MODULAR THERMAL MOLECULAR ADHESION TURBINE

Abstract

A novel molecular adhesion turbine includes improved disc array, flywheel, housing and nozzle structural designs each adapted to exhibit molecularly repulsive and/or molecularly adhesive properties depending upon the particular working fluid used with the turbine. Backflow turbulence and drag forces are reduced, and turbine operating efficiencies are improved as a result. The invention includes an insulating enclosure, which provides added noise cancellation and heat capture benefits. The new molecular adhesion turbine is modular and thus capable of sealable applications, including connecting the turbine to a bladed steam turbine of the type typically used in power plants for heretofore unrealized downstream energy efficiencies.

Description

REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. application Ser. No. 14/262,773, filed Apr. 27, 2014, now pending, which is a continuation-in-part of application Ser. No. 13/871,365, filed Apr. 26, 2013, now pending.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of systems fir deriving power from moving fluids and, more particularly, to a blade less turbine system.

Impeller systems for deriving mechanical power from moving fluids are known. U.S. Pat. No. 1,061,206, which I hereby incorporated by reference, describes an apparatus for converting moving fluids to energy by adhesion to a central rotor comprising a set of flat discs with spaces between each disc. As disclosed in U.S. Pat. No. 1,061,206, such apparatus are also operable as fluid pumps. The discs have flat edges and are secured for rotation on a shaft. Working fluid enters an inlet passage tangentially aligned with the discs. The fluid adheres to the discs transferring its energy to the discs to rotate the shaft.

Each disc has a central opening for the moving fluid to escape from the housing that contains the disc array and shaft. On the other hand, when the discs are rotated by means of an external motor, fluid is elected by the discs through a fluid outlet aligned tangentially with the discs. The mechanical features of this bladeless turbine system and their corresponding inefficiencies are known. The discs are subject to erosion, wear and warping caused by the extreme heat and supersonic rate of flow of the moving fluid over time.

Turbulence is another problem. The moving fluid is typically in a highly pressurized saturated gaseous state. Imperfections in the surfaces of the discs, the housing and other fluid-directing components, therefore, produce turbulence and hence drag on the system. One example is the fluid intake passage. At (sub/super)sonic flow rates, the working fluid often produces harmonic wave patterns at the intake, which disrupts flow and causes turbulence. The physical properties of the particular moving fluid also impact overall system efficiency.

Fluid viscosity contributes to the fluid particle size that manifests between the rotating discs. Fluid viscosity and adhesion control the rate at which the fluid moves through the system as well as system energy yields. The mechanical properties of the system such as the shape of the disc, disc spacing and disc mounting/connective structures, for example, should thus be carefully engineered so that the system is optimally efficient regardless of the particular moving fluid used. Another factor influencing the efficiency of a bladeless turbine is the rate at which the fluid exits the stator housing.

Upon start up of the turbine the moving fluid exits the housing through the outlet ports at a slower rate and the disc array functions at a slower RPM rate than when the turbine is fully operational. Backflow issues are therefore common at start up as a result. As the system picks up speed, the fluid exit rate increases, backflow begins to subside and the pressure of the system equalizes. Initial turbine function and backpressure, however, often delay the time it takes to achieve system equilibrium.

Other constant tormentors such as radiant heat escape and system vibration constantly discount turbine system energy yields as well.

There is, therefore, a need for a more efficient bladeless turbine. The present invention is directed toward this need.

SUMMARY OF THE INVENTION

The invention is a modular thermal molecular adhesion turbine for converting moving fluids into mechanical or electrical energy. The new turbine includes an upper removable stator housing with an open horizontally located chamber to accept various nozzle designs and inserts. Various nozzle designs are interchangeable depending upon the temperature, pressure, pounds per hour of working fluid variations, or other factors requiring alternate inlet nozzle designs. The lower stator housing is fastened to a fixed platform and contains low fiction bearing assemblies at each end of the housing to support the main rotor shaft, which is at a horizontal plane in reference to the system configuration. Both upper and lower stator housings have a half circular port at the central exterior and when joined provide a full circular port to exhaust the working fluid from the interior of the stator housing. This fixed port size is maximized to match the full diameter of the exit holes found in the central area of the discs.

Fitted to the main rotor shaft is a plurality of flat polished discs, which have parabolic end edges instead of fiat and which are coated in repel the incoming working fluid. This modification prevents pitting and erosion of the disc edges while channeling more working fluid into the gap spacing between each disc. Each disc has a male notch that is inserted into the longitudinal female notch running along the length of the central shaft. During the turbine operation the main rotor shaft imparts mechanical rotational power to the preferred electrical conversion source. A spacing washer is positioned between each disc to provide a uniformity of gaps between each. The discs are also coated on both flat sides with greater working fluid adhesion properties near the exterior working area of the disc and working fluid repulsion coating on the surface area nearest the center of the disc.

