Portable generators

A customizable portable generator system and methods for assembling the same. In one example, the generator system generally includes a universal frame including a plurality of mounting interfaces configured for detachably attaching one of a plurality of different engines and a plurality of wheel assemblies and/or support legs. Optionally, at least one handlebar assembly may be detachably mounted on the frame in at least one of two possible positions. In one example, the handlebar may be pivotably mounted to the frame. The frame components may be assembled into a kit from which a user may select various options to custom configure the generator unit. Other appurtenances and accessories may be provided which interface with the generator unit and frame. A modular generator frame and compressed gas-fueled generators are also disclosed.

BACKGROUND OF THE INVENTION

The invention generally relates to engine-generator sets, for producing electric power, and more particularly to a highly customizable portable electric generators.

Portable electric generators produce a ready source of electricity for use in a variety of situations where electricity may not be available from the conventional power grid. Such situations may include power outages, remote locations without access to a nearby source of power from an electric utility, constructions sites, and instances where temporary power hookups from the utility are not practical or convenient for short periods of time.

A customizable portable generator system is desirable.

SUMMARY OF THE INVENTION

A portable generator system is disclosed that is configurable by a user and which may be assembled at the point of sale or later reconfigured afterwards to address changing needs. The portable generator system may include a versatile universal support frame that provides an opportunity for a user to select different sizes/types of engines and accessories which are conveniently interchangeable with a single frame. This may be accomplished through a generator frame that provides common accessory equipment interfaces adapted to accept a variety of accessories and/or readily alter the mounting arrangement of such accessories to vary the functionality of the portable generator system created by the user's preferences.

A universal frame generator system may include a universal engine mounting system that allows a plurality of engines having at least one different characteristic (e.g. KW electrical output capacity, fuel type, auxiliary equipment/accessories, etc.) to be interchangeably mounted to a single configuration and size generator frame via a common engine mounting interface.

A universal frame generator system may further include floor support system configured to mount different type floor supports including pedestal type legs and/or wheel assemblies at different locations which are detachably mounted to the frame via a common mounting system interface.

A universal frame generator system may further include a handlebar mounting system that is configurable to mount different sizes and types of handlebars in a plurality of different orientations.

A universal frame generator system may further include a power cord management system that is configurable to provide a variety of cord support arrangements.

In some example systems, the foregoing frame, engines, accessories, and other appurtenances disclosed herein may be assembled into a kit which presents custom options selectable by a user to equip the generator unit as desired. The kit can be shipped to a distributor or retailer which includes all the components necessary to assemble and create a fully functional generator unit that has been customized at the point of sale to meet the user's preferences. In one example, a generator unit assembly kit includes a universal frame, a plurality of engines having at least one different characteristic, a plurality of wheel assemblies, a plurality of frame support legs, and a plurality of handlebars.

An exemplary method for assembling a generator unit may include a user selecting an engine, at least two of a wheel assembly, pair of support legs, or combinations thereof from a generator kit, and mounting the foregoing components selected on the frame. The method may further include selecting at least one pair of handlebars and mounting the handlebars to the frame in at least one of two positions. In one example, the positions include a horizontal position and a vertical position.

The present application further discloses additional kits, accessories, and appurtenances which interface with and may be mountable on the generator and/or support frame disclosed herein.

The present application further discloses a portable generator with modular frame system. The frame system may generally include a plurality of corner members and connector plates which may be interconnected to collectively form an open space frame configured for supporting an internal combustion engine, related appurtenances, and accessories. The present application further discloses compact gaseous fuel power generators which may be operated from compressed liquid fuel canisters or cylinders. In one non-limiting example, the gaseous fuel may be propane.

All drawings are schematic and not necessarily to scale.

DETAILED DESCRIPTION OF EXAMPLES

The features and benefits of apparatuses, systems, methods, and other innovations disclosed are illustrated and described herein by reference to non-limiting examples. This description of examples is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. Accordingly, the present disclosure expressly should not be limited to such examples illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of protection being defined by the claims appended hereto.

FIGS. 1-7illustrate a non-limiting example of a portable generator20according to the present disclosure. The generator20may include an engine30. The engine30may be an internal combustion engine, or various other engines or motors which may produce mechanical energy. The engine30may be powered by a fuel or resource, such as natural gas, diesel fuel, propane, gasoline, or various other fuels.

The generator20may additionally or alternatively include an alternator32. The alternator32may be an electromechanical device in mechanical communication and operably coupled with the engine30. The alternator32may include or use a rotating magnetic field with a stationary armature, a rotating armature with a stationary magnetic field, or a linear alternator. For example, the engine30may produce mechanical energy when operated which the alternator32may convert into electrical energy, such as without limitation alternating current.

Generator20may further include an onboard fuel tank40configured to store fuel which is supplied to the engine30by a fluid coupling such as without limitation a tube or hose. Generator20further includes a control panel50for operating and monitoring the generator, and to provide an electrical connection interface for power generated by the generating unit. The foregoing components of the generator20are mounted to a support structure such as frame28.

For convenience of further description, without limitation, generator20may be considered to have a front21, rear22, first and second lateral sides23and24, a top25, and bottom26(see, e.g.FIG. 1). These designations are defined with generator20resting in a normal upright operating position on a horizontal support surface as shown. Generator20defines a longitudinal axis LA extending from front21to rear22along a centerline of the frame28.

Various examples of generator20may further include floor supports to raise and space frame28above the floor. The floor supports may comprise one or more sets of support legs60and/or wheel assemblies80for transporting the generator. In some frames, one or more pairs of handlebars160may further be provided to further facilitate transport of the generator20. These features will be further described herein.

Control panel50may be mounted on one of the lateral sides23,24of the frame28by brackets54(see, e.g.FIG. 13) or other similar methods. The control panel may alternatively be located in other mounted positions. The control panel may include a plurality of controls51such as switches and indicators51, power outlets52which are electrically connected to alternator32and/or a power distribution panel, key start53, and other usual appurtenances.

FIGS. 8-14show generator20with the fuel tank40. Engine30is not shown in these figures to more clearly show the frame construction.

The fuel tank40may include a top44, bottom45, and opposing lateral sides43. In one non-limiting example, top44of fuel tank40defines a forward sloping surface41and rearward sloping surface42. Both sloping surfaces41,42assist with shedding water to minimize accumulation and prevent ingress of water into the tank such as during refueling. The front and rear sloping surfaces41,42intersect linearly along a laterally extending peak45on the top of the fuel tank which defines the highest point on the tank. In some fuel tanks40, lateral sides43may also be sloped outwardly towards the sides25and26of the generator20to shed water.

In one example, a removable fuel cap48which operably covers a fill spout47may be disposed on one of the sloping surfaces41or42to facilitate filling the fuel tank40. In one example, the fuel cap may be located on rear sloping surface42. Locating the fuel cap48and spout47on a sloping surface creates better access and convenience for refueling to minimize spills as the user has to reach less far with a fuel can in contrast to flat topped fuel tanks with the fuel cap and fill spout located thereon. However, a flat topped fuel tank40may alternatively be provided in some configurations. The fuel cap48and fill spout47may be mutually threaded to provide a screwed arrangement, but is not limited to such configurations.

Fuel tank40may be supported independently by frame28via support flanges49. In other systems, the tank40may be supported by the engine-alternator assembly30-32.

The frame28may be configured and comprised of a first lateral side frame100and an opposing second lateral side frame101spaced laterally apart from side frame100. In one construction, without limitation, frame28may be a substantially generally tubular frame formed of tube or pipe having a circular cross section. Accordingly, in one example, lateral side frames100,101may be cylindrically tubular in construction and configuration as shown. In other possible constructions, frame28may be formed of square or rectangular tubes having a rectilinear cross sectional shape.

Lateral side frame100generally includes a front vertical member102, top horizontal member105, rear vertical member103, and bottom vertical member104which may be formed as a unitary structure or joined together by any suitable means to form a continuous structure. Similarly, lateral side frame101generally includes a front vertical member107, top horizontal member109, rear vertical member106, and bottom horizontal member108which may be formed as a unitary structure or joined together by any suitable means to form a continuous structure.

In some constructions, the horizontal and vertical members of lateral side frames100,101may be multiple separate pieces joined together by welding or brazing. In other constructions, the lateral side frames may be formed of a single tube having two ends and which is first bent to shape and then joined at the ends after forming a loop.

The vertical and horizontal members of lateral side frames100,101may intersect at four corner sections110which preferably are rounded or angled as shown in some examples to preclude catching the frame on various object when generator20is being transported. Each corner section110in one example may include a short straight section of tube112of various lengths disposed between two elbows1111. In one example, the elbows112may be less than 90 degrees to avoid a squared corner section110. However, in other suitable but less preferred examples, some or all of the corners110may be square in configuration.

