Thermal core and method of use thereof

Abstract

The disclosure describes systems for converting heat energy into work. The systems include at least thermal core which retains and distributes heat, a heat exchanger assembly through which a working fluid flows. Heated air from the thermal core heats the working fluid in an evaporator assembly where the working fluid becomes gaseous. The gaseous working fluid flows to a work-producing component to produce work.

Description

[0001] THERMAL CORE SYSTEM AND METHOD OF USE THEREOF

[0002] BACKGROUND

[0003] Renewable energy forms an ever-increasing fraction of total energy production. However, production of renewable energy using sources such as solar, or wind is limited because there are few cheap and clean ways of storing energy from these sources. For example, many current battery types have a limited lifespan and use expensive materials which are difficult, if not impossible, to recycle. Consequently, there is a need for systems that can store and utilize renewable energy and that are cheap, long-lasting and environmentally friendly.

[0004] SUMMARY

[0005] The disclosure relates to systems or methods for storing and using heat energy to produce mechanical work. The systems include a first component that accumulates, retains, and transfers heat. The systems include a second component that receives heat from the first component. In the second component, a working fluid is flowed through cycles of liquid to gas phase transitions to extract mechanical work from the fluid.

[0006] The systems include at least one thermal core assembly that stores and distributes heat, at least one heat exchanger assembly, at least one evaporator assembly and at least one work-producing component. The heat exchanger assembly flows a working fluid through the system where the working fluid transitions from liquid to gas when heated by heated air from the thermal core assembly. The gaseous working fluid is flowed to a work-producing component where the working fluid expands and drives the rotation of components in the work-producing component to produce work.

[0007] BRIEF DESCIPTION OF THE DRAWINGS

[0008] Figure 1 shows one example of a system according to the disclosure from a first perspective view.

[0009] Figure 2 shows the example of a system of Figure 1 from a second perspective view.

[0010] Figure 3 shows the example of Figure 1 from a third perspective view.

[0011] Figure 4 shows the example of Figure 1 from a fourth perspective view.

[0012] Figure 5 shows the exampie of Figure 1 from a fifth perspective view.

[0013] Figure 6 shows an example of a system of the disclosure where a portion of the thermal core container has been removed to show the container interior.

[0014] Figure 7 shows an example of a system of the disclosure where the top panel of the evaporator assembly has been removed to show the interior of the evaporator assembly.

[0015] Figure 8 shows an example of a system of the disclosure where the evaporator assembly has been shown in an exploded view.

[0016] Figure 9 shows a further example of a system according to the disclosure.

[0017] Figure 10 shows the system of Figure 9 from a second perspective.

[0018] Figure 11 shows a further example of a system according to the disclosure.

[0019] Figure 12 shows a perspective of a scroll expander according to the disclosure.

[0020] Figure 13 is an exploded view of a scroll module shown in a first perspective view.

[0021] Figure 14 is an exploded view of a scroll module of Figure 13 shown in a second perspective view.

[0022] Figure 15 is an exploded view of a scroll module of Figure 14 shown from the side. Figure 16 is an exploded view of scroll expander showing the structure of the scroll module and magnetic module according to the disclosure.

[0023] Figure 18 is a cross-sectional view of an assembled scroll expander,

[0024] DETAILED DESCRIPTION

[0025] It is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0026] The present disclosure relates to systems and methods for converting heat energy into mechanical work. In preferred embodiments, the mechanical work may be used to generate electricity. In preferred embodiments, heat energy is used to extract mechanical work from a working fluid during cycles where the fluid transitions from a liquid state to a gaseous state and back to a liquid state. In preferred embodiments, the systems and methods of the disclosure utilize the principles of the Rankine cycle.

[0027] The systems of the disclosure may use heat energy derived from a variety of sources. That is, heat from numerous sources may be directed or inputted to the systems. For example, waste heat from manufacturing or industrial processes may be inputed into the systems. Further, heat from solar panel arrays be transferred to the systems of the disclosure. For example, the systems may be fited with lenses that concentrate solar radiation to flow to the system. In other embodiments, waste heat from other processes may be directed to system using conduits that flow heat to the system.

[0028] In general, systems of the disclosure include a first component, or heat source, which retains and distributes heat. In preferred embodiments, this first component is a thermal core. The system includes a second component, or heat sink, which is in thermal contact with the first component such that heat energy from the first component is transferred to the second component. In the second component, mechanical work is extracted from a working fluid when the working fluid transitions from liquid to gas. In preferred embodiments, the first component includes a first loop in which a first fluid circulates. For example, air may be circulated through the first loop such that the air undergoes cycles of heating and cooling. In the second component, a working fluid circulates in a second loop such that the working fluid goes through cycles of transitions from a liquid to a gas and back to a liquid. In some embodiments, systems may have more than one first component and more than one second component and more than one first loop and more than one second loop.