These coatings increase the adhesion properties of the working fluid and allow the working fluid to escape through the center holes in each disc with no frictional losses. As mentioned, each disc has openings located near the center with several central spokes supporting the discs and ending in the center to slip onto the main rotor shaft. Each disc spoke has at tapered edge which prevents pitting and erosion when the rotor disc set is operational at very high rotations per minute and working fluid is passing through the internal exhaust channel created by the disc set. The discs have openings near the center so that exhausting working fluid can flow to either side of the internal disc set and exhaust through the turbine stator housing at each end. At the end of each disc set is a single flywheel, which is thicker than the interior discs.

Each flywheel has a greater diameter than the discs and has a male notch at the flywheel disc edge fitting into a recessed matching female notch in the turbine stator housing inhibiting the working fluid from coming in contact with the outer flywheel disc surface and the turbine stator wall. The exterior of the flywheel is coated with material to act as a repellent to the working fluid preventing any frictional losses from the interaction of the flywheels, working fluid and turbine stator walls.

The flywheels and discs have a series of small holes close to half the radius length of the discs. Each disc has matching holes in the flat surface area. A series of small diameter stabilization rods fit through each series of disc holes, terminate and attach at each exterior wall of both flywheels and thus, the flywheels and discs rotate as a single unit on the shaft.

In another aspect of the invention, at the exterior of each side of the turbine stator housing is mounted a tuned port apparatus that can open fully to match the turbine stator exhaust port or can incrementally restrict the exit exhaust hole size to help with leveling internal back pressure during the beginning start up time required by the turbine to reach operational rotations per minute. The working fluid then travels into both exterior exhaust port chambers and exits the system either into the atmosphere, a closed-loop or a complementary condensing unit providing a partial vacuum.

In another aspect, at least two of the turbines are operatively connected together by a common shaft to form a modular turbine system. A working flowable fluid source, such as a bladed steam turbine, may be operatively connected to an inlet port upstream of the modular turbine system, and an exhaust capture means may be operatively connected to the outlet port downstream of the modular turbine.

In yet another aspect, an insulative enclosure is provided, which includes an interior assembly that covers the turbine for noise cancellation and an exterior assembly that covers the interior assembly for heat capture.

One object of the invention is to provide a more efficient bladeless turbine. Related objects and advantages of the invention will be apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cutaway side view of the nozzle receptacle and internal rotary discs.

FIG. 2 is a cutaway of an embodiment of the straight tube nozzle insert.

FIG. 3 is a cutaway of an embodiment of a convergent/divergent nozzle insert.

FIG. 4 is a cutaway view of an embodiment of the convergent/anharmonic nozzle insert.

FIG. 5 is a front view of the nozzle connector flange ring, connector holes and high-pressure o-ring.

FIG. 6 is a front view of a single internal rotating turbine disc.

FIG. 7 is a front view of the inter-disc spacer.

FIG. 8 is a close up view of a disc spoke tapered edge.

FIG. 9 is a front view of a single side of an embodiment of the rotor disc of the invention showing the molecular adhesion and repulsion coating areas.

FIG. 10 is a diagrammatic enlarged cutaway view of a partial internal rotor disc array showing disc gap and specialized disc tip.

FIG. 11 is a front and partial side view of the end flywheel disc with turbine housing notch and coating area facing the internal disc array.

FIG. 12 is a cutaway view of a single complete modular turbine assembly.

FIG. 13 is a cutaway view of a typical modular set of turbines connected together.

FIG. 14 is a side view of the modular turbine enclosure housing and mounting block.

FIG. 15 is a top cutaway view of a modular turbine set with multiple inlet manifold connections from one working fluid input port.

FIG. 16 is a side view of the external tunable exhaust port from the turbine stator housing for disc exhaust.

FIG. 17 is an internal side view of the tunable exhaust apparatus without the gear housing cover.

FIG. 18 is a cutaway front view of an embodiment of the turbine noise cancellation and thermal heat capture enclosure diagrammatically shown with a turbine.

FIG. 19 is a diagrammatic top cutaway view of half of the two-stage modular turbine array working fluid pathway through the complementary external exhaust capture apparatus.

FIG. 20 is a diagrammatic top cutaway view of a bladed steam turbine connected to multiple condensing units.

FIG. 21 is a diagrammatic top cutaway view of a bladed steam turbine connected upstream of the modular turbine showing the modular turbine array stages one and two with complementary condensing unit and additional modular condensing units connected downstream of the modular turbine.

DETAILED DESCRIPTION OF INVENTION

For the purposes of promoting an understanding of the principles of the invention, specific embodiments have been described. It should nevertheless be understood that the description is intended to be illustrative and not restrictive in character, and that no limitation of the scope of the invention is intended. Any alterations and further modifications in the described components, elements, processes, or devices, and any further applications of the principles of the invention as described herein, are contemplated as would normally occur to one skilled in the art to which the invention relates.

In this description the terms “working fluid,” “flowable fluid” and “moving fluid” shall have the same meaning, namely a fluid or gas used with the invention to derive energy. Water in the form of saturated steam has been used in this description as only one such example.

The invention also contemplates the recovery of heat and flowable fluids from both renewable and non-renewable sources where they are otherwise wasted so the may be captured and used in connection with the invention. Heat produced during manufacturing processes and geothermal steam serve as examples.

