Abstract:
A lightweight, foldable cover adapted for attachment to a portable electric generator permits the generator to be operated while covered and shielded from weather. The cover includes rigid or semi-rigid sides hingeably joined and held in position with flexible straps. The cover allows unimpeded exhaust and airflow underneath the cover, and unimpeded access to controls and outlets. The flexible straps attach to the cover and the frame of the generator. The straps are adjustable to accommodate different generator frame sizes, and include quick release devices to allow rapid attachment to, or detachment from the generator frame for refueling or storage. When removed the cover folds nearly flat for storage.

Description:
BACKGROUND 
     1. Field of Invention 
     This invention relates to cover structures, specifically to covers which may be utilized to protect a portable electric generator in the outdoors and while running or idle. 
     2. Description of the Prior Art 
     Portable electric generators are popular for generating electricity in locations without electrical service and as backup power for electrical power outages. They are used outside of inhabited buildings because of the toxic and noxious fumes produced by the combustion engines that power there, in such locations, they are exposed to all manner of weather and are typically not well protected therefrom. 
     When a portable generator is not running and the engine has cooled, it may be covered with a soft vinyl or coated fabric cover, of the many styles commercially available. Such covers do offer protection from weather; however, they are only useful when the generator is not running, since during operation they would block the controls and soon melt from the close proximity to the engine exhaust and hot engine components. 
     Manufacturers of portable generators have recognized the need for weather resistance and have incorporated corrosion-resistant coatings and paint to various components of their portable generators. Furthermore, most have so configured their products to have the fuel tank—usually made of a UV resistant polymer—substantially cover the engine and electrical generator portions underneath. In U.S. Patent Application No. 2011/0095540, Jackson, et al. illustrates a generator so configured with the large fuel tank on top, and furthermore teaches a pair of small moveable covers for weather protection, the first which covers the control panel and the second which covers the outlets. However, Jackson&#39;s application does not provide for weather protection for the tank, fuel cap, frame, wheels, and other components. In U.S. Patent Application 2010/0320774, Bindhammer teaches a pivoting fuel tank for the purpose of facilitating maintenance; however, the shape of the tank will also afford a measure of similarly limited weather protection. 
     In contrast to soft vinyl covers for generators, others have used rigid structures to protect generators from weather. Many people dedicate a separate outbuilding to protect their generators, such as a garden shed. In U.S. Pat. No. 2,424,340, Sterrett teaches a complex rollaway cover for a large generator. In U.S. Pat. No. 4,595,841, Yaguchi teaches a complete wrap-around but removeable cover. In U.S. Pat. No. 5,121,715, Nogami teaches a fully enclosed generator with special provisions for ventilation and cooling. In U.S. Pat. No. 7,642,665, Konop, et. al. teaches a pair of hingedly mounted hoods for protecting a generator while providing access to its components. All of the above referenced inventions suffer from various shortcomings, among them significant bulkiness, weight, cost, and in the case of Konop et. al., insufficient weather protection for the entire generator. 
     Other covers and tents in the prior art which provide for weather protection include U.S. Pat. Nos. 6,276,742; 7,478,862; and U.S. Patent Applications 2009/0038766; and 2011/0226297, all of which apply to vehicles. The Deng patent (U.S. Pat. No. 6,276,742) teaches a cover that is built into the structure of the vehicle and not easily removeable. The Wiegel et. al. patent (U.S. Pat. No. 7,478,862) teaches a spooled fabric which is extended around an item to be protected from weather. The Smith, Jr. application (2009/0038766) teaches a collapsible fabric sun-screen structure attached with suction cups to a vehicle. The Rewis application (2011/0226297) teaches a collapsible canopy frame and cover, attachable to the back of an automobile or truck for sun protection during tailgating events. 
     Collapsible A-frame structures used for other purposes include U.S. Pat. Nos. 837,937; 3,807,104; and 4,237,914. The Legg patent (U.S. Pat. No. 837,937) teaches a hinged roof used for a knockdown chicken house; the Webster patent (U.S. Pat. No. 3,807,104) teaches a portable structure comprising a hinged roof and open floor—essentially, a portable shed. The Gantz patent (U.S. Pat. No. 4,237,914) teaches a portable, two-sided tent of rigid panel or fabric panel construction, adapted to be used on a child&#39;s bed. 
