Electricity generator

• US 9,927,836 B2
• Filed: 03/07/2013
• Issued: 03/27/2018
• Est. Priority Date: 09/25/2012
• Status: Active Grant

• Current Assignee: James Clark, Unruly, LLC
• Original Assignee: Unruly, LLC
• Inventors: Clark, Jim, McRobert, Gary A., Laibowitz, Mathew
• Primary Examiner(s): Pelton, Nathaniel
• Assistant Examiner(s): TORRES RUIZ, JOHALI ALEJANDRA
• Application Number:
  US14/419,462
• Publication Number:
  US 20150185771A1
• Time in Patent Office: 1,846 Days
• Field of Search: 320137
• CPC Class Codes: F03G 5/06 other than of endless-walk type
• CPC Class Codes: G06F 1/1626 with a single-body enclosure integrating a flat display, e.g. Personal Digital Assistants [PDAs]
• CPC Class Codes: G06F 1/1628 Carrying enclosures containing additional elements, e.g. case for a laptop and a printer
• CPC Class Codes: G06F 1/1635 Details related to the integration of battery packs and other power supplies such as fuel cells or integrated AC adapter
• CPC Class Codes: H02J 7/0044 specially adapted for holding portable devices containing batteries H02J7/0045 takes precedence
• CPC Class Codes: H02K 7/116 with gears
• CPC Class Codes: H02K 7/1861 driven by animals or vehicles H02K7/1853 takes precedence

Abstract

The present application concerns handheld electrical generators for charging mobile electronic devices. In one representative embodiment, a manually powered generator for charging a mobile device comprises a first magnet array having a plurality of magnets arrayed in an annular formation on a first surface, a second magnet array having a plurality of magnets arrayed in an annular formation on a second surface positioned opposite the first surface, and a torque input member. The generator further comprises a rotor having a serpentine trace of conductive material disposed between the first and second magnet arrays. The generator is configured to be incorporated into a handheld case or shell for containing the mobile device.

Claims

1. A manually powered generator for charging a mobile device, comprising:

a first magnet array, the first magnet array comprising a plurality of magnets arrayed in an annular formation on a first surface;

a second magnet array, the second magnet array comprising a plurality of magnets arrayed in an annular formation on a second surface positioned opposite the first surface;

a torque input member; and

a rotor disposed between the first and second magnet arrays, the rotor comprising a printed circuit board including a plurality of planar layers, each of the plurality of planar layers comprising a serpentine trace of conductive material extending radially inwardly and outwardly in a continuous manner between a respective inner perimeter and a respective outer perimeter in a serpentine shape so as to form a series of interconnected peaks and valleys around a circumference of the respective planar layer, the respective inner perimeters of each serpentine trace being spaced radially outwardly from a central opening defined in the rotor, the serpentine traces of material being interconnected between the planar layers by one or more vias to form a single conductive pathway, the one or more vias being located adjacent the inner perimeters of the respective serpentine traces, the plurality of planar layers including a top layer and a bottom layer, the top and bottom layers including respective terminals surrounding the central opening and electrically connected to the serpentine traces of the top and bottom layers;

wherein the generator is configured to be incorporated into a handheld case that can be coupled to the mobile device.

2. The generator of claim 1, wherein the rotor is configured to be rotatably driven by the torque input member.

3. The generator of claim 1, wherein rotation of the rotor causes electrical current to be generated in the conductive material.

4. The generator of claim 1, wherein the magnets of the first and second magnet arrays are arranged in alternating polarity.

5. The generator of claim 1, wherein the magnets of the first and second magnet arrays are rare-earth magnets.

6. The generator of claim 1, wherein the first and second surfaces are electrically and magnetically conductive.

7. The generator of claim 1, wherein the axis of rotation of the rotor is substantially perpendicular to a major surface of the mobile device.

8. The generator of claim 1, further comprising a mechanical assembly configured to interconnect the torque input member and the rotor, the mechanical assembly being configured to step up the revolutions per minute of the torque input member such that the rotor rotates at a higher frequency than the torque input member.

9. The generator of claim 8, wherein the mechanical assembly comprises a gear assembly.

10. The generator of claim 8, wherein the ratio of the rotational frequency of the rotor to the rotational frequency of the torque input member is from about 15:

1 to about 24;

1.

11. The generator of claim 1, wherein the electrical current output of the generator is from about 200 milliamps to about 1000 milliamps.

12. The generator of claim 1, wherein the voltage output of the generator is from about three volts to about seven volts.

13. The generator of claim 1, wherein the generator comprises circuit elements configured to convert an alternating current input from the generator having variable voltage peaks to a direct current output of substantially constant voltage.

14. The generator of claim 1, wherein the thickness of the first magnet array, the rotor, and the second magnet array is from about 0.1 inch to about 0.5 inch.