With reference to FIGS. 1-4, the modular thermal molecular adhesion turbine, herein known as ‘turbine’ begins with the introduction of a working fluid into a nozzle inlet opening 103. A straight tube nozzle 205 is shown in a cutaway view showing the working fluid flow direction upon entering nozzle inlet opening 103 and exiting through nozzle exit 203 to impart action through working fluid adhesion upon the internal disc array 1203 (FIG. 12) and each singular disc 106. The interior nozzle coating 204 is a molecular repulsion material to reduce molecular adhesion drag and frictional temperature increases. The area of initial working fluid contact with the internal disc array 1203 occurs at the back-end half of nozzle 203. The turbine stator housing 105 has a receptacle 104 or replaceable nozzle shaft cavity, which allows for easy replacement of various nozzle types.

Each removable nozzle design attaches to the turbine stator housing flange 102 with the corresponding nozzle flange 101 and is fastened through a set of hardware with acceptable matching holes 503, as shown in FIG. 5. A high-pressure gasket 502 is inserted between the turbine stator Range 102 and each replaceable nozzle flange 101. In one embodiment, a high pressure saturated steam gasket 502 made of inorganic fibers with a nitrite binder is used to seal the nozzle flange 101 to the corresponding housing flange 102 using high strength threaded studs with steel washers and nuts and barrier dielectric washers and bolt sleeves.

There are many nozzle designs that can be made adaptable to the turbine stator nozzle shaft cavity 104. In one embodiment, a straight tune nozzle is used. In a more preferred embodiment, a convergent/divergent nozzle may be used, and most preferably, a specially engineered convergent/anharmonic nozzle is applied. A typical straight tube nozzle 205 is used when the working fluid has sufficient fluid power and speed of movement to bring the internal disc array 1203 to the desired operational rotations per minute. The working fluid travels through the fluid flow path 201 of the straight tube housing shell 202 and enters the turbine stator housing 105 unimpeded.

In another embodiment, a convergent/divergent nozzle design, as shown in FIG. 3, has a working fluid flow chamber 301 housed in a rigid shell 302 that allows the working fluid to enter at nozzle inlet opening 103 and travel through nozzle exit 301 into the turbine stator housing 105. This design is for lower power and fluid speeds imparted in the working fluid used. The convergent/divergent nozzle design has an internal flow reduction neck 303, which increases the speed of the working fluid from subsonic to supersonic speeds. The convergent/divergent nozzle design 304 is customized for constant working fluid speeds and does not work at its most efficient with variable or intermittent working fluid speeds.

In one embodiment, the working fluid is saturated steam. In that embodiment, a convergent/anharmonic nozzle 406 is preferably constructed using a solid rod stock of high temperature steel such as 17-22-XX-grade steel. The solid rod stock may be CNC core drilled in stages to provide the correct internal multiple-tapering sections and end boring to produce a structurally sound replaceable nozzle flange 101. The reduction neck compresses the incoming working fluid at subsonic speeds and releases the working fluid at supersonic speed prior to entering the stator housing 105. The multiple stepped flow chambers 402, 403, and 404 do not allow the working fluid to produce harmonic wave patterns inside the flow chamber 401 and thus prevent turbulence.

The outer and inner diameters of the anharmonic rigid shell 405 are formed to compensate for the incoming steam pressure and flow characteristics to ensure proper reduction of the internal working fluid turbulence. A thicker shell with an increased outer diameter is required to handle more highly pressurized working fluid while the opposite is the case with lower pressure fluid. The size of the inner diameter of the rigid shell therefore may be predetermined accordingly. Referring to FIG. 4, a phantom line depicts the portion of the long axis that extends the length of the anharmonic extension chamber of the nozzle. In one embodiment the divergent portion of the interior passage of the nozzle and the long axis of the passage define at least two angles for canceling acoustic resonance frequency peaks of the working fluid. Turbulence typically produced by the resonance of pressurized fluid in turbine applications cannot thus multiply exponentially. In another embodiment, the divergent portion of interior passage of the nozzle defines three angles. Referring to FIG. 4, the passage angles or “steps” are defined according to the following.

Steps, 402 {S₁}, 403 {S₂}, & 404 {S₃}

• A_x=total length 407, 2 decimal place percentages represented in embodiment

A_x={S₁}˜A_x/6.9686[R\Q]+{S₂}˜1.9846[R\Q]×S₁+{S₃}˜2.007[R\Q]×S₂

Angular degree, V₁, V₂ & V₃, where I₁ is the length of the inner diameter of the passage at 408 and E₁ is the length of the inner diameter of the passage at 409.

((E₁−I₁)/2)×15.45%=√((S₁)²−(cosV₁×S₁)²)

((E₁−I₁)/2)×27.48%=√((S₂)²−(cosV₂×S₂)²)

((E₁−I₁)/2)×27.51%=√((S₃)²−(cosV₃×S₃)²)

When using saturated steam as the working fluid, the three “steps” of the chambers 402, 403 and 404, as a percentage of the total length 407, along with their corresponding angles are, approximately: 14.35% and 8.1 degrees; 28.48% and 6.2 degrees; and 57.17% and 4.3 degrees.