In one system, top horizontal members105and109may be angled between front vertical members102,107and rear vertical members103,106respectively to complement the shape of fuel tank40. This may be provided for not only aesthetic reasons, but also to help protect the fuel tank. Accordingly, when seen in side elevation view as inFIGS. 9 and 11, lateral side frames100and101may have a generally asymmetric shape. In alternative configurations, top horizontal members105,109may have a straight or flat horizontal shape between the front vertical members102,107and rear vertical members103,106as shown for example inFIGS. 24 and 25.

The lateral side frames100and101may be structurally connected together by a front cross-piece120and a rear cross-piece121disposed proximate to the top25of generator20. Cross pieces120,121are longitudinally spaced apart along the longitudinal axis LA from front to rear, and extend laterally between the side frames100,101to assist with laterally stiffening the upper portion of frame28. In one example, the cross-pieces120,121may connected to corner sections110of each lateral side frame100,101by any suitable means such as without limitation welding or brazing. It will be appreciated that cross-pieces120,121may be coupled to other portions of each lateral side frame100,101in other examples. The cross-pieces120,121may be arranged substantially parallel to each other and perpendicular to lateral side frames100,101. In a certain construction, cross-pieces120,121are tubular in configuration having a round cross-section similar to the lateral side frames100,101. However, the cross-pieces120,121are not limited to circular tubular constructions and may have rectilinear tubular cross sectional shapes such as square or rectangular.

To help laterally stiffen the lower portion of frame28, a pair of longitudinally spaced apart cross-struts130,132may be provided that extend laterally between lateral side frames100and101. In one example, cross-struts130may be connected to bottom horizontal members104and108of the lateral side frames100,101. The cross-struts130,132may be arranged substantially parallel to each other and perpendicular to lateral side frames100,101. Cross-struts130,132may further be arranged substantially parallel to cross-pieces120,121. In one configuration cross-struts130,132may have a different cross-sectional configuration than the cross-pieces120,121such as without limitation rectilinear as further described herein for reasons which will become apparent. Cross-struts130,132may be connected to lateral side frames100,101by any suitable means including welding, brazing, mechanical fasteners, or other methods used in the art.

The frame28including lateral side frames100,101, cross-pieces120,121, cross-struts130,132, and some other structural brackets, accessories, or appurtenances attached or coupled to the frame may be made of any suitable material including metal or polymer. In one construction, the frame is made of steel and/or aluminum. Any suitable coating, finish, or topical treatment and texture may be provided.

In some systems, the frame28may be configured to provide a common interface configured and arranged to removably and interchangeably mount either legs60and/or wheel assemblies80to frame28for transport and raising the frame28above the floor. This provides a floor support system for generator frame28that is configurable and customizable to meet the preferences and needs of each user. For example, a user may elect four wheel assemblies80(see, e.g.FIG. 19E), four legs60(see, e.g.FIG. 19F), or a combination of legs and wheel assemblies mounted on either of the cross-struts130,132. As further described herein, both the legs and wheel assemblies have a common mounting arrangement and configuration advantageously allowing either wheel assemblies80or legs60to be interchangeably used at any of the four mounting locations on the cross-struts.

As shown inFIGS. 13, 16A-B,22, and23, cross-struts130,132in one arrangment are configured to provide four mounting locations on frame28for structurally supporting and attaching the wheel assemblies80or legs60. In addition, cross-struts130,132may further be configured for mounting and structurally supporting engine-alternator assembly30-32of the generator unit and associated appurtenances, as further described elsewhere herein.

Cross-struts130,132may have a non-tubular rectilinear cross-sectional shape. In one configuration, cross-struts130,132may each have the shape of a flanged structural C-channel including a U-shaped central section comprised of an axially extending web134, pair of legs133extending generally downwards and perpendicular from the web, and pair of lateral side flanges131extending generally outwards and perpendicular from the legs. Other suitable structural shapes, however, may be used.

FIG. 22is a detailed exploded view of a wheel assembly80showing the mounting system interface with cross-struts130,132. Each wheel assembly80includes an axle81rigidly attached to a mounting plate82such as by welding, brazing, or other suitable means, a tire83having a hub84and wheel bearing89defining a through opening configured to receive a portion of the axle there through, washers85, and a cotter pin86. The tire83is mounted on one end of the axle81and mounting plate82is mounted on an opposing end. In one example, as shown, mounting plate82may have a central portion that is concavely shaped to complement the convex shape of axle81.

In one non-limiting exemplary construction, the axle81may terminate at or near the mounting plate82and does not extend across the lateral width of the frame28from side24to side26. Accordingly, each wheel may have its own separate axle81rather than an arrangement wherein two tires83may be mounted on opposing ends of a common axle. Advantageously, this provides two shorter and structurally more rigid axles81which helps prevent breakage rather than using a single long side-to-side axis. This may sometimes occur in instances where the generator20may be hoisted and transported via a forklift or other equipment.

With continuing reference toFIG. 22, mounting plate in one configuration includes a pair of mounting holes87and a pair of angled mounting tabs88. Each pair of mounting holes87and tabs88are spaced apart across axle81as shown and arranged such that a mounting tab and hole are disposed on each side of the axle. Mounting tabs88, which may protrude upwards from the top of mounting plate82, have a somewhat L-shaped configuration with a substantially vertical leg88aattached to mounting plate82and a substantially horizontal free leg88bextending at an angle to the vertical leg. Mounting tabs88are configured to produce an interlocked relationship with cross-struts130,132when the wheel assemblies are mounted to the frame28. Accordingly, cross-struts130,132may each include a pair of spaced apart mounting holes135configured and arranged to be substantially aligned with mounting holes87and mounting tabs88when each wheel assembly80is aligned with and mounted on the cross-struts. Mounting holes135may be preferably located in flange131of cross-struts130,132Mounting holes135are configured and dimensioned to receive mounting tabs.

To mount a wheel assembly80onto frame28, the mounting plate82is first positioned below a cross-strut130or132with the mounting tabs88vertically aligned with their corresponding mounting holes135in the cross-strut on each side of the axle81. It should be noted that the distance between each tab88and its respective companion mounting hole87on each side of axle81in the mounting plate82is slightly larger than the distance between each pair of corresponding mounting holes135on each flange131of cross-struts130,132. Accordingly, when the mounting tabs88are aligned with their corresponding mounting holes135in the cross-strut130or132, the companion mounting hole87(i.e. on the same side of axle81) for each tab will be intentionally slightly offset from and not perfectly concentrically aligned with the remaining mounting hole135on the cross-strut, for reasons which will become apparent.

Once the angled mounting tabs88are each aligned with their corresponding mounting holes135, the tabs are inserted upwards through the mounting holes (e.g., the inner mounting holes135on cross-strut130or132) to abuttingly contact the top of the mounting plate82with the bottom of the cross-struts130,132. The mounting plate82with attached axle81and tire83is then slid inwards in an axial direction along the cross-struts130or132to interlock the mounting tabs88with each opposed flange131on the cross-strut. This engages each mounting tab88with the cross-strut at the holes135such that the horizontal leg88bof the tab slides over the top of flange131of the cross-strut thereby trapping the flange in the gap formed below the horizontal leg88band top of the mounting plate82.FIG. 16Ashows an analogous arrangement of an angled mounting tab88seated with cross-strut130or132.

Upon engaging the angled mounting tabs88with the cross-strut130or132, the remaining holes135in the cross-strut will now each become concentrically aligned with its corresponding mounting hole87in wheel assembly mounting plate82. A threaded fastener136is then inserted through each pair of aligned holes135,87and tightened with a threaded nut137to finish securing the wheel assembly80to the cross-struts130or132and frame28. Each tire83is mounted outboard of frame28when wheel assembly80is mounted on cross-struts130,132.

Since the wheel assembly80are detachably mounted to frame28, the foregoing assembly steps are simply reversed to remove the wheel assembly.

Legs60in one arrangement may have an identical mounting interface arrangement with frame28and cross-struts130,132as wheel assemblies80described above. Since the mounting holes135in cross-struts130,132are all identical in size, location, and arrangement as part of an interchangeable frame support system, a user may elect to interchangeably mount either wheel assemblies80or legs60at any of the four mounting locations on cross-struts130,132thereby providing an opportunity for customization.

Each support leg60may be formed of angled metal plate which is bent and/or welded or brazed together. In one construction, the leg may be steel or aluminum. Legs60may have any suitable configuration, but preferably should be shaped and constructed with sufficient strength and stiffness to support the generator20. In one configuration, leg60includes a substantially flat top mounting plate61which is oriented horizontally, two side plates62disposed at about 90 degrees to each other and attached to plate61, and a flat bottom plate63attached to side plates62. Plates61and63may be substantially parallel to each other. Side plates62may taper inwards from top to bottom to provide a wide support platform at top for engaging cross-struts130,132, and a narrower footprint at bottom for engaging the floor or other horizontal support surface.