[0029] The systems and the associated methods of the disclosure are scalable to particular situations. For example, systems may be sized to accommodate residential, commercial or other requirements. Individual components and assemblies may be added to a system.

[0030] Two or more systems may be connected in a modular format to meet the requirements of a particular situation. In this embodiment, two or more systems may be linked to form a system assembly. A modular format also allows for repair work to be done on one system without interrupting the function of the system assembly. Further a modular format accommodates changing requirements where one or more systems or components may be added or removed.

[0031] According to preferred embodiments, systems of the disclosure include at least one thermal core assembly, at least one heat exchanger assembly, at least one evaporator assembly, and at least one work-producing component. In preferred examples, a working fluid is heated by air from the thermal core assembly and transitions to gas when the working fluid flows through at least one evaporator assembly. The working fluid in gaseous form flows through the at least one workproducing component to generate work. In preferred embodiments, the work-producing component is a scroll expander. In preferred embodiments, the at least one scroll expander is included in a scroll expander assembly.

[0032] Systems of the disclosure may have further components and assemblies. For example, systems may have one or more condensers. In preferred embodiments, the one or more condensers are fluidly linked to the heat exchanger assembly such that the working fluid flows through the one or more condensers. For example, the working fluid flows through the one or condensers after flowing through the scroll expander assembly. The working fluid transitions from a gas back to a liquid in the condenser.

[0033] Systems of the disclosure may have one or more pumps. The one or more pumps are fluidly linked to the heat exchanger assembly such that the working fluid flows through the one or more pumps. The pumps maintain the flow of working fluid through the system and scavenge the working fluid. In preferred embodiments, the pumps may have a combination of high-pressure and low-pressure pumps. The pumps may include one or more magnetic pumps.

[0034] Systems of the disclosure may include one or more fans positioned on the system where the fans facilitate the flow of air through the system. Systems of the disclosure may include one or more sensors positioned on the system. For example, the one or more sensors may be positioned at one or more points that measure the temperature of the air circulating in the system. Other sensors may measure the output of the system. A controller may be present where the controller collects data about the system from sensors, displays the data to a user, and the user may use the controller to alter the operation of the system.

[0035] Systems of the disclosure include a support assembly. For example, the different assemblies and components of the system may be fixed onto the support assembly such that the components of the system are linked or connected in an optimal and compact manner .

[0036] According to the disclosure, a thermal core assembly includes at least one thermal core. According to the disclosure, a thermal core includes a container. A thermal core container includes at least one sidewall, a top wall, and a bottom wall. The sidewalls, the bottom wall, and top wall define or enclose an interior space or volume of the thermal core container. Each of the at least one sidewall, the top wall, and the bottom wall have an external surface and an internal surface where the external surface faces outwardly and the internal surface faces the interior volume or space.

[0037] Thermal core containers may assume a variety of shapes. In preferred embodiments, the container is cylindrical. That is, the thermal core may be drum or barrel shaped. For example, the thermal core may be an oil drum.

[0038] According to the disclosure, a thermal core assembly may have one thermal core, may have two thermal cores, may have three thermal cores, may have four thermal cores, may have five thermal cores, may have six thermal cores, or may have more than six thermal cores. In some embodiments, the system is modular with respect to thermal cores. That is, thermal cores may be added to the system to obtain increased input of heat energy and increased output of mechanical work, as required.

[0039] In preferred embodiments, thermal cores in a thermal core assembly are arranged in rows where each row has two thermal cores, i.e. first and second thermal cores. In preferred embodiments, the dimensions and properties of the thermal cores in the same row are identical. The addition of further rows of thermal cores is done in a modular format, as a particular situation requires. In preferred embodiments, the flow of air between the first thermal cores of each row occurs independently and separately from the flow of air between the second thermal cores of each row.

[0040] In preferred embodiments, the interior space of each thermal core container is filled or partially filled with one or more types of thermal core media. In general, the thermal core media has good thermal conductivity properties and good specific heat properties. In general, the thermal core media absorbs and radiates heat. In preferred embodiments, the thermal core media is formed from constituent parts that pack together to form the thermal core media. The constituent parts may have the same size, may have the same composition, may have a different composition from each other, or may be differently sized.