With respect to this embodiment of the nozzle, the term “steps” is used for convenience in understanding the transition in the interior diameter of the chamber wall and is not intended to necessarily suggest the interior wall of the chamber is not consistently sloped or includes non-smooth annular surfaces. Additionally, each of the aforementioned angles are defined by extrapolating the appropriate portion of the inner chamber wall and the long axis (shown in phantom) until they meet to define an angle. The dissimilar non-integer related angles and corresponding wall lengths prevent flowing fluid harmonics from being produced at any fluid flow speed or pressure. Values, including those corresponding to E₁ and I₁, are dependent upon the particular working fluid used.

With saturated steam as the working fluid, a hydrophobic coating is applied to the internal surfaces of the anharmonic fluid flow chamber 401. An amorphous carbon film about 3 microns in thickness is coated on the high temperature steel by close field unbalanced magnetron sputter ion plating. This coating will provide the hydrophobic properties needed to repel steam particles from adhering to the surface of the convergent/anharmonic fluid flow chamber 401 and provide heat and wear resistance needed for extended operations. As the working fluid exits the selected nozzle design it enters the interior turbine stator housing 105 and begins imparting force on the internal disc array 1203 along the interior disc fiat surface 601 (FIG. 6).

The disc material will be of high tensile strength metal, plastic, alloy or composite. Internal disc material selection will be based on compatibility with the particular working fluid type. In the exemplary embodiment, the working fluid is saturated steam, which interacts with the disc flat surface 601. The disc material may be Inconel Alloy 718 which is a precipitation hardenable nickel-based alloy designed to display exceptionally high yield, tensile and creep-rupture properties at temperatures up to 1300° F. This material is preferable when using saturated steam as the working fluid. Based on the extremely high tensile strength of Inconel Alloy 718 the internal disc array 1201 can be operated at RPMs of over 100,000. Discs can be cut from flat stock using high-speed CNC milling practices, electropolished and mechanically buffed for an ultra smooth surface needed for higher hydrophilic properties of the metal alloy surface.

Each internal rotating disc 601 is comprised of a polished flat surface, interconnected multi-disc stabilization holes 602, center disc opening for internal rotating main shaft 603, center disc male notch 604 for main rotating shaft 1205, multiple disc openings 606 for spent working fluid exhaust, supporting multiple internal disc spokes 607 and tapered disc spoke edge 608. The working fluid comes in contact With the exterior disc surface 601 and during disc rotation follows a decreasing circular path until it reaches the disc openings 606 and exits the center of the rotating disc array 1203 through the stator housing exhaust ports 1605 (FIG. 16). Disc opening 606 in another embodiment can be of various disc openings 609 shapes and sizes so that a wide variety of working fluids can exit the disc openings 606 more efficiently traveling through the decreasing circular flow path ensuring that low adhesion working fluids exit the disc opening 606 prior to the point at which the working fluid causes frictional drag without imparting additional energy to the modular thermal molecular adhesion turbine system. This variable opening area will match the molecular adhesion properties of the working fluid used and allow for weaker adhesion working fluids to exit the system without the spent working fluid causing frictional drag. The tapered disc spoke edges 608 decrease erosion and pitting that flat surface spoke edges would have by cutting through the internal working fluid flow exiting the disc openings 606 instead of hitting the working fluid at a perpendicular angle. In (FIG. 8) it is shown the parabolic tip 801 and a close up view of the spoke taper 608 in relation to the working fluid flow path.

A specific parabolic formula generates the characteristic tapered angle and distance from the beginning of the disc taper to the center point of the parabolic disc tip 801 that is ideal for the physical properties of said working fluid. Following on with the saturated steam example, the formulaic example uses the average steam particle size of 0.015625″ diameter and the fixed disc thickness of 0.03125″. As the steam particle adheres to the Inconel disc surface with a hydrophilic coating of magnesium zirconate the wetted steam particle is pressed down and the distance from the disc surface to the quadrant of the outer circumference of the steam particle decreases to 0.0078125″. By adding the thickness of both the adhered disc sides and free steam particles flowing through the medial disc gap the sum would be 0.03125″. This gap distance, therefore, is ideal for the given estimated average saturated steam particle size to both adhere and impact causing rotational movement in the disc array 1203.

The preferred parabolic shape of the disc end tip for a saturated steam application is thus obtained using formula Y=0.6×(½X)² where Y is the thickness of the disc (in inches) and X is the distance for the perpendicular point Y to the center point of the parabolic disc tip. Thus, using a disc thickness of 0.03125″ and the average water (steam) particle diameter 0.015625 yields a tip height of 0.0375″ and a taper angle of 4.75 degrees for a disc width of 0.03125″ and saturated steam used as the working fluid. If compressed pressurized air were being used as the working fluid the tip height would be greater and the taper angle would decrease due to smaller average working fluid particle size.

Beginning at the midpoint of the disc array 1203 each disc 601 to the left of center has the spoke taper 608 facing from the left exiting working fluid flow likewise each disc 601 to the right of center has the spoke taper 608 facing from the right exiting working fluid flow. This directional taper design acts as an additional motive force aiding the working fluids exhaust path from the internal center disc openings 606 to the turbine stator external exhaust ports 1605. A central disc spacer 605 is placed in-between each disc 601 to provide uniform gap spacing 1002 (FIG. 10) between each disc 601.

