Generator module and generator comprising same

Abstract

A generator module includes a stator, a rotor, and a mechanical switch. The stator includes a first set of patterned conductive coatings, a second set of patterned conductive coatings, a first set of dielectric sectors, and a second set of dielectric sectors. The rotor includes a third set of patterned conductive coatings and a third set of dielectric sectors. The first set of patterned conductive coatings is electrically connected to the first electrical terminals. The second set of patterned conductive coatings is electrically connected to the second electrical terminals. The third set of patterned conductive coatings is electrically connected to the third electrical terminals. The mechanical switch allows the third electrical terminal to be selectively connectable to one of the first electrical terminal and the second electrical terminal.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims priority to U.S. Patent Application No. 18 / 413,158, filed on January 16, 2024, entitled "Generator Module and Generator Including the Same", the entire content of which is incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to power generation, and more particularly to generator devices for power generation. Background Art

[0004] Generators can convert motion - based power into electrical power. Electret - based generators and triboelectric generators are two typical generators. They use dielectrics as functional materials for electrostatic induction and / or triboelectrification, and thus, they can be called dielectric - based generators (DBGs). These generators have the advantages of simple structure, light weight, low cost, and ease of fabrication. In addition, they can be configured in various ways. For example, the rotational mode is one of the most common and promising modes. However, innovation is still needed for the application of generators in multiple fields where conventional permanent - magnet electromagnetic generators encounter difficulties.

[0005] An object of the present disclosure is to overcome or substantially improve one or more of the disadvantages of the prior art, or at least provide a useful alternative. Summary of the Invention

[0006] In one aspect of the present disclosure, a generator module is provided. The generator module includes a stator, a rotor rotatable relative to the stator, and a mechanical switch. The stator includes a stator substrate having a first stator side, a first set of patterned coatings that are conductive and disposed on the first stator side, and a second set of patterned coatings that are conductive and disposed on the first stator side. The first set of patterned coatings is electrically isolated from the second set of patterned coatings. The stator further includes a first set of dielectric sectors that are negatively charged and disposed on the first set of patterned coatings, and a second set of dielectric sectors that are positively charged and disposed on the second set of patterned coatings. Each positively charged dielectric sector is circumferentially adjacent to two negatively charged dielectric sectors. Each negatively charged dielectric sector is circumferentially adjacent to two positively charged dielectric sectors. The rotor includes a rotor substrate having a first rotor side, a third set of patterned coatings that are conductive and disposed on the first rotor side, and a third set of dielectric sectors that are negatively or positively charged and disposed on the third set of patterned coatings. The first stator side of the stator substrate faces the first rotor side of the rotor substrate. The first set of patterned coatings is electrically connected to a first electrical terminal. The second set of patterned coatings is electrically connected to a second electrical terminal. The third set of patterned coatings is electrically connected to a third electrical terminal. The mechanical switch is configured to allow the third electrical terminal to be selectively connected to one of the first electrical terminal and the second electrical terminal.

[0007] In another aspect of the present disclosure, a generator for power generation is provided. The generator includes a housing and a plurality of generator modules. The generator modules are disposed within the housing and share a shaft, thereby forming a chain of generator modules along the longitudinal axis of the shaft. Each generator module includes a stator and a rotor mounted to the shaft. The stator includes a stator substrate having a first stator side, a first set of patterned coatings that are conductive and disposed on the first stator side, and a second set of patterned coatings that are conductive and disposed on the first stator side. The first set of patterned coatings is electrically isolated from the second set of patterned coatings. The stator further includes a first set of dielectric sectors that are negatively charged and disposed on the first set of patterned coatings, and a second set of dielectric sectors that are positively charged and disposed on the second set of patterned coatings. Each positively charged dielectric sector is adjacent to two negatively charged dielectric sectors along the circumferential direction. Each negatively charged dielectric sector is adjacent to two positively charged dielectric sectors along the circumferential direction. The rotor includes a rotor substrate having a first rotor side, a third set of patterned coatings that are conductive and disposed on the first rotor side, and a third set of dielectric sectors that are negatively or positively charged and disposed on the third set of patterned coatings. The first stator side of the stator substrate faces the first rotor side of the rotor substrate. The first set of patterned coatings is electrically connected to a first electrical terminal. The second set of patterned coatings is electrically connected to a second electrical terminal. The third set of patterned coatings is electrically connected to a third electrical terminal. The generator further includes a first common terminal, a second common terminal, and a third common terminal. The first electrical terminal of each generator module is connected to the first common terminal. The second electrical terminal of each generator module is connected to the second common terminal, and the third electrical terminal of each generator module is connected to the third common terminal such that the plurality of generator modules are electrically connected in parallel.

[0008] Other example embodiments are discussed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The following detailed description of various embodiments is set forth with reference to the accompanying drawings. The drawings are provided for purposes of illustration only and depict only exemplary embodiments of the present disclosure. The drawings are provided to facilitate understanding of the present disclosure and should not be regarded as limiting the breadth, scope, or applicability of the present disclosure. The drawings are not drawn to scale unless otherwise specified. Certain portions of the drawings are enlarged for purposes of illustration and should not be regarded as limiting unless otherwise expressly stated.

[0010] Figure 1 A generator module in accordance with certain embodiments of the present disclosure is illustrated.