[0041] In preferred embodiments, the thermal core media fills or partially fills the interior space of the container such that there are gaps or spaces between the constituent parts of the thermal core media. That is, the constituent parts contact or interface with each other such that gaps or spaces are formed between the constituent parts. In preferred embodiments, the constituent parts of the thermal core media retain and emit heat energy. The emitted energy heats air flowing through the gaps between the constituent parts of the thermal core media.

[0042] For example, the constituent parts of thermal core media may be in the shape of spheres, where the packing of the spheres in the container internal space creates gaps between spheres, allowing for the flow of heated air through the gaps between constituent parts. In some embodiments, the spheres may be of a uniform size that is, each sphere has the same volume. In other embodiments, the spheres may have a heterogeneous size.

[0043] In preferred embodiments, the constituent parts of the thermal core media are formed from a material that has good specific heat properties and good thermal conductivity properties. In preferred embodiments, the constituent parts of the thermal core media are formed from steel. For example, the constituent parts may be solid steel spheres. That is, the thermal core media is composed of steel “shot". In preferred embodiments, the spherical steel shot has diameters from about one sixteenth of an inch to about three eighths of an inch about 1.5 mm to 9.5 mm. In other embodiments, the thermal core media may be composed of lead shot. In preferred embodiments, the shot is of uniform size.

[0044] The thermal core may include one or more conduits. In general, the one or more conduits have one or more walls, where each wall has an external surface and an internal surface. The one or more conduit walls define or enclose an interior space where the internal surface faces the conduit interior space. For example, the one or more conduits may be hollow cylinders made from steel or aluminum.

[0045] The one or more thermal core conduits are fluidly linked with the interior space of the thermal core container. That is, the conduits flow fluid, such as air, to and from the interior space of the thermal core container. One or more conduits may extend from an external surface of a wall of the thermal core container to a point external to the container. Other thermal core conduits may extend from the interior space of the thermal core container to a point external to the container. The thermal core conduits may be physically and fluidly connected to other conduits or components in the system. That is, the thermal core conduits form part of a loop or loops that circulates air from the thermal core interior space to an evaporator assembly and back to the thermal core interior space. In preferred embodiments, the one or more thermal core conduits do not contain thermal core media within the conduit interior space.

[0046] According to the disclosure, systems have one or more heat exchanger assemblies. The one or more heat exchanger assemblies are part of a closed system or closed assemblies through which a working fluid flows. The one or more heat exchanger assemblies include lengths of pipes connected together. The pipes include at least one wall where the at least one wall has an external surface and internal surface. The at least one wall defines an interior space, where the internal surface faces inwardly towards the interior space. For example, the lengths of pipe may be hollow cylinders connected together where a working fluid flows through the interior volume or space of the pipe. In preferred examples, the heat exchanger assembly is made using copper pipes.

[0047] The working fluid may be selected from the group consisting of wate r, carbon dioxide, R123, R245, R234fa, ammonia and ethanol and combinations thereof. In preferred embodiments, R234fa is the working fluid. For example, R234fa performs better than other fluids in system efficiency testing.

[0048] The heat exchanger assembly may be physically and fluidly linked to other assemblies and components of the system such that the working fluid flows through these other assemblies and components. For example, the one or more heat exchanger assemblies may be fluidly and physically linked to one or more evaporators. The heat exchanger assembly may be fluidly and physically linked to one or more scroll expander assemblies. The heat exchanger assembly may be fluidly and physically linked to one or condensers. The heat exchanger assembly may be fluidly and physically linked to one or more pumps,

[0049] Systems of the disclosure may include one or more evaporator assemblies. In general, a working fluid transitions from a liquid to a gas in the evaporator assembly. In the evaporator assembly, heated air from the thermal core comes into thermal contact with the working fluid, thereby raising the temperature of the working fluid, facilitating the transition of the working fluid to a gas.

[0050] According to the disclosure, the evaporator assembly includes at least one evaporator, may include at least two evaporators, may include at least three evaporators, may include at least four evaporators or may include more than four evaporators. In preferred embodiments, the evaporators are plate type evaporators. The at least one evaporator is fluidly and physically linked to at least one heat exchanger assembly where the working fluid flows into the evaporator from the heat exchanger assembly to facilitate the transition of the working fluid from liquid to gas.

[0051] In preferred examples, more than one evaporator may be connected in series. For example, two evaporators may be connected in series with respect to the flow of the working fluid so that working fluid flows into a first evaporator, then into a second evaporator. This arrangement improves the efficiency of the working fluid transition from liquid to gas.

