate the combined wind flows A and B as have traveled across the blade 11, and to smoothly exhaust the combined wind flows both across the blade at the curved section 24, without a creating of turbulence and to guide the combined wind flows along the blade to exhaust off of the straight section 25. Which combined wind flow passage off of the blade trailing edge 23 curved and straight sections 24 and 25. In practice, the combination of which curved and straight sections 24 and 25 promotes a non-turbulent separation of the combined wind flow off of the blade trailing edge. Which wind air flow exhaust, because of the trailing edge 23 configuration, is smooth and does not create turbulence as it travels off of the blade trailing edge 23, and this non turbulent wind air flow off the blade 11 at trailing edge separation promotes an efficient translation of the wind flow energy into blade turning with minimum wind energy losses.
Along with the shape of the blade 11 the trailing edge 23, as discussed above, to maximize wind flow energy conversion into blade 11 turning, the bent blade 11 is curved in a uniform arc of from seventy to seventy eight degrees from its leading to trailing edges, 19 and 23, respectively. This smooth curved surface maximizes wind energy conversion to blade turning and provides for a non turbulent wind air flow travel over the blade from leading to trailing edges. As set out above, this preferred uniform arc is formed in the bending of blade 11 from its mounting at blade arc section 15 end connection at holes 15a across the cylinder 25 to the blade end 17 at connection point 17a to the tab 27 that extends outwardly from the cylinder 25, adjacent to the forward hub 18. Which tab 27, shown in
While the bend arc can be at an angle of from seventy to seventy eight degrees to produce the wind conversion efficiency, as set out above, for the four bladed six foot diameter wind sail receptor 10 the bent angle is preferably approximately fifteen (15) degrees. Additionally, as shown in
With the blades 11 bent to an arc of from seventy to seventy eight degrees, combined wind flows A and B will smoothly travel around the blade 11 arc and off of the blade trailing edge 23 at an angle of approximately forty five degrees to the direction of the wind flow entering the wind sail receptor 10 that travels over blade leading edge 19, with little or no air flow traveling through the blades 11. This wind flow re-direction provides a maximum utilization of the energy of the wind flow into wind sail receptor turning that closely approaches and one hundred per cent wind energy utilization to turn a generator to produce an electrical power output.
The wind sail receptor 10 is shown herein as having a six foot diameter the rear hub 12, cylinder 26 and forward hub 18 that are approximately one foot in diameter. As set out above, however, the wind sail receptor 10 can be formed to have from three to five blades 11 but such configuration will require an alteration to the hub and cylinder diameter. For example, the hub and cylinder diameter for a five blade 11 wind sail receptor 10 with three foot blades will be approximately fifteen (15) inches, and the hub and cylinder diameter for a three bladed wind sail receptor 10, where the blades are three feet in length will be approximately twelve (12) inches. Additionally, the wind sail receptor 10 can be upscaled with utilization of longer blades 11 and such will also require an alteration in the rear hub 12, cylinder 26 and forward hub 18 diameter. For a wind sail receptor 10 that has twelve foot diameter across the blades ends, utilizing blades 11 that are approximately five feet in length, the hubs and cylinder 12, 18 and 26, respectively, should have approximately a one foot diameter, and, a wind sail receptor 10 with a diameter of twenty five feet across the blades ends, that will utilize blades 11 that are approximately ten feet in length, the hubs and cylinder, 12, 18 and 26, respectively will have a diameter of approximately five feet.
A preferred embodiment of the wind sail receptor of the invention has been shown and described above. It will, however, be apparent to one knowledgeable or skilled in the art that the above described embodiment may incorporate changes and modifications without departing from the general scope of this invention. Which invention is therefore intended to include all such modifications and alterations in so far as they come within the scope of the appended claims and/or a reasonable equivalence thereof.