When the working fluid is saturated steam, the gap spacing 1002, central disc spacer 605, gap spacing between the discs 601 and flywheels 1107 (FIG. 11), and the disc thickness should all be 0.03125″. This spacing allows for the saturated steam particles to adhere to the disc surfaces and allow enough room for non-adhering steam particles which are just above the planar surface of the discs to impact the adhering steam particles thus providing contact movement to the rotating discs 601. If compressed pressurized air were to be used as the working fluid then the gap spacing would decrease to 0.006125 due to the decreased molecular size of the working fluid particles.

The gap spacing 1002 is variable in size depending on the type of working fluid to be used. Each disc spacer 605 has a central hole 701 (FIG. 7) which fits on the main rotor shaft 1205 to separate each disc 601 and also in-between discs next to the flywheels 1107 (FIG. 11). Each disc 601 side has specialized molecular adhesion and repulsion coating areas (FIG. 9) increasing the energy imparted by the working fluid and aids in the spent working fluid exhaust speed into the central disc openings 606. The molecular adhesion and repulsion coatings are matched to the type of working fluid that is used in the turbine system. The adhesion coating area 901 is applied to the outer disc 601 so that the maximum conversion of energy from the working fluid is realized.

The molecular repulsion coating area 902 is applied to the outer disc 601 so that the working fluid does not incur unneeded frictional resistance as it exits the central disc openings 606. The phantom line 903 of FIG. 9 identifies the barrier between the molecular adhesion coating 901 and molecular repulsion coating 902. The parabolic disc edges 1001 are coated with molecular repulsion material, which directs working fluid into the disc nap spacing 1002 without frictional losses and prevents pitting and erosion.

In one embodiment, the molecular repulsion coating for saturated steam can be an amorphous carbon film about 3 microns in thickness coated on the high temperature steel by close field unbalanced magnetron sputter ion plating. For this application, areas that may require this coating are the inner disc area 902, disc spokes 607, disc spoke tapered edges 608, parabolic disc tips 801, 1001, interior flywheel area 1108 and the internal flywheel inner diameter. The internal aluminum stator housing will be also coated with a hydrophobic polymer, polytetrafluoroethylene, which is heat resistant up to 536 degrees F. and highly wear resistant. Areas needing hydrophilic coatings, when saturated steam is used as the working fluid, are the inner disc area 901 and the internal flywheel area 1104. One type of coating for high hydrophilic properties can be plasma sprayed magnesium zirconate which also provides a very good heat and abrasion resistant permanent layer.

Disc array 1203 has two end flywheels 1107 that are slightly greater in diameter than the discs 601 and are notched 1101 and 1102 at the end to fit into the female notch in the internal turbine stator housing 105. The flywheel notch 1103 provides a nearly complete barrier to the working fluid front entering the area in-between the turbine stator housing 105 and the exterior of the flywheel disc surface 1108. Frictional interaction of the working fluid between the rotating external flywheel surface 1108 and the turbine stator housing 105 is further reduced by coating the external flywheel surface 1108 and coating the internal turbine stator housing walls 1003 with molecular repulsion material. The near total reduction of frictional losses improves the overall turbine efficiency. The molecular adhesion coating is applied to the flywheel interior surface 1109 at area 1104 and the molecular repulsion coating is applied to the flywheel interior surface 1109 at area 1105 and to both the flywheel spokes 1111 and flywheel spoke tapers 1110. There is a boundary line 1106 between the two coating areas that will vary with changes in disc diameter and the type of working fluid used in the turbine system.

With reference to FIG. 12, a cutaway view of the entire modular turbine assembly 1213 shows the upper half of the turbine disc assembly housing 1201, lower half of the turbine disc assembly housing 1202, internal rotor disc array 1203, working fluid exhaust shell 1204, internal main rotor shaft 1205, single shaft connection 1206, rotor Shaft extension 1207 for reduction gear attachment, then to generator/alternator 1212, external exhaust port for working fluid 1208, external exhaust port connector flange 1209, internal cavity of the main exhaust chamber 1210 and modular rotor shaft interconnect dual shaft connection 1211. The working fluid enters the upper turbine stator housing 1201 from the nozzle exit 203 and imparts energy to the disc array 1203. The working fluid exits the central disc array 1203 through the multiple disc openings 606 and exhausts through the turbine stator housing side ports 1605. The working fluid then travels through the internal cavity of the main exhaust chamber 1210 and exits the external exhaust port 1208 into a closed-loop system, the front end expander area of at complementary external exhaust capture apparatus unit 1914 (FIG. 19) or into the atmosphere. The modular rotor shaft interconnect single shaft connection 1206 can be replaced with the modular rotor shah interconnect dual shaft connection 1211 joining another modular turbine to the system.

An example of the modularity of the turbine is shown in (FIG. 13) with a single unit modular turbine 1301 operatively connected to three additional single unit modular turbine 1301 assemblies to form a final group of four turbine units 1302. Any number of single unit modular turbine 1301 assemblies can be connected together for use with any expanded working fluid system.