     All of the covers, canopies, tents, and enclosures either in commercial use or in the patent literature known to applicants and that could be applied to protect a portable generator from the weather suffer from one or more of the following disadvantages:
         a) The cover is heavy;   b) The cover does not span the portable generator entirely;   c) Particularly, the cover does not protect the fuel inlet from precipitation, especially snow and ice;   d) The cover cannot be used while the generator is running;   e) The cover is difficult to remove for access to the components of the generator; and/or   f) The cover is not adjustable for various generator sizes       

     OBJECTS OF THE INVENTION 
     It is one object of the present invention to provide a cover for portable generators to be used outdoors while the generator is running. 
     Another object of the present invention is to provide a cover that covers a generator entirely as viewed from above, thereby protecting the generator as a whole from precipitation. 
     Another object of the present invention is to protect the fuel cap from precipitation, yet provide for easy access for refueling. 
     Another object of the present invention is to provide a cover that is easily and quickly attachable to and removable from a portable generator, to facilitate storage of the cover and easy access to the generator for any purpose. 
     An additional object of the present invention is to provide a cover that may easily be adjusted to fit a variety of generator sizes; 
     A still further object of the present invention is to provide a cover that is lightweight for easy handling. 
     Still further objects and advantages will become apparent from a consideration of the following drawings and description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Detailed descriptions of preferred embodiments of the present invention will be made with reference to the following drawings. 
         FIG. 1  is a perspective view of the preferred embodiment of the present invention shown mounted to a portable generator. 
         FIG. 2  is a side view in elevation of the embodiment illustrated in  FIG. 1 . 
         FIG. 3  is partial section view taken along lines  3 - 3  in  FIG. 1 . 
         FIG. 4 . is an exploded perspective view of certain components shown in  FIG. 2  for greater clarity. 
         FIG. 5  is a partial section view taken along lines  5 - 5  in  FIG. 2 . 
         FIG. 6  is a partial section taken along lines  6 - 6  in  FIG. 1 . 
         FIG. 7  is an alternative embodiment of the detail shown in  FIG. 6 . 
         FIG. 8  is an alternative preferred embodiment of the present invention, more suitable to the illustrated alternative portable generator. 
         FIG. 9  is a partial section view taken along lines  9 - 9  in  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following is a description of the preferred embodiments of the present invention and will be understood by reference to the drawings. Also, as used herein the term “generator” is intended as short-hand for portable electric generator, including the frame, engine, genset, and ancillary components. 
     As illustrated in  FIGS. 1 and 2 , a cover is indicated generally by reference numeral  10  and shown attached to a generator  12 . The cover  10  includes a roof  14 , having a left side  14 A and a right side  14 B that sits upon a frame portion  16  of generator  12 , and completely covers the generator as viewed from above. Contact between roof  14  and generator  12  occurs at upper corners  34  of frame  16 . Roof sides  14 A and  14 B have lower lateral edges  29 , and are made of sufficient size so that lower edges  29  will be positioned away from frame  16  and below upper corners  34  of generator  12 . This keeps precipitation dripping from lower edges  29  away from generator  12 , yet allows for unimpeded access to the controls and outlets of the generator. 
     Roof sides  14 A and  14 B may be made from a polymer or other substantially rigid or semi-rigid material and may be advantageously lightened in weight by utilizing foamed or corrugated polymers. Roof sides  14 A and  14 B are hingedly joined at an apex  26 , the details of which will be described hereinafter. Sides  14 A and  14 B further have a pair of lower slots  18  and a pair of upper slots  28  formed for connections to be described in an explanation of  FIGS. 2 ,  3 , and  5 . 