In one construction, a pad64may be attached to leg60at bottom plate63and formed of a resilient material such as rubber or another elastomeric material to provide surface grip and vibration dampening. Holes65and66may be provided in bottom plate63and pad64respectively in some examples to receive a mounting fastener there through (not shown). Pad64engages the mounting floor or other surface on which the generator20will be located.

With continuing reference to the foregoing figures, legs60include angled mounting tabs88and mounting holes87which are configured, dimensioned, and arranged no mounting plate61to have the same spatial relationship as in mounting plate82of wheel assembly80as already described herein. This permits the legs60to be interchangeable with wheel assemblies80.

Legs60are mounted to cross-struts130,132in the same manner as wheel assemblies80described above; the mounting process not being repeated herein for sake of brevity.FIGS. 16A and 16Bshow legs60fully mounted and fastened to cross-struts130,132. Locking tab88appears protruding upwards through and above flange131of the cross-struts in the interlocked position.

In some systems, the frame28may be configured to provide a universal engine mount system that allows engines30having different characteristics to be interchangeably mounted to a single configuration and size generator frame. The different engine characteristics may include, without limitation, electrical output capacity (e.g. measure in Watts or KW), engine type (e.g. two-stroke, four-stroke), fuel type (e.g. gasoline, diesel), auxiliary equipment, and others. In one exemplary arrangement, without limitation, a common engine mount arrangement is provided which includes four frame engine mounts140fixedly attached to cross-struts130,132. A pair of laterally spaced apart engine mounts140are mounted on each of the cross-struts130,132. The engine mounts140are preferably each configured and arranged identically to provide a common interface with four mating commonly configured and arranged engine mount brackets34(see, e.g.FIGS. 1-7 and 16A) that are provided on a plurality of engines30having at least one different engine characteristic. Preferably, without limitation, the spatial relationship between the engine mount brackets34are common to each of the plurality of different engines30to allow interchangeable use of the engines with a single frame28setup.

FIG. 16Ashows the frame engine mounts140and engine mount brackets34in greater detail. Each frame engine mount140includes a top plate such as angled top plate142configured for engaging an engine mount bracket34on the engine30and a bottom plate such as an angled bottom plate143configured for attachment to cross-struts130,132. Top plate142includes a substantially horizontal flat section142aand a conjoined angled flat section142bdisposed at an angle to the horizontal section. The horizontal top section142amay include an upward turned lip142cto assist with placing and locating the engine mount bracket34on top plate142.

Bottom plate143of frame engine mount140may have a similar configuration as top plate142as shown inFIG. 16Ahaving a horizontal flat section143aand angled flat section143b. Bottom plate143may be spaced vertically below the top plate142in one arrangement. The horizontal section143aof bottom plate143may be attached to cross-struts130,132while the angled section143bis free and projects upwards from the cross-strut at an angle thereto as shown. In one construction, without limitation, top plate142and bottom plate143may each be made from a single metal plate that is bent to shape to produce the horizontal and angled sections.

With continuing reference toFIG. 16A, the top plate142may be connected to bottom plate143by a connecting rod144extending between the angled sections of each plate142and143. In one arrangement, only the connecting rod144supports the top plate142from the mounting plate143and cross-struts130,132in turn. This arrangement advantageously provides a flexible mount which assists with dampening engine vibrations transmitted between the engine and frame28. A motor mount bushing or spacer145, which in some constructions can be metal, may be mounted around rod144between top and bottom plates142,143for additional support.

Referring toFIG. 13and particularly16A, frame engine mounts140may be pedestal-style engine mounts and include a threaded stud bolt141projecting upwards from top plate142of the engine mount. Stud bolt141is configured and dimensioned for insertion through a mating mounting hole36provided in engine mount bracket34. Stud bolt141may be vertically oriented in some examples as shown, or be disposed at an angle with respect to vertical. The orientation of stud bolt141will depend on the corresponding orientation of the mounting hole36in the engine mount brackets34and is not limited to any particular orientation or arrangement so long as the engine30may be securely mounted to the frame engine mounts140.

After the engine mount brackets34is slipped over the bolt141, a threaded nut is used to securely fasten the bracket to the top plate142. This process is repeated at all four motor mounting locations on frame28to complete installation of the engine30on the frame. In some constructions, to further provide additional engine vibration dampening and isolation, a resilient spring or bushing145(not shown) such as without limitation rubber or an elastomer may optionally be mounted between the top plate142and engine mount bracket34around rod144. Such engine vibration dampening devices are well known in the art without further elaboration.

It will be appreciated that engine mount bracket34may have numerous suitable configurations so long as the bracket structure includes a mounting hole36for receiving the engine mount stud bolts141on the frame28. Similarly, frame engine mounts140may have other suitable configurations. Accordingly, the systems are not limited by the exemplary engine mount brackets34or frame engine mounts140disclosed herein.

The frame28may be configured to provide a handlebar mounting system that is configurable and customizable to meet the preferences and needs of each user. For example, a user may elect a single handlebar160mounted horizontally to frame28in a wheelbarrow-type arrangement (see, e.g.FIG. 19A), two horizontally mounted handlebars160(see, e.g.FIG. 19D), a single handlebar160mounted vertically to frame28in a hand truck type arrangement (see, e.g.FIG. 19C), or any combination thereof. As further described herein, the frame28and handlebar160are cooperative configured with an interface that provides both horizontal and vertical mounting options and multiple simultaneous handlebar mounting arrangements.

The handlebar160may include a first handle assembly161(e.g. left in referenced figures) and second handle assembly162(e.g. right in referenced figures) joined together by a laterally extending and elongated tie piece such as without limitation tie bar166. Tie bar166is preferably rigid in construction and have any suitable configuration such as a substantially flat bar as shown, tubular, and others. Preferably, the tie bar166is made metal such as without limitation steel or aluminum. Other suitable metals or other materials may be used to provide the intended structural functionality. Tie bar166is fixedly attached to the handle assemblies161,162such as by welding, brazing, or mechanical means to provide a stiff connection between the handle assemblies. In some configurations, tie bar166may be provided such as when each handle assembly161or162have sufficient lateral stiffness to avoid undue deflection and movement.

Each handle assembly161,162includes an elongated handle163having a proximal grasping end164and opposing distal mounting end165for connection to generator frame28. In one construction, handle163may be tubular having a generally round cross-section. However, other suitable configurations and cross-sectional shapes may be used such as handles having a rectilinear cross-sectional shape, solid round bars, etc. Preferably, handle163is constructed of a material having sufficient strength and thickness to allow a user to lift the generator20without bending or deforming the handlebar. In one example, handle163is preferably made of metal such as without limitation steel or aluminum. Other suitable metals or other materials may be used to provide the intended functionality.

In some configurations, handle163may include an angled section168to produce an axial offset between the grasping and mounting ends164,165as shown inFIGS. 20A and 21. This provides wider lateral spacing between the grasping ends164of the handle for a user. In other examples, handle163may be substantially straight between grasping and mounting ends164,165.

A grip167may be mounted on grasping end164of handle163to provide a comfortable grasping surface for a user. Grip167may have any suitable ergonomic configuration and be made of any type material including resilient polymeric materials to facilitate gripping. The surface of the grip167may be textured and/or include features such as ribbing, stippling, nubs, etc. to further facilitate comfort and grip.

Referring toFIGS. 14B, 19B, 20A, 20B, and 21, mounting end165of handle163is configured to engage a clamp170mutually configured with and operable for attachment to generator frame28. In one example, clamp170may be horizontally spilt collar including a top half section171and bottom half section172. In one example, each half section has a half-tubular concave surface173with an arcuate curvature oriented transverse to longitudinal axis LA and a half-tubular concave surface174with an arcuate curvature oriented parallel to the longitudinal axis LA. The top and bottom half sections171,172together form a first split collar aligned with handle163which includes concave surfaces173and a second split collar aligned with a front or rear cross-piece120,121which includes concave surfaces174; the second collar being oriented perpendicular to the first split collar.

When the two half sections171and172are joined together, both concave surfaces173collectively define a tubular shape that defines a circular rear facing opening175or socket which is configured and dimensioned for receiving mounting end165of a handle163. When the two half sections171and172are joined together, both concave surfaces174collectively define a tubular shape that defines a circular laterally facing opening174or socket (e.g. left or right) which is configured and dimensioned for receiving a portion of front cross-piece120or a rear cross-piece121of frame28. The rear and lateral facing openings or sockets may have other configurations to match and receive handles or frames having other non-circular cross sectional shapes.

Referring again toFIGS. 14B and 20B, top and bottom half sections171,172of clamp170may be removably connected together in one example by any suitable means. A threaded fastener169a(e.g. bolt/screw) and mating nut169bmay be used as a non-limiting example. To facilitate aligning the top and bottom half sections171,172for assembly, a tab182and slot183may be provided on each half section which fit together and interlock when the half sections are joined. It will be apparent that the tab182and slot183will alternate in relative position on the top and bottom half sections171,172for insertion of a tab in a slot and vice-versa. In one example, as shown in the referenced figures, the tab182and slot183may be formed in a peripheral edge portion of concave surfaces174closest to frame front cross-piece120or rear cross-piece121. Other suitable arrangements are possible.