Side view of the exterior of the modular turbine enclosure housing including both locking bracket and mounting block are shown in FIG. 14. This drawing identifies the assembly parts for the exterior turbine housing, which includes the upper locking bracket for multiple modular turbines in tandem 1401, lower turbine stator housing flange connector 1402, upper turbine stator housing flange connector 1403, frictionless bearing assembly 1404, mounting bracket for bearing assembly and interconnect for base mounting plate and upper locking bracket 1405, base mounting plate for modular turbine array 1406 and upper turbine stator chamber receiver for interchangeable nozzle types 1407. To connect more than one modular turbine together, the mounting bracket for bearing assembly and interconnect for base mounting plate and upper locking bracket 1405 is removed then additional modular single turbine units 1301 are added. Also, the base mourning plate for modular turbine array 1406 will be customized to it additional modular single turbine units 1301 when added. The frictionless bearing assembly 1404 reduces shaft friction and improves efficiency.

When multiple modular single turbine units 1301 are connected together to form a group, for example a four unit modular turbine set 1302, a custom manifold 1507 (FIG. 15) is required. This drawing comprises the interconnects for the manifold 1507, upper housing 1201 and the lower housing 1202 all being joined together by the upper locking bracket 1401 through the upper locking bracket holes 1501 for connection to the upper turbine stator housing flange 1403 and manifold 1507, external exhaust port chamber 1502, multiple exhaust manifold connector flange 1503 which interconnects with nozzle insert connector flange 101 and turbine stator housing nozzle chamber flange 102, multiple exhaust manifold chamber shell 1504, working fluid path prior to turbine nozzle inlet 1505, working fluid input port 1506 and the final customized manifold 1507. The manifold 1507 is connected by the manifold flange 1503 to both the nozzle flange 101 and the turbine stator housing flange 102 by through-hole fasteners and each flange has an inserted high pressure o-ring 502 between each flange connection. Working fluid enters the manifold 1507 through the manifold input port 1506 and is distributed evenly to each working fluid path 1505 prior to each turbine nozzle inlet 103.

The upper exterior turbine stator housing 1204 allows for mounting the tunable exhaust base plate 1703 (FIG. 17) which holds in place the nine tuning blades and provides fastening points for the minor rotating tuning gear 1701, the main gear 1705, rotational expander channels 1706 for tuning blades 1602 and slider pegs 1708. The main gear 1705 has matching sprocket teeth 1704 interacting with the minor rotation tuning gear sprocket teeth 1702 to adjust the rotational blades 1602 for varied exhaust port 1604 diameter. This tunable exhaust port assembly 1709 allows the working fluid exhaust pressure to be adjusted to prevent excess backpressure in the turbine system.

This embodiment shows the invisible view of the edge of the tuning blades 1707 which are expanded and contracted through the fixed slider pegs 1708 moving through the expander channels 1706. The tunable port gear housing cover 1601 is fastened to the upper turbine stator housing 1201 and the lower turbine stator housing 1202 and provides an opening for the rotor shaft 1205 to exit through the main exhaust port 1605. An end view of the main shaft 1603 can be seen in relation to the rotational blades 1602 inside the tunable port gear housing cover 1601.

At the beginning of the introduction of saturated steam into the turbine the tunable exhaust apparatus 1709 would be completely constricted making the exhaust port diameter 1604 small preventing the internal pressure and temperature of the saturated steam from decreasing during start up conditions. During start up the RPM of the internal disc array 1203 increases as does the exhaust port diameter to prevent backpressure from building inside the stator turbine housing 105. At operational RPM the exhaust port diameter 1604 is fully open allowing free flowing spent saturated steam to exit the system as hot condensed water.

Heat loss from the modular single turbine assembly 1301 will be prevented through the installation of a noise cancellation and thermal heat capture enclosure 1809 (FIG. 18). This three-piece enclosure drawing shows the final enclosure cover for the matched triple-insulated turbine noise cancellation and thermal heat capture side coupling assembly 1801, hollow interior of the final enclosure 1802, low density thermal insulating foam and noise canceling material 1803, rigid structural box frame material 1804, vacuum impregnated panel (VIP) matched pair sub assembly 1804, flexible double ply steel mesh to absorb minimal vibrational impact from normal turbine operation 1805, matched set of VIP, thermal insulating foam and noise canceling sub assemblies 1806, final enclosure opening which slips over and encloses the matching sub assembly shells when applied against the turbine 1807 and turbine outline 1808. Preventing heat from escaping the turbine through the exterior sides increases the efficiency of the heat engine and also cancels out unwanted noise.

As a follow on to the saturated steam example, the modular thermal molecular adhesion turbine 1213 is shown in a modular stacked two-phase grouping 1913 (FIG. 19) with a complementary external exhaust capture apparatus 1914 attached. The modular stacked two phase grouping 1913 and complementary external exhaust capture apparatus 1914 will replace the common Condenser unit 2013 (FIG. 20) at the backend of a typical bladed steam turbine 2012. Bladed steam turbines are used in power plants and serve here as an example of an upstream working flowable fluid source that is operatively connected to the inlet port of the modular turbine. The bladed turbines produce waste exhaust comprised of high pressure and temperature saturated steam. This drawing shows a top cutaway view of the modular stacked two phase grouping 1913 and a saturated steam flow pathway through the system ending with its exit into the complementary external exhaust capture apparatus 1914. In this embodiment, the external exhaust capture apparatus 1914 is a common cold water tube condensing unit with an external vacuum pump to provide positive flow of the hot condensate exiting the modular stacked two phase grouping 1913.