[0052] The evaporator assembly may include an enclosure. The evaporator assembly enclosure may be composed of one or more panels which are assembled to form the enclosure. For example, the enclosure may have a top panel, a bottom panel and side panels. The panels may be flat sheets of metal joined together or configured such that the assembled panels define an enclosed interior space or volume. Each panel has an external surface and an internal surface where the internal surfaces face inwardly towards the enclosure interior volume. The enclosure may have one or more interior panels that divide the enclosure interior space into further interior subspaces or compartments. The evaporator enclosure may include one or more openings in one or more panels. The openings in the enclosure engage with conduits that flow air to or from the thermal cores.

[0053] The one or more evaporators are positioned within the evaporator enclosure. In preferred embodiments, the one or more evaporators are positioned on the internal surface of a bottom panel of the evaporator assembly enclosure. For example, the one or more evaporators may be positioned over one or more openings on the bottom panel that engage with thermal core conduits. The evaporator assembly enclosure is fluidly linked to the one or more thermal cores such that heated air flows into the evaporator assembly enclosure from the thermal core. For example, a conduit may fluidly link a thermal core and an evaporator assembly where heated air flows through the conduit from the thermal core to the evaporator assembly through one or more openings. Other conduits flow air from the evaporator assembly to the thermal core. In preferred embodiments, the heated air from one or more thermal cores circulates within the enclosure interior space to heat the evaporators.

[0054] According to the disclosure, systems of the disclosure include at least one workproducing component. In preferred embodiments, the at least one work producing component is a scroll expander. In preferred embodiments, one or more scroll expanders are included in a scroll expander assembly. According to the disclosure, working fluid in a gaseous form flows from the one or more evaporators to the one or more scroll expanders, the gaseous working fluid expands in the scroll expander, thereby driving the rotation of components in the scroll expander. In other embodiments, the at least one work-producing component may be a turbine.

[0055] According to the disclosure, the systems may include one or more condensers. Working fluid flows from the scroll expander assembly, through the heat exchanger assembly to the condenser. In the condenser, the working fluid is cooled such that the working fluid transitions from a gas to a liquid in the condenser.

[0056] According to the disclosure, the cooling and transitioning working fluid flows to the heat exchanger assembly then to one or more pumps, where the one or pumps scavenges and accumulates the working fluid in preparation for the next cycle. Example 1 examp Fleigures 1-5 shows different perspective views of an example of a system 100 according to the disclosure. In this example, the efficiency of the system is about 18%, as calculated standard equations for calculating the efficiency of a system utilizing the Rankine cycle.

[0057] In this example, the system includes a thermal core assembly 110, an evaporator assembly 140, heat exchanger assembly 130 and a scroll expander assembly 150. The system also includes other components including a condenser, sensors, a controller, and one or more magnetic pumps. The system also includes a support assembly 170.

[0058] In this example, two thermal cores 101 , 102 are shown as part of the thermal core assembly. In this example, each thermal core container 104,106 is cylindrical. Each container has a sidewall 108, a top wall 110 and a bottom wall 111 , where the sidewall, the top wall and the bottom wall define an interior volume or space of the thermal core container. Each of the sidewall, bottom wall and top wall have an external surface and internal surface where the internal surfaces of each wall face the interior volume of the thermal core container. In this example, thermal cores 101, 102 are identical on size and shape. In preferred embodiments, thermal cores are arranged in rows, where each row has two thermal cores. In this example, the system has single row of two thermal cores, including a first thermal core and a second thermal core.

[0059] In this example, each thermal core container is physically and fluidly linked to conduits such that air flows from each thermal core through a conduit or air fiows to the thermal core through a conduit. In this example, the conduits are one or more hollow cylinders.

[0060] In this example, a first conduit 121 of the thermal core assembly is positioned over an opening (not shown in Figures 1-5) in the top wall of each thermal core container and the first conduit extends vertically from the external surface of the top wall of the thermal core container, such that heated air from the thermal core flows upward through the first conduit. In this example, the first conduit has fan 122 positioned over an opening of the wall of the first conduit such that the fan facilitates the flow of heated air from the thermal core through the first conduit. In this example, the heated air flows to the evaporator assembly 140.

[0061] In this example, each thermal core includes a second conduit 123 where air flows through the second conduit back to a thermal core. In this example, each second conduit extends from the evaporator assembly 140 downwardly through an opening in the top wall of the thermal core container and extending into the thermal core container interior volume. In this example, the second conduit extends downwardly through almost the entire height of the thermal core container interior volume. In this example, the second conduit does not contain thermal core media.