Referring toFIGS. 14B and 20B, bottom half section172may include a positioning flange190including two arcuately spaced apart holes191and192. Holes191and192are preferably separated by an arc distance of 90 degrees apart. In one configuration, the positioning flange190forms a segment of or partial annularly shaped flange that extends around and is disposed at one end of concave surface174on the bottom half section172as shown. The flange190forms a substantially flat arcuate surface193which faces outwards towards on or the other of lateral side frames100,101. Flange190is rotatable in relation to and about front cross-piece120or a rear cross-piece121by rotating the handlebar160. It should be noted that in other configurations, positioning flange may alternatively be formed on top half section171. Either arrangement is suitable.

Frame28includes a locking flange180which cooperates with positioning flange190to lock the position of handlebar160in either a horizontal or upright vertical position (see, e.g.FIGS. 19A and 19C). In one example, a locking flange180may be positioned on frame28near each of four top corner sections110to provide flexibility for a user to mount handlebars160on either the front or rear end of the frame, or on both ends (see, e.g.FIG. 19D). Locking flange180includes a single hole181that is fixed in position in relation to generator frame28. Hole181is selectively and concentrically alignable with either hole191or192of the positioning flange190by rotating the handlebar160between horizontal or vertical positions.

Referring toFIGS. 14B, 19B, and 20B, a locking pin assembly184may be provided which cooperates with locking flange180and positioning flange190to selectively lock the handlebar160in the horizontal or vertical position. The locking pin assembly184includes an cylindrical body185and a locking pin186at one end. Pin186is configured and dimensioned to be insertable through hole181in flange180and hole191or192in flange190. Pin186is movable between a (1) locked position in which the pin projects inwards through holes180and191/192, or (2) an unlocked position in which the pin is retracted outwards from holes180and191/192.

An exemplary method for mounting a handlebar160on frame28will now be described with reference to148,20A,20B,21, and19B. The top and bottom half sections171,172of two clamps170are first positioned over and under one of the front or rear cross-pieces120,121, respectively. The clamps170are selected and arranged so that the positioning flange190of each clamp170is located towards a lateral side frames100,101proximate to a locking flange180. The top and bottom half sections171,172are next brought together and engaged with the front or rear cross-piece120,121selected. The tabs182and slots183are used to guide proper alignment and joining of the top and bottom half sections171,172. The front or rear cross-piece is trapped between the concave surfaces172in the top and bottom half sections171,172. Threaded fastener169ais then inserted through the top and bottom half sections171,172(seeFIG. 208) and engaged with nut169bwhich is partially tightened at this stage of assembly so that the clamp170will not slip off of the front or rear cross-piece120,121.

With continuing reference to the foregoing figures, the mounting ends165on each handle163are inserted into one of the clamps170through rear opening175and engaged with concave surfaces173on the top and bottom half sections171,172. Fastener169amay then be further slightly tightened, but preferably not fully to lightly engage and hold handles163in the clamps170while still allowing the handlebar160to be rotated about the front or rear cross-piece120,121for the desired position of the handlebar.

The handle bar160with attached clamps170are then rotationally adjusted in position about the front or rear cross-piece120,121to concentrically align hole181in each locking flange180on the frame28(seeFIG. 20B) with one of the holes191(for horizontal handlebar mounting position) or192(for vertical handlebar mounting position) in each of the handlebar positioning flanges190. Once the holes are aligned, the locking pin186is inserted through the aligned holes to fix and lock the position of the handlebar160. The fastener169amay then be fully tightened with nut160bto firmly engage the front or rear cross-piece120,121and form a frictional fit between the clamps170and front or rear cross-piece.

It will be appreciated that the foregoing handlebar mounting process and sequence may be varied and still achieve the same result. Accordingly, equivalent mounting processes are possible and the systems are not limited to the foregoing sequence of steps described.

If the user desires to change the mounting position/orientation of the handlebar160, the clamps170may be slightly loosened by partially unscrewing the fasteners169ain each clamp and retracting the locking pins186from the holes180and191/192in the locking flanges and positioning flanges. The handlebar160will now be rotatable about the front or rear cross-piece120,121to change the position of the handlebar from horizontal to vertical, or vice-versa.

FIGS. 24-30illustrate an alternative configuration and features of a generator20and frame28. The generator20, frame28, support legs60, and wheel assemblies80may be essentially the same as already described herein for generator20and frame28with reference toFIGS. 1-24. Instead of or in addition to handlebars160described herein, handlebars having an alternative configuration, construction, and functionality are provided.

The generator28includes a pivotably mounted front handlebar assembly comprising a handlebar250movably coupled to frame28near the front21. Handlebar250may have a generally U-shaped tubular body including two mounting portions252arranged substantially parallel to each other along the longitudinal axis LA and a grasping portion253arranged substantially perpendicular to and spanning between the mounting portions at one end254of the handlebar. Grasping portion253may be vertically offset from and positioned below the mounting portions252. In one arrangement, each mounting portion252may be mounted to one of the top horizontal frame members105or109about a pivot axis251oriented transversely to longitudinal axis LA. The mounting portions252may be mounted to the frame members about pivot axis251proximate to the free ends255of the handlebar250, and in one configuration is spaced inwards from the free ends. In one assembly, the pivot axis251may be formed by transversely mounted pivot members256such as pins or fasteners extending through mounting portions252of handlebar250and top horizontal members105and109. In one configuration, the handlebar250may be disposed inside the top horizontal members105and109.

Handlebar250is pivotably movable with respect to frame28between a folded stowed position (see, e.g.FIGS. 24 and 25) and an extended operating position (see, e.g.FIG. 29shown by dashed lines). In the stowed position, handlebar250is nested in the top25of the frame between the longitudinally-extending top horizontal members105and109. The mounting portions252are oriented substantially horizontal in position. In the operating position, the grasping portion253of handlebar250is rotated forward about the pivot axis251to raise and locate the mounting portions252in a non-horizontal position. The handlebar250protrudes outwards from the frame for transporting generator20. In one configuration, the mounting portions252may be oriented in a generally upright position defined herein as being greater than 0 degrees (horizontal) and less than or equal to about and including 90 degrees (vertical). This arrangement allows the generator20to be transported in hand truck fashion with the handlebar250being upright and vertically or obliquely oriented with respect to the top horizontal members105and109of frame28.

To guide and limit the pivotable range of motion of the handlebar250, a flat guide plate257may be fixedly attached to one or both of each opposing top horizontal members105and109. Guide plate257includes an arcuately-shaped open guide slot258extending 90 degrees between a first and second closed end of the track. A spring-loaded position pin259is fixedly connected through the guide plate257and guide slot258to the handlebar250at or near one of the free ends255of the handlebar. The position pin259is arcuately movable in guide slot258with free ends255by rotating the handlebar250.

The ends260of the guide slot258may be diametrically enlarged and configured with the position pin259for mutual engagement to removably retain the pin259at either end location of the slot. The end260locations of guide slot258define the stowed and operating positions of handlebar250. To enable position pin259to move in the guide slot258, an enlarged operating end261of the pin may be moved and either pulled outwards (in the situation where pin259is biased inwards by the spring) or pushed inwards (in the situation where pin259is biased outwards). In one exemplary configuration, the pin259is inwards biased requiring an outward pull to release and move the pin. This releases the pin259from one of the ends260of the guide slot258, thereby allowing the pin to be moved through the slot to the other end location. Accordingly, an interlock formed between ends260and position pin259allow the handlebar250to be removably locked in either the stowed or operating positions.

Referring toFIGS. 24-30, an alternative rear handlebar assembly including handlebars270is shown which is pivotably movable between a stowed position collapsed against the rear vertical members103,106of frame28and an operating position extending approximately horizontally outwards to the rear of the generator20. This allows generator20to be transported in wheelbarrow fashion. Each rear handlebar270includes a substantially U-shaped mounting clevis271on one end that may be movably mounted to rear vertical members103,106of frame28about a transversely-oriented pivot axis274. Each clevis271may include a pair of spaced apart ears272positioned on opposite sides of either vertical members103or106. The ears272are mounted to the rear vertical members103,106by a transversely mounted pivot member273such as a pin or fastener extending through the ears and vertical members as shown. In one configuration, the mounting clevis271and pivot members273are configured to retain the handlebars270in the stowed and operating positions via a frictional fit.

In one configuration shown inFIGS. 24-30, generator20may include a lifting bar280transversely mounted to top horizontal members105and109of generator frame28. Each end282of the lifting bar280may be configured to engage a frame horizontal members105and109, which may be secured thereto with mounting fasteners281such as without limitation threaded fasteners and nuts. Other suitable means may be used to mount the lifting bar280to frame28, such as welding, soldering, rivets, etc. The lifting bar270extends under and is not operably connected to front handlebar250so as to not interfere with the pivotable movement of the handlebar. In one construction, lifting bar280may have a tubular metal construction for strength. Lifting bar280may be substantially V-shaped in one configuration forming an apex which is raised above than top horizontal members105and109of frame28for grasping manually or with lifting equipment.

