Abstract
A convector includes a rotor having a shaft extending along an axis of rotation, and a plurality of discs offset from one another along the axis of rotation and mechanically coupled to and rotatable with the shaft. The convector also includes a stator having a plurality of plates offset from one another along the axis of the shaft. Each plate of the plurality of plates defines a through-hole configured to receive the shaft and an opening configured to receive a corresponding disc of the plurality of discs. Rotation of the shaft causes each disc to rotate at least partially within the opening defined by the corresponding plate, and relative to the corresponding plate.
Claims
1. A convector, comprising: a rotor having a shaft extending along an axis of rotation, and a plurality of discs offset from one another along the axis of rotation and mechanically coupled to and rotatable with the shaft; and a stator having a plurality of plates offset from one another along the axis of the shaft, each plate of the plurality of plates defining a through-hole configured to receive the shaft and an opening configured to receive a corresponding disc of the plurality of discs, wherein rotation of the shaft causes each disc to rotate at least partially within the opening defined by the corresponding plate, and relative to the corresponding plate.
2. The convector according to claim 1, wherein each disc is fully nested within and aligned with each plate.
3. The convector according to claim 1, wherein the plurality of plates are conductive stator plates configured to conduct heat, and the opening defined by each conductive stator plate is a recessed area on one side of the conductive stator plate, radially outward of the through-hole, and configured to receive the corresponding disc.
4. The convector according to claim 3, wherein the corresponding disc is operatively disposed at least partially within the recessed area defined by the conductive stator plate and rotatable therein.
5. The convector according to claim 4, wherein each conductive stator plate includes a first side and a second side opposite the first side with the second side defining the recessed area of the conductive stator plate, and each disc includes a first side received within the recessed area of the corresponding conductive stator plate, and a second side facing the first side of an adjacent conductive stator plate of the plurality of conductive stator plates.
6. The convector according to claim 5, wherein rotation of the shaft causes each disc to rotate within the recessed area of the corresponding conductive stator plate, and to transfer heat away from both the corresponding conductive stator plate and a corresponding adjacent stator plate of the plurality of conductive stator plates.
7. The convector according to claim 3, further comprising: a base thermally coupled to a first end of each of plurality of conductive stator plates, wherein each conductive stator plates is configured to thermally conduct heat from the first end to a second end of the conductive stator plate opposite the first end.
8. The convector according to claim 3, wherein each conductive stator plate includes at least one boss operatively disposed along at least one peripheral area of the conductive stator plate, and the at least one boss includes an inner sidewall which at least partially circumscribes a radially outer edge of the corresponding disc.
9. The convector according to claim 8, wherein the radially outer edge of each disc is arcuately aligned with the inner sidewall of the at least one boss.
10. The convector according to claim 8, wherein each conductive stator plate defines a scroll-shaped casing around each corresponding disc, and the scroll-shaped casing defines an interior scroll-shaped exhaust portion configured to direct a fluid out of the convector.
11. The convector according to claim 10, wherein the interior scroll-shaped exhaust portions defined by the plurality of conductive stator plates are aligned, and together form a main exhaust port for directing the fluid out of the convector.
12. The convector according to claim 3, wherein each disk is fully received within the recessed area of the corresponding conductive stator plate and circumscribed by the conductive stator plate.
13. The convector according to claim 3, wherein the plurality of conductive stator plates are stacked together along the shaft, and together form an outer wall that encapsulates the rotor.
14. The convector according to claim 1, wherein the plurality of plates are flat conductive stator plates.
15. The convector according to claim 1, wherein the plurality of plates are fin separators, and each fin separator includes a peripheral region that defines the opening in which the corresponding disc is at least partially received.
16. The convector according to claim 15, wherein each disc is fully received within the opening defined by each corresponding fin separator.
17. The convector according to claim 15, further comprising: a plurality of conductive stator plates offset from one another along the axis of the shaft, wherein each respective disc which is at least partially received within the respective fin separator is operatively disposed between a pair of the plurality of conductive stator plates on opposite sides of the respective disc.