[0062] Figure 6 shows a system where a portion of the thermal core 101 has been cut away to show the interior volume of the thermal core container. In this example, the interior volume filled with thermal core media 124 is shown. In this example, the thermal core media is steel shot. That is, the constituent parts of the thermal core media are steel shot. The packing of the spherical steel shot creates gaps between the shot allowing the flow of air through the interior space of the thermal core container. In this example, the interior space is completely filled with steel shot. Figure 6 also shows the extension if second conduit 123 into the thermal core container interior space.

[0063] In this example, the system includes a heat exchanger assembly 130. For example, the heat exchanger assembly may be one or more pipes physically and fluidly linked where a working fluid flows through the one or more pipes. The heat exchanger assembly is fluidly and physically connected to other assemblies and components of the system, including evaporators, work producing components, condensers and pumps.

[0064] In this example, the system includes an evaporator assembly 140. Figure 7 shows the system where the top panel has been removed to show the interior of the evaporator assembly. Figure 8 shows the evaporator assembly in an exploded view. In this example, the evaporator assembly is positioned immediately above the thermal core container assembly on posts 174 of the support assembly 170. In this example, the evaporator assembly includes two plate evaporators 131 ,132. The plate evaporators are fluidly and physically linked with the heat exchanger assembly such that the working fluid flows through the plate evaporators from the heat exchanger assembly. In this example, working fluid flows from the heat exchanger assembly to plate evaporator 131 at port 130A. In this example the two plate evaporators are fluidly linked in series such that the working fluid flows into first plate evaporator 131 and then into a second plate evaporator 132. Working fluid flows back to the heat exchanger assembly 130 at port 1308. The plate evaporators are contained within an evaporator assembly enclosure

[0065] 133. The evaporator assembly enclosure includes panels 134,135,136,137,138,139,143 which are joined to form the enclosure. Top enclosure panel 143 is shown in Figures 1-4.

[0066] The joined panels define an enciosure interior space. Each panel has an external and internal surface where the internal surface faces the enclosure internal space. In this example, the enciosure also includes internal panels 140 a, 140b positioned to separate the enclosure interior space into two equally sized compartments 141 , 142. Plate evaporator 131 is positioned in compartment 141 and plate evaporator 132 in compartment 142. Pipe 146 fluidly connects the evaporators in series. Pipe 146 passes through internal panel 140a.

[0067] In this example, each of bottom panels 134,135 includes openings 144,145.

[0068] First conduits 121 of each thermal core engage with the respective openings 144 such that heated air flows from the thermal core, through the first conduits, then through openings 144 to the enclosure interior space. The heated air circulates within the enclosure interior space to heat the plate evaporators, thereby heating the working fluid and effecting its transition from liquid to gas. In this example, heated air from one thermal core circulates in one compartment and heated air from a second thermal core circulates in a second compartment. The circulating air in each compartment flows back to the through openings 145 to second conduits 122 to corresponding thermal cores.

[0069] In this example, working fluid in a gaseous state flows from the evaporator assembly, flows through the heat exchanger assembly 130 to a scroll expander assembly 160. That is, the scroll expander assembly is fluidly linked to the heat exchanger assembly. In this example, the scroll expander assembly includes four scroll expanders 165 connected in parallel such that the working fluid flows through each scroll expander simultaneously.

[0070] The expansion of the working fluid gas in the scroll expander drives the rotation of components in each scroll expander. In this example, each scroll expander includes a scroll section 152, a magnetic coupling section 153 and a generator 154. Each scroll expander includes sensor 156 for measuring working fluid pressure.

[0071] In this example, working fluid flows from the scroll expander assembly to condenser 147. That is, the condenser is fluidly linked to the heat exchanger assembly. The flow of working fluid through the condenser facilitates the transition of the working fluid from a gas back to a liquid. Condenser 147 includes fans 148.

[0072] In this example, the working fluid flows from the condenser, through the heat exchanger assembly to a low pressure pump, such as low pressure magnetic pump 149. In this example, the working fluid flows to high pressure magnetic pump 151 from the low pressure magnetic pump. The pumps act to scavenge the working fluid such that the working fluid is efficiently collected and prepared to repeat a cycle through the system.