The assembly parts of the modular stacked two phase grouping 1913 consist of a modular turbine array connector flange 1901, common industrial steam turbine exhaust flange 2014, top tier inlet 1920, modular turbine array manifold 1507, mid tier exhaust inlet 1903, sub tier exhaust inlet 1902, two stage modular turbine arrays 1907, 1908, exterior housing 1904, main rotor shaft extension 1905, minor rotor shaft extension 1906, expander exhaust tube 1909, capillary expander joint inlet 1910, external partial vacuum pump piping 1911, modular turbine array separation housing 1912, and complementary external exhaust capture apparatus unit 1914. In this embodiment, the modular turbine array 1913 and complementary external exhaust capture apparatus unit 1914 connects to the waste exhaust from a common bladed steam turbine 2012 (FIG. 20) and converts the waste exhaust into mechanical or electrical energy. The modular turbine array 1913 has a complementary external exhaust capture apparatus 1914 which uses the exiting working fluid energy and external vacuum pump system to create a partial vacuum assisting in forward flow of the working fluid throughout the entire modular turbine array 1913 system increasing overall mechanical or electrical output. Other embodiments call for vacuum means also in fluid communication with the modular turbine for creating at least a partial vacuum in a housing of the modular turbine. A nonexclusive list of vacuum means includes inert means, ambient heat differentials, condenser means, a vacuum pump and vacuum produced by the rotary action of the heat engine/turbine itself.

In the example illustrated, waste saturated steam exhaust leaves the common bladed steam turbine 2012 from exhaust chamber 2005 and enters multiple exhaust inlets of type 1902, 1903 and 1920. There are four levels of the modular stacked two-phase grouping 1913 which are not shown on this drawing (FIG. 19) but are also fed by the bladed steam turbine exhaust 2005. Saturated steam enters each individual modular turbine assembly 1213 and produces mechanical energy that is transferred to the main rotor shaft extension 1905, which runs an external generator 1212. As saturated steam exits the first stage modular turbine array 1907 it enters the second singe modular turbine array 1908 through the exhaust to inlet array connector 1917 to produce additional mechanical energy Which is transferred to the minor rotor shaft extension 1906 which runs an external generator 1212. In this example, a vacuum is pulled by an external vacuum pump tube 1911 which aids the exiting hot water from the second stage modular turbine array 1908 exhaust into the expander exhaust tube 1909 array and then into a common cold water tube condensing unit 2105 (FIG. 21) with an external vacuum pump to provide positive flow of the hot condensate exiting the modular stacked two phase grouping 1913. Other embodiments employ any one or a combination of vacuum means described above.

A common bladed steam turbine 2012 and a joined modular condenser unit 2013 are shown coupled (FIG. 20). This is just one type of waste exhaust system producing saturated steam waste gas that can be used by the modular stacked two phase grouping 1913 to produce mechanical to electrical energy without additional fuel.

The main assembly parts, interconnects and waste gas flow path include inlet for high-pressure, high temperature superheated steam working fluid 2001, stage one expander steam turbine blades 2002, stage two expander steam turbine blades 2003, stage three expander steam turbine blades 2004, common bladed steam turbine high pressure saturated steam exhaust chamber 2005, common bladed steam turbine 2012 high pressure saturated steam exhaust chamber diverted downward flow 2006, multi condenser unit chiller tube matrix 2007, common condenser expander area typical in all modular condenser additions 2008, area for additional modular condenser units based on increased exhaust from common steam turbine base unit enlargement 2009, common condenser expander housing shell 2010 and the flow path of high pressure saturated steam from common steam turbine final exhaust port 2011. A great deal of waste energy is lost through the practice of using a common bladed steam turbine 2012 to produce energy from fossil fuels and other non-renewable energy sources worldwide.

When the two-phase turbine array 2101 is placed at the end exhaust of a common bladed steam turbine 2012 the exiting waste gas will be converted into usable mechanical or electrical energy without additional fuel. A typical cold water tube condensing unit 2105 is connected to the exhaust end of the two-phase turbine array 2101 which allows the exiting hot condensate to enter the condensing chamber 2102 flow over the cold water tube array 2103 and exit the condenser through dry bulb temperature condensate port 2104.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered illustrative and not restrictive in character. It is understood that the embodiments have been shown and described in the foregoing specification in satisfaction of the be mode and enablement requirements. It is understood that one of ordinary skill in the art could readily make a nearly infinite number of insubstantial changes and modifications to the above-described embodiments and that it would be impractical to attempt to describe all such embodiment variations in the present specification. Thus, it is understood that it is desirable to protect all the changes and modifications that come within the spirit of the invention.