     Roof  14  is secured to the frame  16  by a pair of vertical straps  62 , and a pair of horizontal straps  80 , as illustrated in  FIG. 2 . Said straps are preferably made of woven nylon or polypropylene, however, it will be appreciated that any flexible strap or rope material could potentially serve this function as well. One vertical strap  62  and one horizontal strap  80  is positioned at each end of roof  14  for stability;  FIG. 2  is representative of the construction at either end. Each vertical strap  62  is attached at its upper end to roof  14  through slots  28  adjacent to apex  26 . Each vertical strap  62  is secured at its lower end to a horizontal rail portion  74  of frame  16 . The connection of strap  62  to rail  74  is accomplished by a releasable connection indicated generally by reference numeral  65 . Each horizontal strap  80  attaches to left side  14 A, and to right side  14 B, through slots  18 . All straps  62  and  80  are adjustable for effective length. The precise details of strap attachments and adjustment means will be described immediately following, but for the moment  FIG. 2  will serve to describe the theory behind the construction and operation of cover  10 . 
     The effective length of horizontal straps  80  controls the roof angle created between sides  14 A and  14 B of cover  14 ; once straps  80  are taut, the angle cannot increase further. In practice, horizontal straps  80  are first adjusted with roof  14  sitting upon frame  16  until the angle between sides  14 A and  14 B is suitable, typically between 90 and 120 degrees. It can be appreciated that the appropriate angle would depend upon the size of frame  16  of the particular generator in question. Subsequent to setting this angle, vertical straps  62  are adjusted for length to develop vertical tension in the straps. This developed tension tends to pull apex  26  downward, which tends to cause the roof angle to increase, because sides  14 A and  14 B will slide at the upper corners  34  of frame  16 . However, the angle is prevented from increasing due to the countervailing tension in horizontal straps  80 . Therefore, the tension in vertical straps  62  and horizontal straps  80  are in opposition to one another, and this balanced tension serves both to maintain the roof angle between sides  14 A and  14 B, and to maintain tight contact between roof  14  and frame  16  at its upper corners  34 . 
     Referring to  FIG. 3 , vertical strap  62  passes through a slider  50 , then through upper slot  28  in right side  14 B, over apex  26 , back through upper slot  28  of left side  14 A, and back through slider  50  again. Sliders of the type shown at reference numeral  50  and illustrated elsewhere herein are well known in industry and serve the dual purposes of securing straps while still allowing for adjustment of effective length. It should be noted that there are other devices and means, such as double-D rings, that could serve as alternatives for attaching and/or adjusting the straps. These alternatives would be obvious to one skilled in the art and should not be construed to be outside the scope of this invention. 
       FIG. 4  is an exploded view of one of two releasable connections indicated generally by reference numeral  65  shown in  FIG. 2 . The lower end of vertical strap  62  is connected to a male side release buckle portion  92 . A mating female side release buckle portion  94  is secured with a heavy-duty zip-tie  102  near the center of the upper rail  74  of frame  16 . Horizontal strap  80  comprises a straight portion  82  and a loop portion  88  formed near the middle of straight portion  82 . Loop  88  may be formed from a twist in straight portion  82  or from a second length of strap material; and it may be fastened by sewing, heat staking, riveting, or any similar process. The purpose of loop  88  is to limit the amount of sliding that can occur between roof  14  and upper frame corners  34 , and assists in keeping roof  14  centered on frame  16 . 
     During attachment of cover  10  to generator  12 , loops  88  are placed over and around female side release buckle portions  94 , and then male side release buckle portions  92  are snapped into female portions  94 . Thus, with the simple manual attachment or release of only two side release buckles, the cover may be secured to, or removed from, the generator. It should be understood that a “side release buckle” could easily be replaced with a front-release buckle, a toggle buckle, or any of several other quick-release devices known in the art and used with flexible straps or ropes, without departing from the scope of this invention. 
     Referring now to  FIG. 5 , each horizontal strap  80  passes through a slider  118 , then through one of the slots  18  in left side  14 A, through a slider  114 , around a center bar portion  116  of the slider  114 , back through the same slot  18 , and back again through slider  118 . In this manner, strap  80  is attached securely to roof side  14 A, inasmuch as slider  114  is larger than slot  18  and therefore prevented from passing through said slot. Furthermore, it will be appreciated that slider  118  provides for adjustment of the effective length of strap  80 . The construction described in  FIG. 5  is repeated for the attachment of the opposite ends of straps  80  to roof right side  14 B. 