[0011] Figure 2A A stator of a generator module in accordance with certain embodiments of the present disclosure is illustrated.

[0012] Figure 2B Illustrated is disposed on Figure 2A teeth on the stator of the generator module.

[0013] Figure 2C Illustrates a rotor of a generator module according to certain embodiments of the present disclosure.

[0014] Figure 2D Illustrates a thrust bearing structure according to certain embodiments of the present disclosure.

[0015] Figure 2E Shows a fabricated stator of a generator module according to certain embodiments of the present disclosure.

[0016] Figure 2F Shows a fabricated rotor of a generator module according to certain embodiments of the present disclosure.

[0017] Figure 3A Illustrates a generator according to certain embodiments of the present disclosure.

[0018] Figure 3B Illustrates Figure 3A an exploded view of the generator.

[0019] Figure 3C Illustrates Figure 3B a cross-sectional view of an intermediate segment of the shaft.

[0020] Figure 3D Illustrates Figure 3A an inner layer of a stator substrate of the generator.

[0021] Figure 3E Illustrates Figure 3A an inner layer of a rotor substrate of the generator.

[0022] Figure 4 Illustrates a generator according to certain embodiments of the present disclosure and its test setup.

[0023] Figure 5A Illustrates a schematic circuit for a generator according to certain embodiments of the present disclosure.

[0024] Figure 5B Illustrates Figure 5A a schematic charge transfer process of a generator module in the generator.

[0025] Figure 6A Shows the generator capacitance of two generators at different rotational angles according to certain embodiments of the present disclosure, one generator having one generator module and the other generator having two generator modules.

[0026] Figure 6BShows the peak generator current output by two generators at different load resistances according to certain embodiments of the present disclosure, where one generator has one generator module and the other generator has two generator modules, and the rotational speed is equal to π rad / s.

[0027] Figure 6C Shows the time history of the generator current output in the form of a pulse sequence when the rotational speed is equal to π rad / s, the load resistance is 1 ohm, and the number of generator modules is 2, according to certain embodiments of the present disclosure.

[0028] Figure 6D Shows Figure 6C An enlarged view of one pulse of

[0029] Figure 7A Illustrates a demonstration of powering a thermometer using a generator according to certain embodiments of the present disclosure.

[0030] Figure 7B Shows the equivalent circuit for the Figure 7A demonstration of Detailed Description

[0031] The present disclosure will now be described with reference to the following examples, which should be considered illustrative in all respects and not restrictive.

[0032] Unless the context clearly indicates otherwise, throughout the specification and claims, the words "comprising," "including," etc. shall be construed in an inclusive sense rather than an exclusive or exhaustive sense; that is, in the sense of "including but not limited to."

[0033] Furthermore, as used herein and unless otherwise specified, the use of ordinal adjectives "first," "second," etc. to describe a common object merely indicates different instances of the same type of object and is not intended to imply that the objects so described must be in a given sequence in terms of time, space, ranking, or in any other way.

[0034] Example embodiments relate to a generator or a part of a generator (such as a generator module) having improved performance.

[0035] The present inventors have recognized that many existing systems have technical drawbacks in one aspect or another. For example, power capacity is considered one of the most fundamental characteristics of a generator. Existing rotary dielectric-based generators (DBGs) typically include a rotor and a stator, both of which are in the form of circular plates. Thus, to increase the power capacity, a straightforward approach is to increase the diameter of the circular plates. However, such a simple scaling up may do more harm than good. On the one hand, a larger diameter results in a larger volume and makes assembly more difficult. For example, as the sizes of the rotor and stator increase, it may be more challenging to maintain good parallelism between them. On the other hand, most dielectric-based generators are used as high-voltage sources. This poses potential problems when one intends to use their output directly. Custom power management circuits are typically employed to modify the output. In this regard, the much higher voltage output caused by the scaling up of the diameter only makes the situation worse. Therefore, it is challenging to increase the power capacity of dielectric-based generators while avoiding the above-mentioned adverse effects.

[0036] Dielectric-based generators have two typical types, namely triboelectric generators and electret-based generators. Triboelectric generators operate by combining triboelectrification and electrostatic induction between a stator and a rotor that are in contact with each other, while electret-based generators rely only on electrostatic induction between a stator and a rotor that are separated by a gap. In either case, sufficient parallelism should be maintained between the stator and the rotor, especially at high rotational speeds. In existing systems, flanges can be used to maintain a certain distance between the stator and the rotor. In doing so, high-precision machining and assembly are required. Additionally, it tends to become bulky when multiple rotors and stators are mounted on the same shaft because more flanges and related components are needed. Other problems common to both electret-based generators and triboelectric generators are high output impedance and low charge transfer, which result in low power output.

[0037] Example embodiments address one or more of the problems associated with existing systems and provide a technical solution with a new design and improved performance.

[0038] According to one or more embodiments, a generator module is provided that includes a stator and a rotor that rotates relative to the stator for power generation. A mechanical switch is provided to efficiently release the induced charge during the rotation of the rotor. In some embodiments, the mechanical switch includes a flexible conductive brush attached to the rotor and multiple teeth disposed on two sets of patterned coatings on the stator. This design ensures both operational robustness and manufacturing simplicity.