In an alternative configuration shown inFIG. 19A, the lifting member may be a lifting strap210which is attachable to a top portion of the frame28and spans between the lateral side frames100,101. The lifting strap may be formed of any suitable material including metal, polymeric high strength fibers, etc.

The generator frame28may be configurable to provide a power cord management system. As shown inFIGS. 17, 18A, 188, and 24-30, two or more outwards projecting cord wrapping poles200may be provided which are mounted on generator frame28to allow a power cord201to be wrapped around the poles for convenient storage. In one arrangement, the poles200are preferably mounted on the top24of the frame28and project vertically upwards, and more preferably in some arrangements may be mounted on top horizontal members105and/or109. Other suitable mounting positions of wrapping poles200and orientations (e.g. horizontal or vertical) may be used. The poles200may be configured for attachment to frame28by any suitable means including separately or in combination clamping, fasteners, rivets, adhesives, etc. In various exemplary configurations, the poles200may be mounted to top horizontal members105and109of frame28and/or front handlebar250. A transversely oriented flanged end202may be provided having a width greater than the diameter of the poles200to prevent the power cord201from slipping off the poles. The poles200may be made of any suitable material including metal or polymers.

According to another aspect of the generator20, a maintenance reminder kit including a maintenance reminder module290may be provided to track and alert an operator in real time to the maintenance related engine operating parameters requiring attention. This module290essentially takes the guesswork out of separately tracking when routine maintenance needs to be performed.FIGS. 31 and 32show two exemplary configurations of a maintenance reminder module290.

Maintenance reminder module290may comprise a microprocessor and appropriate electronic circuitry configured and operable to obtain, process, and display engine, electrical system, and/or auxiliary component maintenance-related operating information. In one configuration, maintenance reminder module290may communicate with the engine control system to download and process the desired operating parameter for extracting maintenance related data or information. In alternative or additional configurations, maintenance reminders may be initiated and based on engine run time and preprogrammed thresholds operating times or maintenance intervals for initiating each maintenance operation (e.g. change oil, air filter, etc.).

Module290may include a faceplate291including a display292, a maintenance indicator array293comprised of one or more condition indicator lights, and an operating button294. The faceplate291may be mounted proximate to and/or on an electronics housing295housing the electronic components of the maintenance reminder module290, or the faceplate may alternatively be mounted on one part of the generator frame28and the electronics housing may be mounted on another different part of the frame distanced from and not mechanically coupled to the faceplate. Alternatively, the electronic components of the maintenance reminder module290may be incorporated and housed with the engine control system components and the faceplate291may be mounted on the frame at a suitable location, thereby eliminating a need for a separate electronics housing295. The faceplate291may be mounted to generator frame28at any suitable location. In one non-limiting arrangement, the maintenance reminder module290may be mounted on control panel50.

Referring toFIG. 31, the indicator lights of the maintenance indicator array293may be illuminated buttons, bulbs, LEDs, etc. that include such maintenance-related alerts as without limitation “Change Oil,” “Change Spark Plug,” “Change Air Filter,” and “Add Oil” in this non-limiting example. When an engine operating condition associated with one of the foregoing maintenance parameters reaches a predetermined set point or level based on run time or actual monitoring of engine operation, the indicator will become illuminated until cancelled by pressing the operating button294, which may function as a reset button. The display292may be an LCD, LED, or other suitable type illuminated display showing for example and providing a digital readout of the total running time of the generator20(e.g. service hours) from initial purchase and operation of the unit. The control circuitry may be configured so that the total running time cannot be reset with button294. It will be appreciated that additional and/or other engine maintenance indicators may be used to alert an operator to a required maintenance condition.

FIG. 32shows a maintenance reminder module290in which the display292may provide a real time digital readout of a selected engine-related maintenance parameter. As opposed to alerting an operator when maintenance work may be immediately required, an operator can to track the status of maintenance related engine operating parameters to plan maintenance work in advance. The operating button294may be configured (in circuitry) to function as both a maintenance parameter select and a reset button. Repeatedly pressing button294sequentially cycles the display292through each maintenance parameter in a predetermined order. The indicator light associated with the maintenance parameter or information being displayed will be illuminated.

In one non-limiting exemplary configuration, the maintenance parameter tracked and displayed on display292may include “Power %” (available electric power), “Oil %” (remaining oil life), “Air Filter %” (remaining air filter life), “Spark Plug %” (remaining spark plug life, “Valve Adjustment %” (remaining valve adjustment life, and “Run hours” (total running time or service hours of the generator20from initial purchase and operation of the unit). Other or additional parameters may be tracked.

It will be appreciated that numerous variations of the maintenance indicator array293, maintenance indicators provided, and programmed functionality are possible.

Modular Generator Frame System

FIGS. 33-103depict various views of a portable generator398with modular generator frame system300. The frame system300may generally include a plurality of interconnected corner members320and connector plates340that collectively form an open space frame designated herein as generator frame301. The generator frame301is configured for mounting various components of a power generator, appurtenances, and accessories. In one configuration, generator frame301may support a permanent fuel tank360, a removable portable fuel tank380, engine311, handles318for lifting and maneuvering the generator, control panel400, and others appurtenances and accessories (e.g. tool holders, fire extinguisher holders, power cord wrapping poles, etc.) for forming a fully functional generator. Any suitable type of engine and fuel source may be used, including for example without limitation liquid fuels or gaseous fuels such as propane.

Generator frame301may include four lateral sides302, a top303, opposing bottom304and an open interior space305for housing the fuel tank360, engine311, and other accessories or appurtenances. The four lateral sides302may be joined together by four vertically extending corners306at the top303and bottom304of the frame. In one configuration, corners306may be disposed at a diagonal and oblique angle to the two adjoining lateral sides302as shown. Other corner configurations are possible.

Generator frame301may be considered to generally have the shape of a cube wherein the lateral sides302have a substantially similar height and width. The corners306may have a truncated shape in appearance created by the diagonal configuration of the corners. Accordingly, in one configuration, the generator frame301may appear to have an identical profile when viewed from either of the sides, the top, or the bottom. The diagonal corners306provide a generally octagonal shape (in top plan or side view) for generator frame301in one configuration.

The corner members320and connector plates340will now be described in greater detail with general reference toFIGS. 51-66. Each corner member320may include a central body321and one or more outwardly and radially projecting mounting tangs322cooperatively configured to engage locking elements on the connector plates340for assembling a complete frame301. Body321may be open in structure in one configuration defining a central opening323for weight reduction and to allow various appurtenances or accessories to be mounted and positioned therein and therethrough. The central opening323may have a complementary configuration to the perimeter shape of the central body321, or alternatively a different shape.

In one non-limiting example, body321may be generally triangular shaped with truncated corners forming six integral short and long segments as shown defining a three-sided corner structural element. The short segments324may be disposed adjacent a connector plate340at each corner region and the long segments325having a longer length span between two short segments324. The short and long segments324,325may have any configuration including polygonal and/or non-polygonal shapes. The short segments324define mounting portions341which include radially extending mounting tangs322for coupling to a connector plate assembly comprising a pair of coupled connector plates340, as further described herein. In one configuration, as shown, each corner member320includes three mounting portions341and mounting tangs322which may each be arranged approximately 120 degrees apart about a common center point327defined at the geometric center of the corner member body321. Each mounting tang322defines a mounting axis330which intersect at the common center point327of body321; the mounting tangs extending radially outwards from the center point along the mounting axis.

Mounting tangs322may have an elongated shape. The mounting tangs322include a free end325configured to lockingly engage a connector plate340and a fixed end326attached to or integrally formed with central body321of the corner member320. In one construction, without limitation, mounting tangs322may be integrally formed with body321as part of a single unitary structural unit that may be bent or otherwise formed into the shape shown. In one arrangement, mounting tangs322are obliquely disposed at an angle A1with respect to the corner member body321. This allows the creation of angled corners for the generator frame301in which the central body321of corner members320are disposed at an angle A1between 0 and 90 degrees to the connector plates340when mounted on the mounting tangs322. In some non-limiting examples, A1may be about 45 degrees.

For convenience of reference, the shape and features of generator frame301may be further described with respect to a three-dimensional X-Y-Z Cartesian coordinate reference system (see, e.g.FIGS. 33, 36, and 38). The reference system includes X, Y, and Z axes and defines an X-Y, X-Z, and Y-Z reference planes.