[0073] Controller 157 is part of the system of this disclosure. A controller may be present where the controller collects data about the system from sensors, displays the data to a user, and the user may use the controller to alter the operation of the system. The system of this example includes support assembly 170. The support assembly is designed to position the assemblies and components of the system to optimize the operation of the system, to allow easy maintenance, and configure a compact system to allow easy transport. The support assembly in this example includes platforms and posts that support the platforms. In this example, the support assembly is formed from a metal, such as steel. For example, the system is supported on a first platform 171. In this example, the first platform resembles a pallet, designed to permit transport of the system using a forklift.

[0074] Second platform 172 supports the scroll expander assembly adjacent to the evaporator assembly at approximately the same height as the evaporator assembly. Third platform 173 supports the magnetic pumps at position below the condenser position. Condenser 147 and controller 157 are mounted on posts of the support assembly.

[0075] Example 2

[0076] In this example, a system having six thermal cores is shown in Figures 9 and 10. That is, the system shown in Figure 9 and 10 has three rows of thermal cores, each row having two cores, first row has first thermal core 201 and second thermal core 202, second row has first thermal core 236 and second thermal core 237 and third row has first thermal core 238, and second thermal core 239.

[0077] Second and third rows are each placed on separate pallet platforms 271 ,273 such that the addition of rows of thermal cores is modular.

[0078] Figures 9 and 10 show the configuration of conduits to permit the flow of air to and from evaporator assembly 240 and between thermal cores. The evaporator assembly interior volume is divided into two compartments as previously described. First conduits 231a, 231 b flow heated air from thermal cores 201 and 202 respectively to respective compartments of the evaporator assembly as previously described. Second conduits 232a, 232b respectively flow air from the compartments of the evaporator assembly to thermal cores 238 and 239. Second conduits 232a, 232b include fans 241 positioned on the conduits to facilitate the flow of air from the evaporator assembly.

[0079] Third conduits 235a, 235b flow air from respectively thermal cores 238,239 to the second row of thermal cores 236,237. Fourth conduits 234a,234b flow air back to thermal cores 201 and 202 respectively. In this configuration, the flow of air through first thermal cores 201,236,238 is separate from the flow of air through the second cores of each row 202,237,239.

[0080] Example 3

[0081] In this example, a system having four thermal cores is shown in Figure 10. That is, the system shown in Figure 11 has two rows of thermal cores, each row having two cores, first row has first thermal core 301 and second thermal core 303, second row has first thermal core 336 and second thermal core 337.

[0082] Figure 10 show the configuration of conduits to permit the flow of air to and from evaporator assembly 340 and between thermal cores. The evaporator assembly interior volume is divided into two compartments as previously described. First conduits 331a, 331b flow heated air from thermal cores 301 and 302 respectively to respective compartments of the evaporator assembly as previously described. Second conduits 332a, 332b respectively flow air from the compartments of the evaporator assembly to thermal cores 338 and 339. Second conduits 332a, 332b include fans 341 positioned on the conduits to facilitate the flow of air from the evaporator assembly.

[0083] Third conduits 335a, 335b flow air from respectively thermal cores 338,339 to the first rows of thermal cores 201 ,202. In this configuration, the flow of air through first thermal cores 201 ,238 is separate from the flow of air through the second cores of each row 202,239.

[0084] Example 4

[0085] According to the disclosure, an example of a scroll expander 600 is provided as shown in Figures 12 to 18. This example of a scroll expander may be employed in the scroll expander assembly of the disclosure.

[0086] As shown in Figure 12, scroll expander 600 includes a scroll module 630, a magnetic drive module 640, and a generator module 650. In this example, the scroll module is located at a first end of the scroll expander, and the generator module located at a second end of the scroll expander, with the magnetic drive module located between these two modules. The scroll expander is mounted on plate 700 and includes sensor 730 mounted on generator.

[0087] In this example, gaseous working fluid from the system flows into the scroll expander 600 through port 631 located at the first end of the scroll expander. The working fluid expansion drives the rotation of components within scroll module 630 which in cause the rotation of a first magnetic component within the magnetic drive module. In turn, the rotation of the first magnetic component drives the rotation of a second magnetic component within the magnetic drive module. The second magnetic component is placed externally to the first magnetic component and is not in direct physical contact with the first magnetic component. Instead, the magnetic fields of first and second magnetic components interact.

[0088] The second magnetic component engages with generator 650, to cause rotation of the generator shaft. The positioning of the first and second magnetic components permits a scroll expander design that eliminates the possibility of working fluid leaking into the generator, thereby reducing the chance of failure of the system. For example, in this example, there is no drive shaft that extends from the scroll module to the generator module. That is, the scroll module and magnetic module are fluidly isolated from the generator.