18. The convector according to claim 17, wherein the plurality of conductive stator plates are flat, and the plurality of fin separators and the plurality of conductive stator plates are stacked together along the shaft, and together form a plurality of chambers in which the plurality of discs rotate with the shaft, and an outer wall that encapsulates the rotor.
19. The convector according to claim 17, wherein each of the plurality of conductive stator plates defines a through-hole which is aligned with the through-holes of the fin separators and is configured to receive the shaft.
20. A convector, comprising: a volute-shaped housing having a radially outer casing defining a single exit port for guiding a fluid out of the housing, the volute-shaped housing including a front plate at a front end, a rear plate at a rear end, and a base plate at a bottom end thereof, the radially outer casing coupled to the front plate, the rear plate, and the base plate; a stator having a plurality of plates disposed inside the radially outer casing of the housing and configured to conduct heat; and a rotor having a shaft and plurality of discs, the shaft extending longitudinally through a front aperture defined by the front plate of the housing, along an axis from the front plate of the housing to the rear plate of the housing, and through a rear aperture defined by the rear plate, the plurality of discs disposed inside the radially outer casing along the shaft, interleaved with the plurality of plates of the stator, and rotatable with the shaft about the axis, wherein the plurality of plates of the stator, the plurality of discs of the rotor, and at least one of the front plate or the rear plate of the housing together define a plurality of axially aligned holes radially outward of the shaft for guiding an intake fluid into the convector to a plurality of chambers between the plurality of plates and the plurality of discs, and wherein the housing, the stator, and the rotor together define a flow path through the volute-shaped housing to the single exit port for guiding the fluid out of the convector.
Description
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0042] The foregoing and other features and aspects of the invention may be best understood with reference to the following description of certain exemplary embodiments, when read in conjunction with the accompanying drawings, wherein:
[0043] FIG. 1 is a view of a prior art blower or pump.
[0044] FIG. 2 is a view of a prior art cycle boundary layer turbine.
[0045] FIG. 3 is a view of a prior art cylinder with rotating flat discs and fixed fins.
[0046] FIG. 4 is a view of a prior art disk augmented heat transfer system.
[0047] FIG. 5 is a view of a prior art forced air cooling apparatus for semiconductor chips.
[0048] FIG. 6 is a view of a prior art spinning heat sink.
[0049] FIG. 7 is a view of a prior art toroidal fluid mover.
[0050] FIG. 8 is a view of another prior art spinning heat sink.
[0051] FIG. 9 is a perspective view of four basic convectors in accordance with exemplary embodiments.
[0052] FIG. 10 is an exploded illustration of the convectors shown in FIG. 9.
[0053] FIG. 11 is a perspective view of a convector embodiment with a hollow shaft.
[0054] FIG. 12 show some characteristic components of a convector embodiment shown in FIG. 11.
[0055] FIG. 13 illustrates the comparison between convector embodiments with solid and hollow shafts.
[0056] FIG. 14 illustrates the comparison of rotors with solid shafts and rotors with hollow shafts.
[0057] FIG. 15 shows a basic convector design, components and basic operation details.
[0058] FIG. 16 is a perspective view of a convector designed for cooling electronic components.
[0059] FIG. 17 illustrates an exploded view of the convector shown in FIG. 16.
[0060] FIG. 18 shows an isometric view of a rotor designed with a compression system.
[0061] FIG. 19 shows the comparison of a rotor with free floating discs and a rotor with a compression system.
[0062] FIG. 20 depicts the frontal, top and cross-sectional views of various disc design embodiments.
[0063] FIG. 21 illustrates several discs with various surface configurations and finishes.
[0064] FIG. 22 is a perspective view of a hollow shaft design versus a solid shaft design.
[0065] FIG. 23 illustrates a top view of a representative hollow shaft design and various cross-sectional geometries of hollow shaft designs.