[0039] According to one or more embodiments, a generator module or a generator including one or more generator modules employs a design similar to a thrust bearing. The thrust bearing structure may be arranged on the stator. For example, a plurality of recesses may be formed in the stator such that each recess receives a bearing ball. The recesses may be formed along the inner circumference and the outer circumference of the stator to receive the bearing balls. Alternatively, the thrust bearing structure may be arranged on the rotor in a similar manner (as if it were formed on the stator) or in a different manner (as long as it can fulfill the desired function). The design similar to a thrust bearing allows the rotor and the stator to be mounted on the shaft with a small separation gap and good parallelism, which is particularly advantageous for electret-based generators. In some embodiments, the bearing balls may be lubricated ceramic balls to ensure that the generator rotates smoothly even at high rotational speeds and the contact friction is reduced.

[0040] According to one or more embodiments, a generator including a plurality of generator modules is provided, and the generator modules have a mechanically series and electrically parallel configuration. First, this configuration enables the generator modules to be mechanically assembled in series or added on a single shaft in a compact structure, and the number of the installed modules can be easily expanded. Thus, the power capacity can be flexibly adjusted according to actual needs. Second, this configuration allows the electrical outputs of the generator modules to be superimposed to achieve an increased current output. Since the generator modules are electrically connected in parallel, the voltage output across the terminals of the generator modules remains unchanged. Compared with the high voltage outputs in many existing systems, in many practical applications, this configuration is advantageous in terms of power management and transmission. This design also enables a modular design and an expandable power capacity.

[0041] One or more embodiments include a generator that is rotary, modular, and capacity-expandable. Compared with existing generators that operate by electrostatic induction and / or triboelectrification, these technical advantages make the generator more practical, applicable, and capable.

[0042] One or more embodiments include a generator module or a generator mainly made of plastic, such that the generator module or the generator has the potential to be more cost-effective and more suitable for applications in a corrosive environment (e.g., in the ocean) than many existing generators based on permanent magnets and metal coils. In some embodiments, for example, the main materials used to manufacture the generator (such as the substrates for electrets or triboelectric films, the rotor and the stator, and a housing including a shell and a plurality of cover parts) are all plastic, which is much cheaper than the rare earth magnets commonly used in conventional permanent magnet generators. Further, in certain applications where a lighter generator is particularly advantageous and desirable, plastic makes the generator according to one or more embodiments lighter, portable, and easy to carry or install.

[0043] Reference Figure 1, the generator module 10 includes a stator 120 and a rotor 140. The stator 120 and the rotor 140 can be mounted on a shaft 101 having a longitudinal axis L such that, in operation, the rotor 140 rotates about the longitudinal axis L and relative to the stator 120.

[0044] The stator 120 includes a stator substrate 121. The stator substrate 121 has a first stator side 121a and a second stator side 121b opposite the first stator side 121a. A first set of patterned coatings 122 is conductive and disposed on the first stator side 121a. A second set of patterned coatings 123 is conductive and disposed on the first stator side 121a. The first set of patterned coatings 122 is electrically isolated from the second set of patterned coatings 123, which can be achieved, for example, by a patterning process during fabrication. The first and second sets of patterned coatings can be metal coatings. For example, these metal coatings can include one or more of copper, iron, aluminum, etc. In some embodiments, copper is used for the metal coating due to its excellent electrical conductivity and physical properties. In some other embodiments, non-metallic materials (such as doped semiconductors) can be used as the patterned coatings. In some other embodiments, the patterned coatings can include one or more conductive polymer materials. In some embodiments, each patterned coating in the first or second set of patterned coatings can be referred to as a patterned coating sector or a coating sector.

[0045] A first set of dielectric sectors 124 is negatively charged and disposed on the first set of patterned coatings 122. A second set of dielectric sectors 125 is positively charged and disposed on the second set of patterned coatings 123. Each positively charged dielectric sector is adjacent to two negatively charged dielectric sectors along the circumferential direction. Each negatively charged dielectric sector is adjacent to two positively charged dielectric sectors along the circumferential direction. The first and second sets of dielectric sectors include a suitable dielectric material. For example, each dielectric sector can include an electret film or a triboelectric film.

[0046] The rotor 140 includes a rotor substrate 141. The rotor substrate 141 has a first rotor side 141a and a second rotor side 141b opposite the first rotor side 141a. The first rotor side 141a faces the first stator side 121a of the stator substrate 121.

[0047] The third set of patterned coatings 142 is conductive and disposed on the first rotor side 141a. The third set of dielectric sectors 144 is negatively or positively charged and disposed on the third set of patterned coatings 142. The third set of patterned coatings may be a metal coating, such as a copper coating, an iron coating, an aluminum coating, etc. Similarly, the third set of patterned coatings may include non-metallic materials, such as one or more conductive polymer materials, as long as these materials have satisfactory conductive properties. The third set of dielectric sectors includes dielectric materials. For example, each dielectric sector may include an electret film or a triboelectric film. In some embodiments, each patterned coating in the third set of patterned coatings may be referred to as a patterned coating sector or a coating sector.