[0089] Figures 13-15 show more detailed views of a scroll module. The scroll module includes stationary scroll 601, drive scroll 603, rotating cranks 657, and drive crank 667. In preferred embodiments, stationary scroll and drive scroll are largely composed of aluminum and the rotating and drive crank are largely composed of steel.

[0090] In an assembled scroll module, the stationary and drive scrolls are configured to form a scroll module chamber 709, into which the working fluid flows. The volume of the scroll module chamber is determined by the size and shape of elements attached to the drive and stationary scrolls and the shape of the scrolls themselves. In this example, stationary scroll includes a stationary scroll plate 680 having first or inner surface 622, and second or outer surface 620. In this example, the stationary scroll plate is approximately triangular. In other examples, the stationary scroll plate may assume other shapes. The stationary scroll plate is fixed to the scroll housing 635 (Figure 16).

[0091] Stationary scroll fixed elements 614, 616, 663 are fixed on the inner surface 622 of the stationary scroll. Each fixed element is approximately cylindrical and projects away from the inner surface of the stationary scroll towards the inner surface 627 of the drive scroll 603. One stationary scroll fixed element is obscured in the view of Figure 13. Each stationary scroll fixed element has an opening 618 where the opening extends through the width of the fixed element and through the stationary scroll plate. In this example, fixed elements 614, 616, 663 each having openings 618 are placed equidistant apart in an approximately triangular pattern on the inner surface of the stationary scroll . Stationary scroll 601 also includes a scroll structure 697 affixed to the inner surface of the stationary scroll plate. The scroll structure projects towards from the inner surface of the stationary scroll plate towards the inner surface of the drive scroll.

[0092] Drive scroll 603 includes plate 682 having a first or inner surface 627 and second or outer surface 629 where the inner surface 627 faces the inner surface 622 of the stationary scroll. In this example, the drive scroll p l ate is approximately triangular.

[0093] Drive scroll 603 includes three drive scroll openings 668 which extend through the width of the drive scroll plate, from inner surface to outer surface. Drive scroll openings 668 align with stationary scroll openings 618 when the scroll module is assembled. Drive scrolls 601 also includes a scroll structure 701 a nd affixed to the inner surface of the drive scroll and projecting away from inner surface of the drive scroll towards the inner surface of the stationary scroll.

[0094] During operation and rotation of the drive scroll, stationary scroll structure 697 and drive scroll structure 701 mesh. Drive scroll 603 also includes a center opening 711 on the outer surface of the drive plate.

[0095] In this example, scroll module includes three rotating cranks 657, one for each of the aligned openings 618, 668 on the stationary scroll and drive scroll respectively. Each rotating crank includes two arms 693 (for example, Figure 15), each arm having a first distal end and a second proximal end. The arms are positioned such that the proximal ends are adjacent to each other. A rotating element 659 is located at the point where the two proximal ends of the arms meet such that the proximal ends of the arms contact and are fixed to the rotating element. In this example, the arms of the rotating crank are approximately the same length.

[0096] In an assembled scroll module, one arm of each rotating crank is inserted in an opening 618 on the stationary scroll and the other arm of the rotating crank is inserted into the aligned opening 668 of the drive scroll. In the assembled scroll module, the rotating element 659 of each rotating crank is positioned at the surface of the opening 668 of the drive scroll. The expanding working fluid drives the rotation of the drive scroll through the rotation of the rotating element of the rotating crank. Crank bearings 703 are placed in openings 618 and 668 and hold rotating cranks 657 in place when the rotating cranks are placed in the stationary and drive scrolls.

[0097] Drive crank 667 has a top cylindrical portion 679 and bottom portion 685, in the shape of a sector of a circle. Drive crank has inner 705 and outer 707 surfaces. Balance weight 671 is attached to the inner surface of the drive crank.

[0098] Drive crank includes shaft 677 placed on and projecting away from the inner surface 705 of the drive crank. Drive crank shaft 677 is positioned on the cylindrical portion of the drive crank. D u ri ng operation, shaft 677 engages with center opening 711 and center bearings 708 on the outer surface 629 of the drive scroll.

[0099] In this example, working fluid flows into the scroll module chamber 709 through port 631. The expansion of the working fluid within the scroll module chamber drives the rotation of the drive scroll 603, through rotation of the rotating elements 659 of the rotating cranks. The drive scroll is engaged with the drive crank through the engagement of drive crank shaft 677 with the center opening 711 on the outer surface of the drive scroll, thereby causing rotation of the drive crank.