The central body331of the corner members320may form four generally flat diagonal corners306of generator frame301each laying in a plane P1that may be disposed at angles A2and A3with respect to both the X-Y and Y-Z reference planes. In one non-limiting configuration, angles A2and A3may each be between 0 and 90 degrees. In some non-limiting examples, angles A2and A3may be about 45 degrees. In a similar manner, corner members320may further form four generally flat sloping top sides and corresponding bottom sides of generator frame301(extending in the X and Z directions) each laying in a plane P2that may be disposed at angles A4and A5with respect to both the X-Y and X-Z reference planes. In one non-limiting configuration, angles A4and A5may each be between 0 and 90 degrees. In some non-limiting examples, angles A4and A5may be about 45 degrees.

In one exemplary construction, corner members320including central body321and mounting tangs322may be formed from a single generally flat plate or sheet. Corner member320may therefore comprise a single unitary structural component. The corner members320may be made of suitable metal material having sufficient mechanical/structural strength and thickness, such as without limitation aluminum, steel, or other metallic materials. In one example, without limitation, corner members320may be made of aluminum sheet material having a thickness ranging from about and including 0.125 inches to 0.625 inches. In one example, without limitation, the thickness without limitation is about 0.125 inches. Corner members320may be made by any suitable fabrication process or combination of processes, including for example without limitation die-stamping, bending, casting, forging, machining, milling, drilling, etc.

Referring toFIGS. 51-58, connector plates340may have an axially elongated and generally flat body including an axial centerline348, an outer surface348, inner surface349, opposing ends350, and opposing lateral sides351. Axial centerline348aligns with mounting axis330defined by mounting tangs322when the corner members320and connector plates340are assembled. When assembled, a pair of connector plates340may be coupled together with opposing inward facing inner surfaces349covering opposing outer and inner surfaces331,332of the mounting tangs of corner members320. Connector plates340may have a lateral width W1and axial length L1larger than the width. The lateral sides351may have any shape (in top plan view), including straight, convex, concave, angled, and others.

The corner members320and connector plates340may each include mutually configured and mating mechanical interlock features to form a strong, mechanically coupled generator frame301. The interlock features may include a lateral interlock feature and an axial interlock feature.

In one non-limiting example to form a lateral interlock feature, the connector plates340may include lateral locking tabs343configured to engage complementary configured lateral locking recesses328formed in lateral sides333of the mounting tangs322of each corner member320. The locking tabs343may project inwardly on the connector plates340towards and in a direction transverse to an axial centerline348defined by the connector. In one configuration, two locking tabs343may be provided. Locking tabs343may be offset from axial centerline348. In one configuration, locking tabs343may be integrally formed as unitary parts of opposing raised peripheral portions347formed on the inner surface349of connector plates340. Each raised portion347projects above the inner surface and is axially elongated extending for a distance parallel to centerline348. In one exemplary configuration, raised portions347may each extend axially from a point proximate to an end350of the connector plate340to a point proximate to the midline M1of the connector plate340(M1being defined as lying across a point midway between opposing ends350and dividing the connector into two halves). Accordingly, raised portions347may be arranged asymmetrically with respect to the midline M1of the connector plate340being on either one half or the other.

In some examples, locking tabs343may be formed alone on connector plates340without raised peripheral portions347. It will further be appreciated than in additional or alternative examples, the lateral locking tabs343may instead be formed on the lateral sides of the mounting tangs322and locking recesses328may instead be formed in raised portions347on connector plates340providing a reverse construction. In either construction described herein, these lateral locking features assist with preventing axial withdrawal of the mounting tangs322from the connector plates340without disassembly of the inner and outer connector plates340.

The peripheral raised portions347and lateral locking tabs343collectively define a pair of inward facing and opposing bearing surfaces342engaged with mounting tangs322. The bearing surfaces342may have a complementary configuration to the peripheral shape of corner member mounting tangs322. This in turn further defines a mounting cavity335on the inner surface349of each connector plate340having a complementary configuration to the perimeter of mounting tangs322. The mounting tangs322substantially fill the cavity335when mounted therein, thereby forming a mating and interlocked keyed fit between the connector plates340and corner members320.

In one non-limiting example to form an axial interlock feature, the connector plates340may further include locking protrusions345arranged to engage complementary configured end locking recesses329formed on the mounting tangs322. The locking recesses329may be disposed and formed in the free ends325of the mounting tangs322and face outwards away from body321and center point327. In one arrangement, the locking protrusion345may be formed on inner surface349of connector plate340projecting outwards from and perpendicular to the inner surface in a direction transverse to the axial centerline348. The locking protrusions345may be aligned on the axial centerline348of the connector plates340in one exemplary arrangement as shown. In other possible arrangements, the locking protrusions may be offset from the centerline348.

Locking protrusions345may have a shape (in top plan view of inner surface349of connector plate340) that is configured to help resist axial withdrawal of the corner member mounting tang322in cooperation with the complementary shape of the end locking recesses329. In some examples, locking protrusion345may have a non-rectilinear polygonal shape. In one example, the locking protrusions345and locking recesses329may have a trapezoidal shape. In addition to preventing axial and sliding withdrawal of a mounting tang322from the connector plate340, the locking protrusions345help maintain the mounting tangs in proper position on a first connector plate until the second connector plate may be mounted thereto using fasteners352as described herein. This keeps mounting holes346and334in concentric alignment to permit insertion of the fasteners through the mounting tangs322and both connector plates.

The connector plates340may extend between and be operable to mechanically couple a spaced apart pair of corner members320together on the frame301. In one possible arrangement, a pair of connector plates340may be mounted back-to-back with the foregoing interlock features described herein on each connector facing inwards towards each other for linking the pair of corner members together. In one configuration, one of the connector plates340may be arranged opposite to and inverted 180 degrees in longitudinal orientation to its mating connector on the opposite side of corner member mounting tang322. In these foregoing positions, therefore, one each of the connector plates340may be placed on opposite sides of the mounting tang322of the corner member320, thereby trapping the mounting tang between the connector plates. It should be noted that the locking protrusion345on one connector plate340will actually be located between the raised portions347of the opposite connector plate340, and vice-versa. The mounting tangs322may be considered to form a male fastening element and the two assembled connector plates340a female fastening element configured to receive the male element at least partially therein.

To secure each connector plate340together on the mounting tang322of corner member320, one or more fasteners352may then be inserted through mounting holes334and346formed in the mounting tangs and connector plates, respectively. In one arrangement, each connector plate340includes two mounting holes346and each mounting tang322includes one mounting hole334. These holes334,346become concentrically aligned when the connector plates and tangs are positioned together on each side of the mounting tang322. Any suitable fasteners352may be used, including as an example without limitation threaded fasteners (e.g. bolts, screws, etc.) with mating nuts for detachable securement thereby allowing the frame to be easily assembled and disassembled. In one arrangement, two fasteners352may be provided for each corner member mounting tang-connector assembly322/340. One fastener352each may be located proximate to each end350of the connector plate340. In other possible examples, the connector plates340may be more permanently joined together with the mounting tang322trapped between them such as with rivets, welding, soldering, etc.

The connector plates340may be made of any suitable material having sufficient strength, stiffness, and thickness to form a substantially rigid structural member which resists bending and deflection without the application of undue force. In some non-limiting examples, the connector plates340may each be made of metal, such as without limitation aluminum, steel, or other. In one non-limiting exemplary construction, the connector plates340may be made of die-cast aluminum. In one example, each connector plate340may have a thickness ranging from about and including 0.125 inches to 0.625 inches. In one example, without limitation, the thickness may be about 0.25 inches. Connector plates340may be made by any suitable fabrication process or combination of processes, including for example without limitation die-stamping, bending, casting, forging, machining, milling, drilling, etc.

In one configuration, the outer surface348of the connector plates340may include an anti-rotation element353which cooperates with an accessory clip354attachable to the plate. Referring toFIG. 65, the anti-rotation element353may be a rectilinear recess359in one configuration which engages a mating rectilinear mounting protrusion355formed on the clip354to prevent rotation of the clip with respect to the connector plate340. The clip protrusion355engages the walls formed around the recess to prevent twisting of the clip. The recess359may be disposed and formed around the mounting holes346on the connector plate340such that the holes extend through plate into the recess. In one exemplary configuration therefore, the accessory clips354may detachably retained on the connector plates340by the same fastener352used to secure the plates to the mounting tangs322of the corner members320via a through holes357formed in the clip.

In one possible configuration, the accessory clip354may include a pair of lateral extensions358each containing attachment apertures356of any suitable shape configured to engage a mounting feature of the accessory (e.g. straps, clips, fasteners, etc.). The lateral extensions358may be oriented 180 degrees apart and project laterally in opposing directions from the clip mounting protrusion355and fastener352in one arrangement. The accessory clip354may be formed of metal such as aluminum, steel, titanium, etc. as some non-limiting examples for strength. It will be appreciated that the accessory clips354and attachment apertures356may have numerous possible configurations and shapes depending the design of the accessory to be attached.