[0048] The first set of patterned coatings 122 may include a plurality of patterned coatings. For example, the number of patterned coatings in this set may be 3, 4, 5 or more. The first set of dielectric sectors 124 may include a plurality of dielectric sectors. For example, the number of dielectric sectors in this set may be 3, 4, 5 or more. The number of coatings in the first set of patterned coatings 122 is equal to the number of dielectric sectors in the first set of dielectric sectors 124, such that each dielectric sector is disposed on a corresponding patterned coating. This number is denoted as n1.

[0049] The second set of patterned coatings 123 may include a plurality of patterned coatings. For example, the number of patterned coatings in this set may be 3, 4, 5 or more. The second set of dielectric sectors 125 may include a plurality of dielectric sectors. For example, the number of dielectric sectors in this set may be 3, 4, 5 or more. The number of coatings in the second set of patterned coatings 123 is equal to the number of dielectric sectors in the second set of dielectric sectors 125, such that each dielectric sector is disposed on a corresponding patterned coating. This number is denoted as n2. Further, n1 = n2.

[0050] The third set of patterned coatings 142 may include a plurality of patterned coatings. For example, the number of patterned coatings in this set may be 3, 4, 5 or more. The third set of dielectric sectors 144 may include a plurality of dielectric sectors. For example, the number of dielectric sectors in this set may be 3, 4, 5 or more. The number of coatings in the third set of patterned coatings 142 is equal to the number of dielectric sectors in the third set of dielectric sectors 142, such that each dielectric sector is disposed on a corresponding patterned coating. This number is denoted as n3. In some embodiments, optionally and advantageously, n3 = n1.

[0051] The first set of dielectric sectors 124 is associated with a first set of patterned coatings 122 that can be electrically connected to a first electrical terminal. The second set of dielectric sectors 125 is associated with a second set of patterned coatings 123 that can be electrically connected to a second electrical terminal. The third set of dielectric sectors 144 is associated with a third set of patterned coatings 142 that can be electrically connected to a third electrical terminal. These electrical connections can be achieved through metal wires (such as copper pin terminals or leads) and printed circuit board (PCB) technology. The first, second, and third electrical terminals are not shown in Figure 1 but will be described and illustrated in one or more embodiments below with reference to one or more figures.

[0052] In some embodiments, optionally and advantageously, a mechanical switch can be provided to allow the third electrical terminal to be selectively connected to one of the first and second electrical terminals in order to avoid or mitigate the accumulation of induced charges during the rotation of the rotor. As an example, the mechanical switch can include a flexible conductive brush attached to the rotor and a plurality of teeth formed on the stator. During the rotation of the rotor, the brush will continuously contact the teeth, thereby connecting or disconnecting the third electrical terminal from the first or second electrical terminal.

[0053] Figure 2A , Figure 2B , Figure 2C , Figure 2D , Figure 2E and Figure 2F illustrate a generator module according to certain embodiments and its stator 220 and rotor 240. The stator 220 includes a stator substrate 221 coated with a conductive patterned coating. A first set of dielectric sectors consisting of three dielectric sectors 224 and a second set of dielectric sectors consisting of three dielectric sectors 225 are provided on the patterned coating. The dielectric sectors 224 are negatively charged (indicated by the symbol "-"), while the dielectric sectors 225 are positively charged (indicated by the symbol "+"). The dielectric sectors 224, 225 are arranged alternately along the circumferential direction of the circular stator. The dielectric sectors 224 are coupled to a first electrical terminal 227a via the corresponding patterned coating. The dielectric sectors 225 are coupled to a second electrical terminal 227b via the corresponding patterned coating.

[0054] The materials of the dielectric sectors 224, 225 can be appropriately selected. In some embodiments, the dielectric sectors 224, 225 include polytetrafluoroethylene (PTFE) films that are appropriately charged or polarized. In some other embodiments, the dielectric sector 224 includes a fluorinated ethylene propylene (FEP) film or any other suitable triboelectric material, and the dielectric sector 225 includes a polycarbonate (PC) film or any other triboelectric material with a positive polarity. In some embodiments, other polymers with good or superior charge retention capabilities can be used for the dielectric sectors 224, 225. Advantageously, the thicknesses of the dielectric sectors 224, 225 are the same.

[0055] Figure 2A An enlarged view of the central region 226 of the stator 220 is also shown. As illustrated, each patterned coating corresponding to a respective dielectric sector is provided with teeth 226a formed at its inner circumference near the central region 226, thereby forming a plurality of teeth. Each tooth can be part of the associated patterned coating. Alternatively, each tooth can be formed separately and electrically connected to the associated patterned coating. Six teeth are shown for illustrative purposes in the present embodiment. As will be described later herein, these teeth form part of a mechanical switch.

[0056] In Figure 2B an enlarged view of the tooth 226a is shown. The tooth 226a is illustrated as an elongated extension emerging from the patterned coating 223 that supports the dielectric sector 225. Blind holes 228 are shown, which are used to establish electrical connections between the coating sectors and the corresponding inner layers, and thus, electrically connect the coating sectors of the same group together.