[0100] Figures 16 and 17 show further features of the scroll expander of this example. As it cools and expands, the working fluid flows outwardly from the \ through the channels and chambers of the scroll expander chamber, ultimately flowing through port 687 out of the scroll expander to the condenser. Scroll housing 635 encloses the components of the scroll module. Sealing flange 637 includes a flat circular portion 649 that seals one end of the scroll module, adjacent to the magnetic drive module.

[0101] Sealing flange 637 also includes a cylindrical wail portion 641 , the wall having inner 717 and outer 719 surfaces and the cylindrical wall portion having an orifice 643 therethrough. A first magnetic component 632 or male magnetic component is placed within th© orifice 643. In this example, first magnetic component 632 includes a first magnet shaft 633 that engages with orifice 711 on outer surface of drive crank 667. Through the engagement of first magnetic shaft 633 in orifice 711 , the rotation of drive scrolls 603 and drive crank 667 results in rotation of the first magnetic component.

[0102] A second magnetic component 644 or female magnetic component is placed externally to the first magnetic component 632. That is, the second magnetic component is placed on the outer surface 719 of the cylindrical wall of the sealing flange 637, such that the second magnetic component encompasses the first magnetic component, with the intervening cylindrical wall 641 of the sealing flange placed between the first and second magnetic components. A drive coupler 720 is present where the drive coupler encloses and shields the first and second magnet components. Flange 713 is placed between the drive coupler 720 and generator 650. In preferred embodiments, sealing flange 637 and drive coupler 720 are made of plastic. The use of plastic for these components reduces undesirable magnetic currents in the magnetic drive module.

[0103] The rotation of the first magnetic component 632 induces rotation of the second magnetic component 644. The second magnetic component engages with generator driveshaft 653 such that the second rotating magnetic component rotates the driveshaft of the generator. The second magnetic component is isolated from and not exposed to the working fluid. Consequently, working fluid does not leak from the scroll module to the generator.

[0104] In one preferred example, the scroll expander weighs about 55 pounds and has total length of about 18 inches and a maximum height at the scroll module end of about 9 inches.

[0105] The disclosure has been described in an illustrative manner, and it is to be understood that the terminology, which has been used herein, is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings and the disclosure can be practiced otherwise than as specifically described.

Claims

Claims1. A system for generating electricity from heat, comprising: at least one thermal core assembly, comprising: at least one thermal core; said thermal core comprising at least one container; said at least one container comprising at least one sidewall, a top wall, and a bottom wall- each of said at least one sidewall, a top wall, and a bottom wall having an internal surface and an external surface; said sidewall top wall and botom walls enclosing an interior container volume; said container interior volume comprising one or types of thermal core media; at least one heat exchanger assembly said at least one heat exchanger assembly comprising; at least one heat exchanger, comprising a sidewall; said at least one sidewall enclosing a volume; said volume comprising a heat exchanger media; an evaporator assembly,said evaporator assembly comprising at least one evaporator; said evaporator fluidly connected to said heat exchanger assembly; and at least one scroll expander assembly said scroll expander assembly comprising at least one scroll expander; said at least one scroll expander assembly fluidly connected to said at least one heat exchanger.

2. The system of claim 1 wherein said thermal core media comprises solid spheres.

3. The system of claim 1 wherein said thermal core media comprises metallic spheres.

4. The system of claim 2 wherein said thermal core media comprises steel shot.

5. The system of claim 1 wherein said at least one container is cylindrical.

6. The system of claim 5, said thermal core assembly comprising at least two thermal cores, said at least two thermal cores arranged in rows of two thermal cores per row.

7. The system of claim 1 wherein said thermal core comprises conduits, said conduits having at least one conduit sidewall, said at least one conduit sidewall having an external surface and having an internal surface, said conduit sidewall enclosing a volume;said conduit extending through said top wall of said container into said container volume;8. The system of claim 1 said scroli expander assembly comprising four scroll expanders connected in parallel.

9. The system of claim 8, wherein each of said scroll expanders comprises a scroll module, a magnetic module and a generator.

10. The system of claim 9 , wherein each of said scroll modules comprises a stationary scroll, a drive scroll and a drive crank.11 .The system of claim 8, wherein each of said magnetic modules includes a first magnetic component and a second magnetic component, wherein said second magnetic component is external to and surrounds the first magnetic component.

12. The system of claim 8, wherein said scroll module and said magnetic module are fluidly isolated from said generator.

13. The system of claim 1 , further comprising at least one magnetic pump.

14. The system of claim 1 further comprising at least one condenser.15.The system of claim 1 , further comprising at least one controller.

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