[0066] FIG. 24 depicts various air opening designs on hollow shafts.
[0067] FIG. 25 is a perspective view of various hollow shafts presenting variations related to the number of main air passages and shaft ends.
[0068] FIG. 26 illustrates the top view of several discs and hollow shafts, a perspective view of a single disc placed onto a hollow shaft and a close up view for clarification of the design.
[0069] FIG. 27 presents the perspective view of various hollow shafts and a cross-sectional view of a hollow shaft with openings designed to impart a rotational motion to the fluid.
[0070] FIG. 28 depicts the perspective view of various solid shafts with relative small shaft-diameter designs and respective cross-sectional geometries.
[0071] FIG. 29 presents the perspective view of several convectors set-up in series for a cooling application related to high power electronic components.
[0072] FIG. 30 presents the isometric view of various base designs.
[0073] FIG. 31 shows the isometric view of various flat-fin design geometries.
[0074] FIG. 32 shows the isometric view of various fins with built-in structures (bosses and indentations).
[0075] FIG. 33 shows the isometric view of a convector design based on non-flat fin structures.
[0076] FIG. 34 is an exploded view of the convector shown in FIG. 33.
[0077] FIG. 35 shows the isometric view of volume convectors and pressure convectors.
[0078] FIG. 36 presents the cross-sectional view of two volume convectors.
[0079] FIG. 37 shows the cross-sectional view of three pressure convectors.
DETAILED DESCRIPTION OF THE INVENTION
[0080] The present invention generally relates to novel devices, methods and systems for facilitating the convective transfer of heat by the movement of fluids utilizing a plurality of equally parallel and spaced rotating discs and static plates using the disruptive boundary layer mechanism.
[0081] FIG. 9 shows four characteristic designs for novel convectors utilized in applications related to the transfer of energy, in the form of heat, from or to a fluid utilizing a combination of interleaved flat-static plates and flat-rotating discs, where the surfaces of the discs and plates are located at relatively close proximity from each other. Furthermore, the cross-sectional shape of these devices (referred here and thereof as a scroll-shape (σ)), is purposely designed so that the devices behave as fluid propulsors while simultaneously acting as energy (heat) transferring devices utilizing convective mode energy transfer mostly by boundary layer disruption on the surfaces of the stator plates. The devices shown differ from each other by slight external variations, but much pronounced internal differences. For example, 901 is a device designed to include a hollow shaft with openings at both ends. The openings serve the purpose of fluid intakes. These types of devices have discs that are not attached to the shaft and are able to move freely. 902 shows a device designed with a solid shaft that also has freely moving discs. These types of devices require radially intake openings to surround the shaft on the back and frontal walls, the rotating discs and the stator plates. 903 is another device that is designed with a solid shaft, but, unlike the devices of 902, the discs are held in place with a compression system consisting of disc spacers and compression mechanisms located at both ends of the shaft with the remaining design characteristics remaining the same. 904 presents a device designed for non-compressible fluids and it is also designed utilizing a solid shaft with a compression system plus seals to prevent the fluid from leaking. These devices can have one or two fluid intake ports.
[0082] Regardless of the application on hand, most convectors share a large number of characteristic design parameters and components. FIG. 10 shows some of these common components including a frontal plate 10A, a bearing at the frontal end of the shaft 10B, a shaft 10C, circular discs 10D, a cover or casing 10E, a base 10F, fins 10G, a bearing located on the back end of the shaft 10H, a back plate 10I, a coupler 10J and a motor 10K.