[0057] Referring again to Figure 2A , a cross-sectional view of the region 24 of the dielectric sector 224 is shown when cut along a direction perpendicular to the direction from the dielectric sector 224 towards the stator substrate 221. The cross-sectional view shows that the stator substrate 221 is double-sided, which is optional rather than necessary. That is, on one side, the patterned coating 222 is provided on the stator substrate 221 and the dielectric sector 224 is provided on the patterned coating 222. On the other side, the patterned coating 222a is provided on the stator substrate 221 and the dielectric sector 224a is provided on the patterned coating 222a. Advantageously, the patterned coating 222 and the patterned coating 222a are symmetrically arranged with respect to the stator substrate 221, and the dielectric sector 224 and the dielectric sector 224a are symmetrically arranged with respect to the stator substrate 221. In Figure 2E a top view of the manufactured stator is shown.

[0058] Referring to Figure 2C, the rotor 240 includes a rotor substrate 241 coated with a conductive patterned coating. A third set of dielectric sectors, which consists of three negatively charged (indicated by the symbol "-") dielectric sectors 244, is disposed on the patterned coating. This is for illustrative purposes only. It should be understood that in some embodiments, the dielectric sectors 244 may be positively charged. The dielectric sectors 244 are coupled to the third electrical terminal 247 via the underlying patterned coating.

[0059] The material of the dielectric sectors 244 can be appropriately selected. In some embodiments, the dielectric sectors 244 include a negatively charged or polarized polytetrafluoroethylene (PTFE) film. In some other embodiments, the dielectric sectors 224 include a fluorinated ethylene propylene (FEP) film or any other suitable triboelectric material with a triboelectric polarity opposite to that of the dielectric sectors 225. Advantageously, the thickness of the dielectric sectors 244 is less than the thickness of the dielectric sectors 224, 225. For example, the dielectric sectors 244 may have a thickness of approximately 10 μm, and the dielectric sectors 224, 225 may have a thickness of approximately 100 μm.

[0060] Further, a brush 246 is disposed near the central region of the rotor 240. The brush 246 and the multiple teeth of the stator 220 form a mechanical switch that facilitates the release of the induced charge and enhances the output of the generator module. The brush 246 can be a flexible conductive brush. This is advantageous. First, it ensures the desired selective contact with the teeth during operation. Second, the brush is robust and not prone to damage or unfavorably impede the rotation of the rotor due to the introduction of unnecessary friction. For example, the brush 246 includes a first end 246a and a second end 246b. The first end 246a can be mounted to the third electrical terminal 247, for example, by an M0.6 screw. In some embodiments, welding or conductive adhesive can be used to mount the first end 246a. The second end 246b has a brush head 246c that can be electrically contacted with each of the multiple teeth during operation.

[0061] Further, referring to Figure 2C and Figure 2D, a thrust bearing structure is provided on the rotor 240. This is for illustrative purposes only. In some embodiments, the thrust bearing structure may be provided on the stator. The thrust bearing structure includes a plurality of recesses formed on the rotor 240 and a plurality of bearing balls, wherein each bearing ball 252 is received in a corresponding recess 253. A portion of the bearing ball 252 projects from the recess 253 to ensure that there is always a minimum clearance 254 between the rotor and the stator when the generator module is in operation. In the present embodiment, eight bearing balls 250a, 250b, 250c, 250d, 250e, 250f, 250g, and 250h are arranged along the outer circumference of the rotor 240, and three bearing balls 251a, 251b, and 251c are arranged along the inner circumference of the rotor 240. The thrust bearing structure promotes stable operation at relatively high rotational speeds and controls the separation gap between the stator 220 and the rotor 240. The thrust bearing structure further promotes improved parallelism between the rotor and the stator. The bearing balls may be lubricated ceramic balls to ensure that the generator rotates smoothly even at high rotational speeds and the contact friction is reduced. In Figure 2F A top view of the manufactured rotor is shown.

[0062] Reference Figure 3A and Figure 3B , the generator 300 includes a housing 310, a shaft 301, and a plurality of generator modules. The plurality of generator modules are provided within the housing 310 and share the shaft 301, thereby forming a chain of generator modules along the longitudinal axis L of the shaft 301.

[0063] Each of the generator modules may be a generator module as described above according to one or more embodiments. In the present embodiment, four generator modules 32, 34, 36, and 38 are provided. The four generator modules include three stators and two rotors. The stators may be spaced apart using washers and nuts. The stators and rotors are bilateral. Thus, each two facing sides of the stator and the adjacent rotor form a generator module. Let N s , N r and N g represent the numbers of the stator, rotor, and generator module, respectively. Then, there will be: N g =(N s +N r ) - 1.

[0064] The shaft 301 includes a first segment 301a, a second segment 301b, and an intermediate segment 301c between the first segment and the second segment. The intermediate segment 301c has a cross-section 301d ( Figure 3C), the cross-section has a rounded square shape. Since the stator and the rotor are mounted on the intermediate segment 301c, this rounded square cross-section design advantageously allows additional generator modules to be easily added to the generator without using flanges.

[0065] All the first set of dielectric sectors of the generator module are electrically connected using copper pin terminals 327a. All the second set of dielectric sectors of the generator module are electrically connected using copper pin terminals 327b. These two terminals serve as the output terminals of the generator and can thus be regarded as the first common terminal and the second common terminal respectively. The power output can be easily and flexibly adjusted by changing the number of stators and / or rotors so as to add or remove generator modules.