15. The generator of claim 14, wherein the thickness of the first magnet array, the rotor, and the second magnet array is about 0.1 inch.

16. The generator of claim 1, wherein the thickness of the magnets of the first and second magnet arrays is from about 0.02 inch to about 0.1 inch.

17. The generator of claim 1, wherein the rotor rotates about one or more conductive axles, and the electricity generated in the rotor is conducted away from the rotor to the mobile device through the conductive axles.

18. The generator of claim 1, wherein the electricity generated in the rotor is conducted away from the rotor to the mobile device by one or more brushes.

19. The generator of claim 1, wherein the generator has an overall thickness less than one centimeter and is configured to output at least five volts of continuous electrical output via manual torque input from the torque input member.

20. A case for a handheld mobile electronic device, comprising:

an electrical generator that is manually powered and configured to transfer electrical power to the mobile electronic device, the electrical generator comprising;

a first magnet array, the first magnet array comprising a plurality of magnets arrayed in an annular formation on a first surface;

a second magnet array, the second magnet array comprising a plurality of magnets arrayed in an annular formation on a second surface positioned opposite the first surface;

a torque input member; and

a rotor disposed between the first and second magnet arrays, the rotor comprising a printed circuit board including a plurality of planar layers, each of the plurality of planar layers comprising a serpentine trace of conductive material extending radially inwardly and outwardly in a continuous manner between a respective inner perimeter and a respective outer perimeter in a serpentine shape so as to form a series of interconnected peaks and valleys around a circumference of the respective planar layer, the respective inner perimeters of each serpentine trace being spaced radially outwardly from a central opening defined in the rotor, the serpentine traces of material being interconnected between the planar layers by one or more vias to form a single conductive pathway, the one or more vias being located adjacent the inner perimeters of the respective serpentine traces, the plurality of planar layers including a top layer and a bottom layer, the top and bottom layers including respective terminals surrounding the central opening and electrically connected to the serpentine traces of the top and bottom layers; and

wherein the electrical generator is incorporated into the case such that the thickness of the case is substantially less than or equal to the thickness of the mobile electronic device.

21. The case of claim 20, wherein the case further comprises a battery, the battery being in communication with the electrical generator and the mobile electronic device.

22. The case of claim 21, wherein the generator is configured to provide electrical power to the battery, and the battery is configured to provide electrical power to the mobile electronic device.

23. The case of claim 20, wherein the case is configured to be releasably installed around the mobile electronic device.

24. The case of claim 23, wherein the case is configured to be in electrical communication with the mobile electronic device when the case is installed around the mobile electronic device.

25. The case of claim 23, wherein the total thickness of the case and the mobile electronic device is from about one half inch to about one inch.

26. The case of claim 25, wherein the total thickness of the case and the mobile electronic device is about 0.8 inch.

27. The case of claim 20, wherein the thickness of the case is from about 0.2 inch to about 0.5 inch, the length of the case is from about three inches to about eight inches, the width of the case is from about two inches to six inches, and the power output of the generator is greater than two watts.

28. The case of claim 20, wherein the case is coupled to the mobile electronic device by one or more cords.

29. A method of charging a mobile device, comprising:

providing a case for a mobile device comprising an electrical generator in communication with the mobile device, the electrical generator comprising;

a first magnet array, the first magnet array comprising a plurality of magnets arrayed in an annular formation on a first surface;

a second magnet array, the second magnet array comprising a plurality of magnets arrayed in an annular formation on a second surface positioned opposite the first surface;

a torque input member; and

a rotor disposed between the first and second magnet arrays, the rotor comprising a printed circuit board including a plurality of planar layers, each of the plurality of planar layers comprising a serpentine trace of conductive material extending radially inwardly and outwardly in a continuous manner between a respective inner perimeter and a respective outer perimeter in a serpentine shape so as to form a series of interconnected peaks and valleys around a circumference of the respective planar layer, the respective inner perimeters of each serpentine trace being spaced radially outwardly from a central opening defined in the rotor, the serpentine traces of material being interconnected between the planar layers by one or more vias to form a single conductive pathway, the one or more vias being located adjacent the inner perimeters of the respective serpentine traces, the plurality of planar layers including a top layer and a bottom layer, the top and bottom layers including respective terminals surrounding the central opening and electrically connected to the serpentine traces of the top and bottom layers;

rotating the torque input member;

multiplying the rotational frequency of the torque input member with the gear assembly;

rotating the rotor adjacent the magnets at the multiplied rotational frequency to generate electrical current; and

conducting the electrical current away from the rotor and into the mobile device;

wherein the electrical generator has a thickness of less than one centimeter and is configured to generate a continuous electrical output of about five watts.