[0083] Simple in design, novel scroll-shaped (σ) convectors, such as the one shown in FIG. 11, have just a few characteristic external features. These features include frontal and back fluid intakes, a top fluid exhaust, components to mount the motor against the casing of the convector (bosses, spacers and screws), a device that provides rotational motion (motor), a mechanism to attach the motor to the shaft (coupler), a flat base and in most cases a scroll-shaped casing. The assembly (FIG. 12) of the convector includes a frontal plate 12C, provided with a nesting feature 12A to hold and retain a bearing 12D and an opening 12B to clear the end of a shaft 12H. An array of flat discs 12G are provided with an opening 12F, such as the one shown on disc 12E, allows the discs to be inserted onto a shaft 12H. The discs 12G are placed between fixed, static plates 121 that are in intimate-thermal contact with a base 12K. A circular opening 12J is provided on all of the static plates to allow the shaft 12H to rotate freely. To provide stability to the static plates, extra holding bars are provided as shown in the close view 12L. A motor 120, held in place with screws and spacers 12Q is attached to the shaft with the help of a coupler 12P. A scroll-shaped casing 12M is provided with an exhaust port 12N to let the exhaust fluid escape the device.
[0084] Convectors design versatility allows the use of hollow shafts or solid shafts. FIG. 13 shows the main fluid intakes on a design that includes a hollow shaft. In designs such as these, the main fluid intakes are located at both ends of the shaft 13A with a fluid passage that covers the entire length of the shaft 13B and that includes multiple fluid passages 13C, so that the fluid entering the device gets distributed between the fins and the rotating discs. In contrast, a convector designed with a solid shaft is provided with fluid intake openings located at both the frontal and back walls of the device 13D. These openings are also provided on all of the components within the device such as the discs 13F and the static plates 13G making a continuous set of fluid passages that run the length of the device 13E. Although convectors do not have a rotor per se, the overall assembly of discs and shaft within the device makes them behave rotor-like.
[0085] FIG. 14 compares rotors made with solid shafts 14B and hollow shafts 14H. Both assemblies consist of an array of flat-parallel discs equally spaced 14A and 14G. Rotors with solid shafts have flat-circular discs 14C that are provided with several openings 14D surrounding a central hole intended to clear the rotating shaft. The openings on the discs are intended to create several continuous fluid passages 14F. Rotors designed with hollow shafts 14H get populated with flat-parallel, equally spaced discs 141 that have a single central opening intended for the shaft 14H. Hollow shafts are intended as conduits for the fluid that enters the device. The fluid enters the device via two sets of fluid intakes located at both ends of the shaft 14K, and moves within the shaft through a central passage 14J. The fluid is dispersed between the discs (and plates) with the help of many fluid openings 14L located on the sides along the length of the shaft.
[0086] A typical convector (see FIG. 15) is designed to have a multiple number of flat-parallel discs 15A and a multiple number of flat plates 15B that are interleaved 15C in a manner such that the surfaces of the discs and the surfaces of the static plates will end up at relative close distances. With the help of a shaft 15D, bearings 15E and an external motor 15F the discs can be rotated concurrently 15J. The resistance to move, experienced by the fluid against the surfaces of the discs and static plates, causes the fluid to move and to be pushed out of the device that is completely contained with a casing 15G. The fluid 15L exits the device via an exhaust port 15K and end openings 15H provided on the lateral walls, discs and plates 15H create a passage for fresh fluid 151 to enter the device and to move between the discs and plates.