[0066] Furthermore, both the stator and the rotor are aligned according to their dielectric sectors such that there is no phase difference between the outputs of different generator modules. The stator does not rotate during operation and thus the alignment of their dielectric sectors can be achieved when assembling the stator. For the rotors, since the rotors are driven by a single shaft, they can rotate in phase such that their dielectric sectors remain aligned. The arrangement of the rotors and the stator ensures that the dielectric sectors of the same group have the same projection in the longitudinal direction of the shaft.

[0067] As illustrated, each stator substrate 321 is bilateral and each rotor substrate 341 is bilateral. Take the first set of patterned coatings as an example. This set of patterned coatings on one side of the stator substrate 321 is electrically connected to the first set of patterned coatings on the other side of the stator substrate 321. To do this, as an example, two PCB vias can be placed respectively at the positions where the first terminal 327a and the second terminal 327b will pass through. Blind holes 328a and 328b are used to electrically connect the patterned coatings (such as the copper coating sectors with dielectric sectors provided thereon) on one side of the stator substrate to their nearest patterned inner coatings. Blind hole 348 is used to electrically connect the patterned coatings (such as the copper coating sectors with dielectric sectors provided thereon) on one side of the rotor substrate to their nearest patterned inner coatings. Thus, the coating sectors on each side of the stator are electrically connected to their nearest inner layer through blind holes (illustratively in this embodiment, each sector uses 1 blind hole and each group of sectors uses 3 blind holes), and the coating sectors of the same group are connected together on the inner layer and then connected to the terminals, where the centrally placed via electrically connects the two sides of the stator. In this regard, the rotors are arranged similarly. Note that the via 349 ( Figure 3E ) serves as the common electrical terminal of the rotor, but it is only used during the pretreatment process. The vias shown in the figures are for illustrative purposes. In fact, more vias or fewer vias can be used, and the vias used can be arranged in different ways.

[0068] By way of example, the housing 310 includes a first cover member 312, a second cover member 314, and a shell 316 that form an internal space for accommodating a plurality of generator modules. The first cover member 312, the second cover member 314, and the shell 316 can be assembled using screws and nuts.

[0069] By way of example, each stator can be made of four layers of PCB boards, and each rotor can be made of four layers of PCB boards. In some embodiments, the first cover member, the second cover member, the shell, all stator substrates, and rotor substrates are made of plastic, so that the generator according to one or more embodiments herein is cost-effective, lightweight, and adaptable to a wider range of applications, such as in a corrosive environment (e.g., in the ocean) where a conventional generator may be prone to corrosion or damage.

[0070] Figure 4 Illustrated is a generator and its test setup according to certain embodiments of the present disclosure. As shown, a coupler 402 couples the output shaft of a motor 404 to a generator 400. The generator 400 can be the generator described above according to one or more embodiments. The motor 404 drives one or more rotors of the generator 400 to rotate for power generation. By measuring the output, the performance of the generator 400 can be characterized.

[0071] For illustrative purposes and without loss of generality, Figure 5A Illustrated is a simplified circuit of a generator including four generator modules 52, 54, 56, and 58. There are three stators 520-1, 520-2, and 520-3 and two rotors 540-1 and 540-2. Each of the stators and rotors is bilateral.

[0072] In operation, a first set of dielectric sectors for the three stators is always aligned regardless of the rotation angle of the rotors, and the first set of patterned coatings is electrically connected to a first common terminal T1. A second set of dielectric sectors for the three stators is always aligned regardless of the rotation angle of the rotors, and the second set of patterned coatings is electrically connected to a second common terminal T2. The terminals T1 and T2 are used as output terminals to supply power to a load R. A third set of patterned coatings of the two rotors is electrically connected to a third common terminal T3. A mechanical switch 560 selectively connects the terminal T3 to one of the terminals T1 and T2.

[0073] In this way, the generator modules are serially mounted on a single shaft from a mechanical perspective and are electrically connected in parallel to the output terminals of the generator. The brushes on each rotor and the teeth on the corresponding stator together form a two-way switch that can alternately connect the switch terminals to T1 and T2 during continuous unidirectional rotation.

[0074] Figure 5B Depicted isFigure 5A The charge transfer process of the generator. For the sake of simplicity, only one generator module is used to illustrate this charge transfer process. The charge transfer process is a cyclic process that follows the order of (a) -> (b) -> (c) -> (d) -> (a) ... When the third group of dielectric sectors completely overlaps with the first group of dielectric sectors (see stage (a)), the switch terminal is connected to T2, and the amount of charge on the electrode E3 (note that electrode E3 refers to the third group of patterned coatings) changes from -Q3-Q2 (this is stage (d)) to -Q1-Q3. This is because the surface charge on the first and third groups of dielectric sectors is closer to the surface charge on E3 (in this embodiment, the thickness of the first or second group of dielectric sectors is much greater than the thickness of the third group of dielectric sectors), which triggers a charge (or electron) transfer of Q2-Q1 from T2 (or the switch terminal) to T1, as shown in stage (a).

[0075] Once the rotor leaves the aligned position relative to the stator, the switch is opened. When the third set of dielectric sectors overlaps with both the first and second sets of dielectric sectors (such as shown in stage (b)), E1 (which refers to the first set of patterned coatings) loses electrons in the amount of ΔQ, while E2 (which refers to the second set of patterned coatings) gains the same amount of electrons. That is, electrons in the amount of ΔQ are transferred from T1 to T2, inducing a reverse current. Once the third set of dielectric sectors are aligned with the second set of dielectric sectors, as shown in stage (c), the switch terminal is connected to T1. Similar to stage (a), electrons in the amount of Q2-Q1 are transferred from T1 to T2, generating a charge of -Q3-Q2 on E3, a charge of -Q1 on E1, and a zero charge on E2.