     Considering now the construction detail of roof portion  14 , as shown in the section view of  FIG. 6 , it will be understood that sides  14 A and  14 B of cover  14  can be made from a single sheet of material. By forming a crease  42  into a single sheet of material and subsequently bending the sheet, it will naturally fold around the narrowed, less rigid crease, and thus form an apex  26  opposite crease  42  as well as sides  14 A and  14 B. If the material chosen for cover  14  has sufficient resiliency and fatigue strength, crease  42  can serve the function of a “living” hinge, even to the point of allowing sides  14 A and  14 B to come together for flat storage. 
       FIG. 7  illustrates an alternative embodiment to the construction detail of roof  14  from the illustration of  FIG. 6 . In  FIG. 7 , a roof portion generally indicated by reference numeral  130  comprises a left roof panel  134  and a right roof panel  136  joined by a flexible hinge  150 . Roof panels  134  and  136  include upper longitudinal edges  135  and  137  respectively. Flexible hinge  150  comprises a central resilient portion  152  that terminates in a left side bifurcation  154  and a right side bifurcation  156 . Bifurcations  154  and  156  resiliently hold upper edges  135  and  137  respectively. It will be understood that many different types of hinges other than those described herein could be utilized to accomplish the purpose of a hinged connection between roof panels  134  and  136  without departing from the scope of this invention. 
     Some portable generators have frames sufficiently different from frame  16  in  FIG. 1  such that an alternative embodiment to the cover  10  of  FIG. 1  needs to be utilized. Referring to  FIG. 8 , an alternative embodiment may be appreciated. A generator frame  160  includes a far side  164  and a near side  166 ; near side  166  in turn includes a handle portion  170  projecting outwardly from the frame  160  for the purpose of easily moving the generator. The handle  170  includes left side portion  170 A, right side portion  170 B, and central portion  170 C. Central portion  170 C is that portion of the handle gripped by the user when moving the generator. It can be seen from the drawing of  FIG. 8  that the near side portion  166  of frame  160  does not include a portion equivalent to upper rail  74  in  FIG. 2 , and therefore, a vertical strap cannot be used to attach a cover generally indicated by reference numeral  172  to frame  160  at near side  166 . This limitation applies only to near side  166  of frame  160 ; at far side  164 , the means of attachment of the cover  172  to frame  160  is identical to that illustrated in  FIGS. 1 through 5  and will not be described again here. 
     As illustrated in  FIGS. 8 and 9 , cover  172  includes a roof  174 , having a left side  174 A and a right side  174 B that sits upon generator frame  160 . Contact between roof  174  and frame  160  occurs at handle portions  170 A and  170 B at near side  166  of the frame  160 . Contact between roof  174  and frame  160  also occurs at upper corners of frame  160  at far side  164 . Roof sides  174 A and  174 B are hingedly joined at an apex  178 , in a manner such as previously described in  FIG. 6  or  FIG. 7 . Sides  174 A and  174 B each include an upper rear slot  182 , a lower rear slot  184 , and a lower front slot  186 . Rear slots  182  and  184  are used for connections of straps in a manner such as previously described in  FIGS. 1 through 5 . Front slot  186  is formed for communication with a horizontal strap  190  to be further described in reference to  FIG. 9 . 
     Referring now particularly to  FIG. 9 , horizontal strap  190  is positioned along the underside of handle  170 , and in tangential contact with left side  170 A and right side  170 B. Strap  190  communicates with roof sides  174 A and  174 B by passing through slots  186 , through a pair of sliders  192  and back through slots  186 , terminating in the space underneath roof  174 . The ends of strap  190  are adjustably secured with a pair of sliders  194  located in the space between handle portions  170 A and  170 B. The effective length of strap  190  is accomplished by moving sliders  194 . Said effective length is set to ensure that roof sides  174 A and  174 B remain in constant contact with handle sides  170 A and  170 B respectively. Once the effective length of strap  190  has been adjusted as described, it does need to be adjusted again for removal or re-installation of the cover  172  to generator frame  160 . 
     Although the present invention has been described in terms of the preferred embodiments above, various modifications and/or additions to the preferred embodiments would be quickly apparent to someone skilled in the art. Nevertheless, it is intended that the scope of the present invention extends to all such modifications, additions, and variations. 
     The embodiments described herein should be understood to be illustrative in nature and not limiting to the scope of the invention as defined by the appended claims.