[0087] Convectors can be designed for applications related to the temperature control of high power electronic components such as microprocessors in computers or amplifiers in power sources. A device designed for use with a microprocessor is depicted in FIG. 16, where a mounting mechanism is provided to ease the installation of the device. Just like most convectors, the device (referring to FIG. 17) has a motor 171 that can be attached to a frontal wall 175 on bosses where threaded holes are provided 174. Screws 172 can be utilized to mount the motor against the wall. Spacers 173 and a coupler 175 help align the motor with the shaft of the convector 17A. A bearing 179 is press-fitted into a nesting location 170 on the frontal wall 175. An opening on the nesting location 170, allows the shaft to expose its end to meet with the end of the motor's shaft. A base 17F made from highly conductive metal is populated with flat plates or fins 17E, into equally spaced grooves 17G machined on the top surface of the base. The device shown here is designed with a solid shaft and with a single air pipe 17M located on the back wall 17J. The pipe directs the incoming air to a series of radial openings 17K, located at some distance from the central point where the shaft 17A revolves. Radial air openings 178 are provided also on the discs 177 and fins 17E. The discs 177 are designed to have a central opening 17C were the shaft 17A can slide freely. Fins are also provided with a circular clearance opening 17H intended to allow the shaft to rotate without touching the fin's walls. Because the fins 17E are wide at the point where they get attached to the base, fin separators 17D with a circular shape on the inner wall facing the discs, are added to the assembly. This design includes also a retaining bar 17X to prevent the fins from moving and disc spacers 17Z to keep the discs 177 at the right distance from the fins 17E. A bearing at the back side of the shaft 1W is also press-fitted into a cavity or nest 17L located on the back wall 17J. The base 17F, fin separators 17D, fins 17E, holding mechanism 17P, screws 17Q, captive screws 17R, springs 17S and retainers 17T are pre-assembled before the discs 177 and disc separators 17B get placed in between the fins. Once this operation is completed, the shaft 17A is placed through all of the discs 177 and disc separators 17B and the front wall 175 with bearing 179 attached, is placed over the shaft 17A. In a similar procedure, the back wall 17J with respective bearing 17W is placed over the other end of the shaft. At this point, the retaining bar 17X is placed over the top of the fins 17E and the casing 17N, with a built-in exhaust port 17V, is placed over the complete fin-disc assembly. After the casing and walls are fully secured with fasteners (not shown), the motor 171 is attached to the end of the shaft with the use of a coupler 176. Screws 172 and spacers 173 help attach the motor to the front wall 175 to finish assembling the device.
[0088] Some convectors are designed with rotor assemblies that require a compression mechanism; FIG. 18 shows a rotor where a solid shaft 18B is populated with flat, circular, equally thick, equally-spaced discs 18A. The assembly includes disc spacers 18C, end seals 18D with O-rings 18E and a compression structure 18G fitted with set screws 18H. The shaft design 18B includes a threaded section for the compression mechanism 18G and smooth, cylindrical surfaces at both ends to allow the bearings that will be mounted at its ends to rotate with minimum effort. The end of the shaft where the motor gets attached can be provided with a flat section to ease the mounting procedure.
[0089] Depending upon the application, convectors can be designed with solid shafts coupled to free-floating discs or with solid shafts where the discs have to have a compression system. FIG. 19 shows two rotor assemblies to show the main differences between these two options. The rotor on the top left is of the kind where a compression mechanism is included 191, along with end-seals 192 and nesting O-rings 195. The compression structures 191 are threaded on the shaft 193 and held securely in place with the help of set screws 196. Disc spacers 197 and keys 198 placed on the shaft 193, secure all of the discs 194 at pre-determined distances. The rotor at the bottom of the drawing exemplifies the free-floating disc type. These rotors are provided with discs 194 where a central opening allows the shaft 193 to slide freely. Because the discs float on the shaft without any impediment, this type of rotor can only be utilized in devices oriented with the edge of the discs perpendicular to the surface the device sits on. Devices with rotors that include a compression system can be utilized in any orientation.
[0090] One of the main components of convectors is discs, in fact, many of them. Discs, circular in shape are flat and thin and they are utilized in convectors as part of rotor assemblies and can be manufactured from metals and non-metals alike. Placed between fins, discs (with same diameter and thickness) help in the process of heat exchanging as they rotate creating disturbance in the boundary layer of the stator plates' surfaces. Discs do not have to be completely flat as can be seen in FIG. 20. Circular discs 20A that have flat cross-sections with some specific thickness 20B are the most common design utilized in convectors. Another design approach includes flat discs 20C with a thicker section 20E in the center of the disc. This design removes the need for disc spacers and the thicker section 20D provides better support and a stronger holding mechanism to the shaft. Yet another design on flat discs 20F includes a metal insert 20G placed in the middle of a non-metal disc, the insert could be made thicker than the rest of the disc 20H. Discs with metal inserts are much stronger than any of the other designs shown and if they are properly designed, they can also eliminate the use of separate disc spacers. Of all of the designs, discs with metal inserts are the most complicated and expensive to manufacture.