The corner members320and connector plates340advantageously allow a light-weight generator frame to be shipped in an unassembled “knock down” condition to reduce packaging size requirements and shipping costs. The frame may then be assembled at the final destination which may be a point of sale, job site, or other. In addition, the modular frame system disclosed herein provides the opportunity to customize the frame and generator system in various ways to meet the end user's preferences.

An exemplary method for assembling a generator frame will now be described. The method may begin by providing a kit including a plurality of corner members320each having three mounting tangs322, connector plates340, and fasteners such as threaded fasteners352. Two corner members320and two connector plates340may first be selected from the kit, or alternatively may be selected separately later during the assembly process. A mounting tang322of a first corner member320may be positioned on and abuttingly engaged with the inner surface349of a first connector plate340. More particularly, the mounting tang322may be positioned and inserted into the complementary configured mounting cavity335of the selected first connector plate340. The first connector plate340may be located on a flat work surface to facilitate assembly.

A mounting tang322of a second corner member320may then be positioned on and abuttingly engaged with the inner surface349of the first connector plate340opposite the half having the mounting cavity335and mounting tang322of the first corner member320already in position. The locking protrusion345of the first connector plate340may be inserted into the end locking recess329in the mounting tang322of the second corner member320during placement of the tang.

With mounting tangs322of the first and second corner members320positioned on the first connector plate340, the second connector plate340is selected and positioned over the first connector with the inner surface349facing the inner surface349of the first connector. The second connector is rotated and inverted in orientation with respect to the first connector so that the mounting cavity335lies on an opposite half of the second connector than on the first connector. While maintaining this position, the second connector plate340is placed against the mounting tangs322of both the first and second corner members320already engaged with the first connector plate340as described above. The mounting tang322of the second corner member320may be positioned on and abuttingly engaged with the inner surface349of the second connector plate340. More particularly, the mounting tang322may be positioned and inserted into the complementary configured mounting cavity335of the second connector plate340.

The mounting tang322of a first corner member320(already inserted in the mounting cavity335of the first connector plate340) may be positioned on and abuttingly engaged with the inner surface349of the second connector plate340opposite the half having the mounting cavity335. The locking protrusion345of the second connector plate340(facing inwards) may be inserted into the end locking recess329in the mounting tang322of the first corner member320during placement of the tang. The mounting tangs322of the first and second corner members320are now clamped and trapped between the first and second connector plates340positioned on opposite sides or faces of the mounting tangs. To complete the connection, a fastener352is inserted through each of the two mounting holes342in the first and second connector plates340and through the mounting holes334of the first and second corner member mounting tangs322and secured with a threaded nut. The first and second corner members320are now mechanically coupled together.

To complete assembly of a full generator frame301, additional corner members320are then mechanically connector to each of the remaining two mounting tangs322of the first and second corner members in a similar manner to that described above. The foregoing process is repeated until a total of eight corner members320are interconnected using additional connector plates340and fasteners352. The completed and assembled frame is shown for example inFIG. 41-50depicting the completed frame only (without engine and appurtenances) for clarity.

It will be appreciated that generator frame301may partially assembled during the assembly process to provide greater access for mounting individual components thereon. For example, the bottom half of the generator frame301may be assembled and then the motor mounted on the motor support. The top half of the generator frame301may be assembled separately and then the permanent fuel tank360, control panel400, etc. can be mounted. The bottom and top halves may then be joined together via the four vertical connector plates340. Numerous assembly variations are possible to maximize access and speed for assembling the complete generator. Advantageously, an assembled generator frame may be readily dismantled partially or completely to replace engine or other components, or to add accessories by simply removing fasteners352from the appropriate connector plates340.

Referring toFIGS. 67-82, the permanent fuel tank360includes a top361, bottom362, lateral sides363extending between the top and bottom, and corners367extending between adjacent sides. The upper portions of lateral sides363may be downwardly sloping or angled in one configuration to complement the orientation of the connector plate340assemblies disposed laterally adjacent to the sides in the generator frame301. In some configurations, adjoining lower portions of lateral sides363below the sloped upper portion may be vertically oriented. Corners367extend between adjacent lateral sides363and may be configured to complement the orientation of corner members320disposed laterally adjacent to the fuel tank corners367in the generator frame301. Corners367may be may be arranged on a diagonal (i.e. angled between 0 and 90 degrees) with respect to the adjacent lateral sides363. In one configuration, fuel tank corners367may be downwardly sloping or angled defining an outward and upward facing flat diagonal surface368. Fuel tank360may have a shape selected to maximize volumetric storage capacity while conforming at least part to the angular or sloping shaped parts of the generator frame301where the fuel tank is mounted. In one non-limiting configuration, fuel tank360may have an octagonal shape in top plan view. Other suitable shapes may be used.

The permanent fuel tank360may further include a fill spout373disposed on one of the four corners367and a removable closure cap374. Cap374may be configured to threadably engage the spout373which may be externally threaded.

In one configuration, fuel tank360may include a recessed well364formed in the top361of the fuel tank for removable storage of a portable fuel tank380. The well362may be complementary configured with the shape of the portable fuel tank380(in top plan view) to form a nested fuel tank arrangement. The portable fuel tank380and cooperative mounting with permanent fuel tank360is further described herein.

Fuel tank360may be made of any suitable material approved for the storage of liquid fuel. In example, the fuel tank360may be made of a fuel-grade molded plastic material. Other suitable materials including metal may be used.

Fuel tank360may be mounted to any suitable part of generator frame310. In one arrangement, the fuel tank360may be mounted near the top303of generator frame301and extends horizontally across the frame between all four lateral sides302substantially filling the upper third of the interior space305of the frame. The fuel tank360may extend from a location inside of and proximate to each of the four horizontal connector plates340that form the top half of the generator frame301. In one arrangement, the top361of fuel tank360may be flush with or slightly recessed below the top303of the generator frame301for protection. Accordingly, the fuel tank360may not protrude substantially above generator frame301, if at all in some configurations.

In one arrangement, permanent fuel tank360may be mounted to and suspended from generator frame301at the corner locations of the generator frame301, and more particularly near the top portions of the corners306at top corner members320. The flat diagonal surface368at corners367may include a mounting element371comprised of a threaded recess369and centrally-located cylindrical protrusion370disposed therein. Recess369and protrusion370may each be circular in one configuration. A circular depression372may be formed in corner367around recess369in some configurations, for reasons described elsewhere herein.

To mount the permanent fuel tank360, a fuel tank mounting assembly comprised of a corner cap430and fuel tank fastener420may be provided. Referring toFIGS. 89-102, the corner cap430of the assembly may have a generally truncated triangular shaped body comprising three radially extending wings440to complement the shape of corner members420to which the cap may be attached. The wings440may further be slightly arcuately shaped in an inwards direction to complement the contour of the corner members320to which they are mounted. Corner cap430includes an outer surface431, opposing inner surface432, lateral sides437, raised plateau protuberance434disposed on the inner surface, and a centrally located through hole433. In one configuration, protuberance434has a peripheral shape selected to complement the peripheral shape of central opening323and is insertable into the opening for securing the corner cap430to the corner member320. Protuberance434and central opening323may therefore have a generally triangular shape. The protuberance434prevents the cap430from rotating with respect to corner member320via mutual engagement between the polygonal-shaped sides of the protuberance with mating surfaces surrounding the central opening323of the corner member. The hole433may be configured to insert the shank of fastener420therethrough for engaging a mounting element371on fuel tank360, as further described herein. A diametrically enlarged and inwardly protruding boss433may be formed around the hole433on the raised plateau-shaped protuberance434which may be configured for insertion into the depression372formed on the fuel tank corners367. The interaction and engagement of the boss433with depression372helps align and center the corner cap430on the corner member320to align hole433with threaded recess369to facilitate proper insertion of fastener420.

The fuel tank fastener420may include a head421and threaded shank422. In one configuration, shank422may be generally cylindrical in shape having one end423adjoining head421and a substantially flat terminal end424to preclude the possibility of puncturing fuel tank360. In one arrangement, terminal end424may include an open circular socket425configured for receiving cylindrical protrusion370of the fuel tank mounting element371when the tank is mounted to the generator frame301. It will be appreciated that in alternative examples, both socket425and protrusion370may be omitted wherein the threaded shank is solid and engages mating threaded recess369on the fuel tank360.

The exposed outer surface426of head421may include an operating feature428configured for engaging a mutually configured working end of a tool or key used to rotate the fuel tank fastener420. Any suitably shaped operating feature428and tool may be used.