Claims

1. A turbine comprising:

a hollow housing with walls adapted for supporting a rotatable shaft inside the housing, said walls having an inlet port and an outlet port formed therein so that flowable fluid can pass in and out of the housing;

a disc array mounted on the shaft for capturing energy from the fluid to rotate the shaft; and

a pair of flywheels each mounted on the shaft in book end fashion with respect to the disc array to form a barrier between an interior wall of the housing and the disc array to prevent frictional interaction of the flowable fluid between the flywheel and the interior wall.

2. A turbine according to claim 1, wherein each flywheel includes, with respect to the flowable fluid, an internal molecularly adhesive surface and an external molecularly repulsive surface.

3. A turbine according to claim 1, wherein the disc array comprises a plurality of equally spaced discs each having opposite sides that converge to define a parabolic tip.

4. A turbine according to claim 3, wherein at least two of said turbines are operatively connected together by a common shaft to form a modular turbine system.

5. A turbine according to claim 3, wherein each side of each disc has, with respect to the pressurized fluid, an outer molecularly adhesive area and an inner molecularly repulsive area, the parabolic tip is molecularly repulsive with respect to the fluid.

6. A turbine according to claim 1, further comprising a tunable outlet port device connected to the outlet port for adjusting the rate the fluid flows out of the housing.

7. A turbine according to claim 6, wherein at least two of said turbines are operatively connected together by a common shaft to form a modular turbine system, and the tunable outlet port device is adapted to be capable of adjusting the rate the fluid flows out of at least one housing of said system.

8. A turbine according to claim 1, further comprising a nozzle connected to the inlet port, the nozzle has an interior passage with a convergent portion and a divergent portion.

9. A turbine according to claim 8, wherein the divergent portion of the interior passage of the nozzle and a long axis of said passage define at least two angles for canceling acoustic resonance frequency peaks of a flowable fluid.

10. A turbine according to claim 8, wherein the interior passage of the nozzle has a wall that is adapted to be molecularly repulsive with respect to the flowable fluid.

11. A turbine according to claim 1, wherein at least two of said turbines are operatively connected together by a common shaft to form a modular turbine system.

12. A turbine according to claim 1, further comprising an insulated enclosure, which includes an interior assembly that covers the turbine for noise cancellation and an exterior assembly that covers the interior assembly for heat capture.

13. A turbine according to claim 1, wherein at least two of said turbines are operatively connected together by a common shaft to form a modular turbine, and a working flowable fluid source is operatively connected to an inlet port upstream of said modular turbine.

14. A turbine according to claim 13, further comprising an exhaust capture means operatively connected to the outlet port downstream of said modular turbine.

15. A turbine comprising:

a hollow housing with walls adapted for supporting a rotatable shaft inside the housing, said walls having an inlet port and an outlet port formed therein so that flowable fluid can pass in and out of the housing;

a nozzle connected to the inlet port having an interior passage with a convergent portion and a divergent portion;

discs mounted on the shaft for capturing energy from the fluid to rotate the shaft, each of the discs has opposite sides that converge to define a parabolic tip, and a central opening formed in each disc for the passage of flowable fluid exiting said housing, spokes intersect each of the openings and converge at a hub which receives the shaft, each of said spokes has a tapered spoke edge for cutting through and directing the flowable fluid passing through the openings;

a pair of flywheels each mounted on the shaft in book end fashion with respect to the disc array, the discs and the flywheels are adapted for receiving connection elements so as to rotate as a single unit on the shaft; and

a tunable outlet port device connected to the outlet port for adjusting the rate the fluid flows out of the housing.

16. A turbine according to claim 15, wherein each flywheel includes, with respect to the flowable fluid, an internal molecularly adhesive surface and an external molecularly repulsive surface, the tapered spoke edge of each spoke is molecularly repulsive with respect to the fluid.

17. A turbine according to claim 15, wherein at least two of said turbines are operatively connected together by a common shaft to form a modular turbine system.

18. A turbine according to claim 15, wherein each side of each disc has, with respect to the pressurized fluid, an outer molecularly adhesive area and an inner molecularly repulsive area, the parabolic tip is molecularly repulsive with respect to the fluid.

19. A turbine according to claim 15, Wherein the divergent portion of the interior passage of the nozzle and a long axis of said passage define at least two angles for canceling acoustic resonance frequency peaks of a flowable fluid.

20. A turbine according to claim 18, wherein at least two of said turbines are operatively connected together by a common shaft to form a modular turbine system, and the tunable outlet port device is adapted to be capable of adjusting the rate the fluid flows out of at least one housing of said system.

21. A turbine according to claim 15, further comprising an insulative enclosure, which includes an interior assembly that covers the turbine for noise cancellation and an exterior assembly that covers the interior assembly for heat capture.

22. A turbine according to claim 15, wherein at least two of said turbines are operatively connected together by a common shaft to form a modular turbine, and a working flowable fluid source is operatively connected to the inlet port upstream of said modular turbine.

23. A turbine according to claim 22, further comprising an exhaust capture means operatively connected to the outlet port downstream of said modular turbine.

24. A turbine according to claim 23, further comprising vacuum means in fluid communication with the modular turbine for creating at least a partial vacuum in a housing of the modular turbine.