[0091] Discs are an integral component of convectors and they could be flat with smooth surfaces or relatively flat with features on both surfaces. FIG. 21 shows a sample of the large variety of designs and surface geometries that discs intended for use in convectors could have. Of all of the designs, the most straight forward and simple is that of a perfectly flat disc with smooth ages and polished surfaces 21A; other designs include discs with surfaces on which certain features (bosses, dimples, indentations, etc.) have been provided across the full face of the disc 21B, 21i, 21K; other design variation include specific geometric features such as vanes, grooves, dimples, bosses, indentations or bumps set in radial, circular or spiral configurations 21C, 21D, 21E 21F, 21G, 21H, 21J, 21L; yet another variation includes non-smooth edges 21K. Depending upon of the desired effect expected from the discs, the addition of features to the surfaces of discs help increase their total surface area. In return, the greater surface area help their performance as aids in the heat exchanging process. If discs are utilized with non-compressible fluids, discs may be designed to include radial features to act as vanes and help stir and push the fluid.
[0092] Shafts utilized in convectors can be of the solid-bar type or the hollow-tubular type. FIG. 22 shows both of these types. Shafts made from solid bars 22B are simple and have just a few features. Shafts of the hollow-tubular type 22A are complex and have many more features than the solid-bar type. Regardless of the type, shafts of both types share several features, among these features, shafts have an area intended for bearings to ride on 22C, planar areas to support the discs 22D, and a mechanism to attach them to a rotating device 22E. A hollow tubular type of shaft includes extra features such as air passages located at both ends 22F, and air passages along the full length of the shaft 22G. For obvious reasons, the complexity of hollow-tubular shafts makes them difficult and expensive to manufacture.
[0093] Shafts of the hollow-tubular kind (FIG. 23) are designed with some distinct features that include fluid passages at both ends 23B, an area at the both ends to allow a bearing to be mounted 23A and fluid passages along the full length 23C. Shafts of this type have cross-section geometries with features that help discs placed over them to get “locked” or “keyed” in place, so that if the shaft rotates, so do the discs. Some of the cross-section designs include, but are not limited to, round shafts 23D with bumps along the length 23E; round shafts 23F with grooves along the length 23G; shafts with three sides 23H; shafts with four sides 23i; shafts with five sides 23J; shafts with six sides 23K and shafts with seven sides 23L.
[0094] Hollow-tubular shafts are designed to have, in most cases, fluid openings at both ends and a series of fluid openings along its length to help distribute the fluid that enters the ends. FIG. 24 shows a top view of a sample that includes fluid openings at both ends 24A and a variety of shapes for the openings along the length. It should be understood, that the geometries and shapes presented, constitute only a glimpse of a large number of possible geometries and shapes. The fluid openings can be oval-shaped 24B, diamond-shaped 24C, rectangular-shaped 24D, round-shaped 24E, square-shaped 24F, cross-shaped 24G, consist of a large number of small round holes 24H or have a variable set of rectangular 24i or round openings 24J. In any case, the openings have to be placed at regular intervals along the length of the shaft and most be designed so that the shaft remains strong and capable for operation at high speeds and to help distribute the fluid between the discs that make up the rotor and the fins or plates that make up the stator. Shafts of this type can be manufactured with metals and non-metals, but the need for strength and durability makes the choice for metals a given.
[0095] Hollow-tubular shafts are always provided with, at minimum, a single, main-fluid intake (or a set of smaller openings) at one of its ends and at most, two points of attachment for a rotating device (one at each end of the shaft). FIG. 25 shows the various options available, including shafts with two attachment features to a rotating device 25D or a single attachment feature to a rotating device 25D. All shafts are provided with main fluid openings at either one or both ends of it. The feature that allows fluid enter the device may consist of a single opening or a series of smaller openings designed at one or both ends of the shaft 25A, 25B and all shafts must include a smooth area at both ends to place and hold a bearing there 25C.