[0076] In the case of continued unidirectional rotation, the third set of dielectric sectors then overlaps both the first and second sets of dielectric sectors again, as shown in stage (d). The charge transfer that occurs between E1 and E2 is similar to that of stage (b). Until this stage, the full cycle is completed. As the rotation continues, it then enters stage (a) again and the cycle starts over.

[0077] Figure 6A , Figure 6B , Figure 6C and Figure 6D The characteristics of a prototype generator obtained by measuring different electrical outputs according to one or more embodiments are shown. Figure 4 The measurements were performed with a setup similar to the setup shown in .

[0078] Figure 6AShows the measured capacitance of two generators in a single rotation at a step of 1.8 degrees. The number of generator modules included is 1 and 2 respectively. These two generators are labeled "1-module" and "2-module" respectively. As clearly shown, there are 6 spikes in each rotation because the switch opens 6 times per rotation. Further, the larger the number of generator modules, the larger the spikes. In addition, compared with the peak capacitance of the 1-module generator, the peak capacitance of the 2-module generator is approximately doubled, indicating a good superposition mechanism for the two modules in the dual-module generator.

[0079] Figure 6B Shows the peak current measured at various load resistances, which also confirms the proposed superposition mechanism, that is, the superposition output of the mechanical series and electrical parallel components of the generator modules. In addition, as the load resistance R increases from 10 0 ohms to 10 8 ohms, the peak current gradually decreases and remains at the same order of magnitude, that is, dozens of μA, indicating that the generator can be regarded as a current source.

[0080] In fact, the generator outputs a current pulse sequence, such as Figure 6C and Figure 6D as shown in the example. Figure 6C Shows the time history of the generator current output in the form of a pulse sequence when the rotational speed is equal to π rad / s, the load resistance is 1 ohm, and the number of generator modules is 2. It can be seen that a pulse is generated whenever the switch opens. Therefore, based on the electret design pattern, there are 6 pulses per rotation. When the number of dielectric sectors is constant, the frequency of the pulses mainly depends on the rotational speed. If the rotational speed of the generator increases, the pulse sequence will become denser, and correspondingly, the output current will become larger. Figure 6D Is Figure 6C an enlarged view of a single pulse in. Considering that each tooth actually has a certain width rather than an ideal line, the small peak 601 is considered to be caused by the continuous contact between the brush and the tooth.

[0081] Figure 7A Shows a demonstration of using the generator 700 to power a thermometer, and Figure 7B shows Figure 7A the equivalent circuit of. The generator 700 can be the generator described above according to one or more embodiments. The demonstration shows the thermometer 702, the capacitor 704, the rectifier 706, and the transformer 708. This demonstration is only an example of how to apply the generator according to one or more embodiments. It should be understood that the generators described herein can be used in a wide range of applications.

[0082] It will be further understood that the various features in the above embodiments of the present disclosure can be combined together and need not be applied in isolation from each other. Those skilled in the art can readily make similar combinations of two or more features from the above embodiments or preferred forms of the present disclosure.

[0083] Unless otherwise defined, the technical and scientific terms used herein have the ordinary meanings as commonly understood by those of ordinary skill in the art to which the exemplary embodiments belong. The embodiments are illustrated in non-limiting examples. Various modifications conceivable by those skilled in the art based on the embodiments disclosed above will fall within the spirit of the exemplary embodiments.

Claims

1. A generator module, comprising: A stator; A rotor that can rotate relative to the stator; And A mechanical switch, Wherein, the stator includes: A stator substrate having a first stator side; A first set of patterned coatings that are conductive and disposed on the first stator side; A second set of patterned coatings that are conductive and disposed on the first stator side, the first set of patterned coatings being electrically isolated from the second set of patterned coatings; A first set of dielectric sectors that are negatively charged and disposed on the first set of patterned coatings; and A second set of dielectric sectors that are positively charged and disposed on the second set of patterned coatings, each positively charged dielectric sector being adjacent to two negatively charged dielectric sectors along a circumferential direction, and each negatively charged dielectric sector being adjacent to two positively charged dielectric sectors along the circumferential direction, Wherein, the rotor includes: A rotor substrate having a first rotor side; A third set of patterned coatings that are conductive and disposed on the first rotor side; and A third set of dielectric sectors that are negatively charged or positively charged and disposed on the third set of patterned coatings, Wherein, the first stator side of the stator substrate faces the first rotor side of the rotor substrate, Wherein, the first set of patterned coatings is electrically connected to a first electrical terminal, the second set of patterned coatings is electrically connected to a second electrical terminal, and the third set of patterned coatings is electrically connected to a third electrical terminal, Wherein, the mechanical switch is configured to allow the third electrical terminal to be selectively connected to one of the first electrical terminal and the second electrical terminal.

2. The generator module according to claim 1, wherein Each patterned coating sector in the first set and the second set of patterned coatings is provided with teeth, thereby forming a plurality of teeth, Wherein, the mechanical switch includes a conductive brush and the plurality of teeth, and the conductive brush is attached to the rotor.