[0096] As it has been indicated in FIGS. 12, 13 and 14, there are various approaches and rotor assemblies that depend upon of the mechanism that holds the discs in place. The most simple of these mechanisms require that the discs be designed with central openings matching the perimeter and shape of the shaft that ultimately will hold them. FIG. 26 shows for ease of understanding, a single disc 26A placed over a hollow shaft 26B. There are many variations that the shaft may have, as far as its cross section is concerned. From the sample presented 26C, the first item on the top row, first column has been selected to show a close view of the shaft-disc relationship 26D. It can be observed, that for the cylindrical shaft with four-lobes, that the central opening on the disc is slightly greater by some dimension 26E. Regardless of the shape and number of sides that the shaft may have, the central opening on the discs, must allow the easy installment of the shaft.
[0097] Because fluids have the natural tendency to look for the path of least resistance when placed in a condition where flow is compromised, hollow shafts with regularly spaced fluid passages may not work as expected. That is, fluid may not flow at the same rate at every point along the length of the shaft. In situations like this, the fluid may come at faster or slower rates at different points between the rotating discs and the static plates. This behavior will cause heat transfers to be different at every point with a different flow rate affecting the overall efficiency and performance of the device. Referring to FIG. 27, to avoid this behavior, shafts with single intake ports 27A can be designed to have regularly spaced openings with variable open area. The openings closer to the main fluid entry port should be designed to have a small open area and the area should be increased as the axial location of the openings is increased too. If the shaft is provided with dual fluid entry points, the same approach utilized on single fluid entry point should be used, the resulting effect is that of small open area passages near the entry ports and large openings in the middle of the shaft 27B, 27C. If turbulent flow is required, a special shaft 27D with tangential ports 27F to the inner diameter 27E can be designed. Of course, the designs previously discussed represent only a few of many designs that can help control the flow rates of fluid entering the device through the shaft.
[0098] As it has been pointed before, convectors, or should it be said, rotors for convectors can be designed with either hollow shafts and/or solid shafts. FIG. 28 shows a sample of possible, but not limited to, configurations and geometries for several solid shafts. Solid shafts are components designed to perform various tasks including holding several discs, provide rotational motion to the discs and locking or keying the discs so that they can be rotated simultaneously. Some three-dimensional designs (and their cross sections) include round shafts with lobes 28A, round shafts with grooves 28B, three sided shafts 28C, square shafts 28D, five sided shafts 28E and hexagonal shafts 28F. Solid shafts have several advantages over other shaft designs. Some of these advantages include design simplicity, small size, small weight and small cost. Solid shafts should be considered the first choice over any other choice when designing convectors.
[0099] FIG. 29 shows a conceptual three-dimensional model of a group of fluid-cooled convectors 29C, driven by a single motor 29F. Connected in series with the help of flexible couplers 29E, the convectors 29C, provide cooling to a group of microprocessors 29B that are mounted to a PC board 29A and held under some even pressure against the convectors with the help of some retaining mechanism 29D. As the rotors within the convectors spin with help from the external motor 29F, they draw fresh fluid 29G from the outside, through a lateral intake 29H. After the fluid has picked up the heat from the internal plates, heat and air 29i get expelled through an exhaust port 29J. An advantage of this kind of set up is that the exhaust from all the individual convectors can be directed to a single exhaust pipe, and the pipe can be directed to an area away from the processors to avoid exhaust recirculation. Other advantages of this type of system is that it eliminates or reduces the use of fans, eliminates or reduces the noise levels, they are compact, and because they are efficient, they reduce the amount of power needed to operate them and the convectors can utilize compressive or non-compressive fluids.
[0100] Although FIG. 30 provides a sample of designs possible for bases utilized in convectors, this does not limit other designs not included here, but in general, all bases are made of highly thermal conductive materials, have multiple channels for attachment of plates or fins that are usually brazed, bonded or mechanically held in place, and because bases are intended to transfer heat from a component or a device placed against them, they have their bottom surfaces to be machined and polished to very small tolerances (±0.0005 inches [˜13 micrometers]) to improve heat transfer. Bases can be utilized in conjunction with heat pipes and vapor chambers in order to provide better and efficient heat transfer capabilities.
[0101] Flat plates or fins for convectors come in many shapes, configurations and sizes, FIG. 31 presents, but does not limit, designs of several fin or stator plates where plates with multiple, radial openings near the center are plates utilized on convectors build around a solid shaft. Discs with a single, circular opening are utilized along hollow-tubular shafts.
[0102] Fin or stator plates do not have to be flat components. They can also have features to help contain the fluid as it spins between their surfaces or to strengthen the overall assembly. FIG. 32 presents, but does not limit, designs of several fins or stator plats build with several features such as a central clearance opening 32A, and flat indented areas 32B and bosses 32C to help contain and delimit the rotating discs. Depending upon the design, this type of design can practically eliminate the need of a casing for some convectors.
[0103] FIG. 33 presents a device built with three dimensional stator plates 33A. As stated several times before, the purpose of fin separators is to create a cylindrical cavity for the spinning discs. The cavity helps create a chamber 33B that gives all fluid propulsing devices, such as convectors, the ability to behave as pumps or as blowers with exhaust ports tangential to the outer diameter of their chambers 33C. As it is shown in the exploded view of the device FIG. 34, the front cover 34C, the back cover 34D and all of the fins 34A that conform the stator 34B have features like bosses and indentations that prevent the use of fin spacers. The back cover 34D clearly shows the scroll shape of the inner chamber of the device.
[0104] Convectors are by design, fluid propulsors like pumps and blowers. Their performance as such depends on a technical characteristic that must be present in every design: the scroll-shape (σ) of the chamber where the discs rotate. FIG. 35 shows various convectors each of which has an external feature that makes the design different from the rest. For example, convector 35A has a straight plume exhaust, convector 35B has a flared plume exhaust, convector 35C has a narrow, plume-less exhaust, convector 35D has a narrow plume exhaust and convector 35E has no casing, exposing a multiple set of plume-less exhaust openings. The cross-sections of convectors 35A and 35B are shown in FIG. 36 to demonstrate the common denominator between these two convectors. So, while the convector on the left side of the drawing has a straight plume exhaust 36D, the convector on the right has a flared plume exhaust, but all of the remaining characteristics are in both devices, exactly the same. These characteristics include: 1) a chamber design 36A that wraps the disc early in its development and slowly increases in diameter; this design characteristic is purposely added to devices whenever the movement of large fluid volume is required; devices with this feature are referred as volume convectors; as a result, convectors 35A and 35B fall under this category; b) inclusion of fin separators or built-in structures to act as fin separators 36C; and c) disc diameter 36B is the same for both devices.
[0105] The cross-sectional views of three convectors shown in FIG. 35 labeled 35C, 35D and 35E are shown in FIG. 37 to demonstrate the common denominator between these convectors. So, while the convector on the left side of the drawing has a straight and narrow plume-less exhaust 37D, the convector in the middle has a straight, narrow plume exhaust and the convector on the right side of the drawing has a narrow, plume-less exhaust on a device that has no casing. But, regardless of the differences described, the remaining characteristics in all of the devices are exactly the same. These characteristics include: 1) a chamber design 37A that wraps the disc completely, but with a narrow gap between the edge of the discs and the inner diameter of the chamber 37C; this design characteristic is purposely added to devices whenever the amount of pressure needed from the device is large; devices with this feature are referred as pressure convectors; convectors; as a result, convector 35C, 35D and 35E fall under this category; b) inclusion of fin separators or built-in structures to act as fin separators 37B; and c) disc diameter 37A is the same for all of the devices.