3. The generator module according to claim 2, wherein, The conductive brush includes: A first end mounted on the first rotor side of the rotor substrate and electrically connected to the third electrical terminal; and A second end having a brush head that can be in electrical contact with one of the plurality of teeth to selectively connect to one of the first electrical terminal and the second electrical terminal.

4. The generator module according to claim 1, further comprising a thrust bearing structure disposed on one of the first stator side of the stator substrate and the first rotor side of the rotor substrate.

5. The generator module according to claim 4, wherein The thrust bearing structure includes: A plurality of concave holes formed in one of the first stator side and the first rotor side; and A plurality of bearing balls, wherein each bearing ball is received in a corresponding concave hole.

6. The generator module according to claim 1, wherein, The first set of dielectric sectors and the second set of dielectric sectors have the same thickness.

7. The generator module according to claim 6, wherein, The first set of dielectric sectors and the second set of dielectric sectors have a greater thickness than the third set of dielectric sectors.

8. The generator module according to claim 1, wherein, Both the stator substrate and the rotor substrate are made of plastic.

9. The generator module according to claim 1, wherein, The first set of patterned coatings, the second set of patterned coatings, and the third set of patterned coatings are all patterned metal coatings or include one or more conductive polymer materials.

10. The generator module according to claim 1, wherein, Each of the first set of dielectric sectors, the second set of dielectric sectors, and the third set of dielectric sectors includes one of an electret film and a triboelectric film.

11. A generator for generating electricity, comprising: A housing; And A plurality of generator modules disposed within the housing and sharing a shaft, thereby forming a chain of generator modules along the longitudinal axis of the shaft, Wherein each generator module includes a stator and a rotor mounted to the shaft, wherein the stator includes: A stator substrate having a first stator side; A first set of patterned coatings that are conductive and disposed on the first stator side; A second set of patterned coatings that are conductive and disposed on the first stator side, the first set of patterned coatings being electrically isolated from the second set of patterned coatings; A first set of dielectric sectors that are negatively charged and disposed on the first set of patterned coatings; and A second set of dielectric sectors that are positively charged and disposed on the second set of patterned coatings, each positively charged dielectric sector being adjacent to two negatively charged dielectric sectors along a circumferential direction, and each negatively charged dielectric sector being adjacent to two positively charged dielectric sectors along the circumferential direction, Wherein the rotor includes: A rotor substrate having a first rotor side; A third set of patterned coatings that are conductive and disposed on the first rotor side; and A third set of dielectric sectors that are negatively charged or positively charged and disposed on the third set of patterned coatings, Wherein the first stator side of the stator substrate faces the first rotor side of the rotor substrate, Wherein the first set of patterned coatings is electrically connected to a first electrical terminal, the second set of patterned coatings is electrically connected to a second electrical terminal, and the third set of patterned coatings is electrically connected to a third electrical terminal, The generator further includes a first common terminal, a second common terminal, and a third common terminal, wherein the first electrical terminal of each generator module is connected to the first common terminal, the second electrical terminal of each generator module is connected to the second common terminal, and the third electrical terminal of each generator module is connected to the third common terminal, such that the plurality of generator modules are electrically connected in parallel.

12. The generator according to claim 11, wherein, The shaft includes a first segment, a second segment, and an intermediate segment between the first segment and the second segment, and wherein the intermediate segment has a cross-section in the shape of a rounded square.

13. The generator according to claim 11, wherein, Each generator module includes a mechanical switch that allows the third electrical terminal to be selectively connected to one of the first electrical terminal and the second electrical terminal.

14. The generator according to claim 13, wherein, Each patterned coating sector of the first and second groups of patterned coatings is provided with teeth, thereby forming a plurality of teeth, and wherein the mechanical switch includes a conductive brush and the plurality of teeth, the conductive brush being flexible and attached to the rotor.

15. The generator according to claim 11, wherein, The plurality of generator modules are aligned in terms of the dielectric sectors of the stator and the rotor such that the outputs of the plurality of generator modules are in phase.

16. The generator according to claim 11, wherein, The dielectric sectors of the plurality of generator modules include one of polytetrafluoroethylene (PTFE) film or triboelectric materials.

17. The generator according to claim 11, wherein, The housing includes a first cover member, a second cover member, and a shell that form an internal space for accommodating the plurality of generator modules, wherein the first cover member, the second cover member, the shell, and the stator substrate and the rotor substrate of each generator module are made of plastic.

18. The generator according to claim 11, wherein, Two adjacent generator modules in the generator share a stator substrate or a rotor substrate.

19. The generator according to claim 11, wherein, Each generator module includes a thrust bearing structure disposed on one of the first stator side of the stator substrate and the first rotor side of the rotor substrate, wherein the thrust bearing structure includes: a plurality of concave holes formed on one of the first stator side and the first rotor side; and a plurality of bearing balls, wherein each bearing ball is received in a corresponding concave hole.

20. The generator according to claim 11, wherein, Each stator substrate is symmetrically provided with a double-sided coating and formed with a via hole such that the coatings on both sides are electrically connected, wherein each rotor substrate is symmetrically provided with a double-sided coating and formed with a via hole such that the coatings on both sides are electrically connected.

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