The process for mounting the permanent fuel tank360to generator frame301will now be briefly described. In one example, without limitation, the fuel tank360may be mounted to the generator frame301using mounting element371at three corner members320to prevent twisting of the tank with respect to the generator frame. It will be noted that the remaining corner member420includes provisions for the fuel tank spout373and cap374. Fuel tank360is positioned inside the top303of frame301, as shown for example inFIG. 74. At one corner, the corner cap430may be positioned on the corner member320to insert protuberance434into central opening323of the corner member. Boss433on the inside of cap430is inserted into depression368on the fuel tank360. Hole433in cap430is concentrically aligned with threaded recess369on fuel tank360. Fuel tank fastener420is inserted through corner cap430(i.e. hole433) and rotated to engage threaded shank422with mating threaded recess369on the fuel tank. The fastener420is rotated and tightened which draws the tank360and cap430together along the centerline axis of the fastener shank422with the corner member320being interspersed in between. The cap430is compressed against the outer surface of the corner member420between the head421of fastener420and corner member and the fuel tank corner367on the interior of the generator frame301. In one configuration, without limitation, the outer surface431of the corner cap430may include a recess438formed around hole433and the fastener head421may be seated in the recess and substantially flush with the outer surface431. In other configurations, the fastener head421may protrude above the outer surface431of the corner cap430either with or without a recess438if provided.

In one example, corner cap430and fuel tank fastener420may be formed of a suitable strength plastic material in addition to the fuel tank360and corner mounting elements371. Accordingly, a metal-free fuel tank mounting system may therefore be provided. This arrangement advantageously reduces weight and minimizes or eliminates interaction of the plastic fuel tank with metal edges to reduce wear or puncture of the tank.

Referring toFIGS. 41, 42, 46, and 48, the corner cap430associated with the fill spout373and closure cap374of the permanent fuel tank360may include a diametrically enlarged circular fill spout opening439configured to receive the fill spout. The fill spout373may project outwards through the opening439and the closure cap374is attached to the fill spout373at the exterior of the corner cap374. In one configuration, the fill spout373may be configured to engage and retain the corner cap430in position on the generator frame301. In one non-limiting example, the fill spout373may include secondary external threading to attach the corner cap430. It will be appreciated that the fuel spout corner cap430may be configured similarly to the corner caps430described above associated with mounting the permanent fuel tank360with exception of the larger central fill spout opening439in lieu of the smaller fastener hole433and boss435.

According to another aspect of the generator398, a removable portable fuel tank may optionally be provided that is configured for detachable mounting in the modular generator frame system300. The portable fuel tank380advantageously extends the volumetric capacity and runtime of generator398. The fuel tank380may be configured for detachable coupling to the generator398so that the fuel tank380may be dismounted and removed without undoing fasteners or other mechanical coupling devices. This allows rapid change-out of portable fuel tanks in the modular generator frame system300. In one configuration, as described below, the portable fuel tank380may be configured for mounting directly to and is supported by the permanent fuel tank360.

Referring toFIGS. 83-88, the portable fuel tank380includes a top381, bottom382, lateral sides383extending between the top and bottom, and corners384extending between adjacent sides. In one configuration, the sides383may be substantially flat. Corners384may be may be arranged on a diagonal (i.e. angled between 0 and 90 degrees) with respect to the adjacent lateral sides383defining a flat diagonal surface392. Fuel tank380may further include a compact handle385formed integrally with the body of the tank. In one example, a lateral portion of the handle may form one of the four lateral sides383of the fuel tank and an angled portion may form at least in part one of the corners384. This arrangement provides a handle without substantially altering the octagonal configuration or size of the fuel tank380.

The removable portable fuel tank380may further include a fill spout386for refilling the tank and a closure cap387threadably engaged with the spout. In one configuration, the fill spout386may be disposed on one of the four corners384of the fuel tank380. The corner384having the fill spout386may be configured and dimensioned such that the fill spout and cap387when in place do not extend laterally beyond either adjacent lateral side383to maintain a substantially uniform perimeter dimension and profile for insertion into the well364of the permanent fuel tank360.

Portable removable fuel tank380may further include a fluid coupling391allowing the tank to be fluidly connected to the permanent fuel tank360. Advantageously, the provides the permanent fuel tank360with two potential refueling connections and options. In one configuration, the fluid coupling may include an assembly comprising a tubular outlet nozzle389fluidly connected to a one-way valve388. Valve388may be configured to allow liquid fuel to flow outwards from the portable fuel tank380to permanent fuel tank360, but not to re-enter in a reverse direction back through the nozzle389. The nozzle389and valve389may be disposed in the bottom surface on the bottom383of the portable fuel tank380. In one arrangement, nozzle389may be located in the geometric center of the portable fuel tank380. To protect the nozzle389from damage during transport and refilling, the nozzle may be disposed in a recess390formed in the bottom383of the fuel tank380. Nozzle389may therefore be configured to not protrude above the bottom surface on the bottom382of the fuel tank380. The recess390may be circular in shape in one non-limiting configuration; however, other shapes may be used. Nozzle389and valve388may be formed of plastic in one construction or a combination of plastic and metal.

The outlet nozzle389of portable fuel tank380may be configured and operable to engage a mating fluid coupling365formed in the top361of the permanent fuel tank360to place the two tanks in fluid communication for transferring fuel from the portable tank to the permanent tank. In one configuration, fluid coupling365may comprise a raised tubular inlet coupling366which projects upwards from the recessed flat surface portion of the top361of fuel tank360inside the well364. Coupling366may be tubular shape. The coupling366and outlet nozzle389of the portable fuel tank380may be cooperatively configured and arranged so that the nozzle389may be inserted into the coupling. Accordingly, the inlet sleeve366may have an internal diameter sized slightly larger than the outer diameter of the outlet nozzle389. In one configuration, outlet nozzle389and inlet sleeve366are cooperatively configured to allow the nozzle to be axially and slidably inserted into the sleeve. In operation accordingly, the portable fuel tank380may be axially inserted downwards into the open top well364of the permanent fuel tank360. This motion would slidably insert outlet nozzle389into inlet sleeve366thereby fluidly coupling the portable and permanent fuel tanks380and360together. This allows the contents of portable fiel tank380to be transferred via gravity to the permanent fuel tank360. Advantageously, the total volumetric fuel capacity of generator398is therefore increased by providing one or more portable fuel tanks380which can be interchanged.

The portable fuel tank380may have a volumetric capacity of at least 10% of the permanent fuel tank360. For example, in one representative non-limiting example, the permanent fuel tank360may have a capacity of about 11 gallons and the removable portable fuel tank380may have a capacity of about 2 gallons. Any suitable permanent and portable fuel tank capacities may be used.

Referring toFIGS. 36 and 40, the generator control panel400may include an emergency stop push button401which functions as a single readily accessible kill switch to stop the engine. In one example, the stop button401may be generally circular in shape. In one arrangement, the stop button401may be disposed in the center of a rotary operating dial402configured and operable to change the operating state of the motor (e.g. fuel, choke, run, start, etc.) to simplify the starting sequence. The push button401is actuated by depressing the button inwards towards the control panel400.

Referring toFIGS. 39, 40 and 103, the generator frame301may include a motor mount bracket410configured for attaching the motor mounts414of engine311. In one configuration, the motor mount bracket410may be an elongated and structurally stiff element formed of a suitable metal having two opposing mounting ends411configured for attachment to opposing connector plates340on the bottom of the generator frame. Bracket410may include a center section412extending between the ends411having a substantially horizontal position when attached to generator frame301for positioning and mounting the engine311thereon. The center section412may include spaced apart mounting holes413(e.g. two, four, etc.) configured for receiving threaded motor mounts of engine311therethrough having a matching layout pattern.

The mounting ends411of bracket410may be configured to engage the connector plates340and the same fasteners352used to connect each pair of connector plates together. Accordingly, in one arrangement the ends411may each include two attachment holes415for engaging both fasteners352of each opposing connector plate assembly. The ends411may have a substantially flattened shape and be upturned at an angle or slope complementary to the angular or sloped orientation of the connector plates340to which the bracket410is attached. The bracket410may bridge or span between the connector plates340without any interim supports. In one configuration, the center section412of the motor mount bracket410may have an elongated opening416for weight reduction. The bracket410may have any suitable cross-sectional structural shape which may be uniform or varied between the mounting ends411. In non-limiting exemplary constructions, the motor mount bracket410may be made of aluminum or steel.

Gaseous Fuel Power Generators

FIGS. 104-108illustrate some non-limiting examples of portable generators for producing electric power which may be fueled by one or more gas canisters or cylinders containing a compressed liquid fuel, which changes to gaseous phase when released from the containers. In one non-limiting example, the fuel source may be propane. The canisters or cylinders may be interchangeably/replaceable in design or permanent refillable type gas containers in various examples. The generators shown may include an engine configured to operate on a gaseous fuel source and include all related appurtenances and accessories necessary for a fully functional generator system (e.g. alternator, electrical system, pressure regulators, relief valves, controls, electrical outlets, etc.).

FIG. 104depicts a non-limiting example of a portable generator configured in the form of a backpack. In one configuration, without limitation, the backpack generator500may be fueled by one or more gas replaceable gas canisters502. The canisters502may be standard 16 ounce propane canisters in one example. The external housing504of the backpack generator may be formed at least in part from a soft cover material in one configuration made from NFPA rated fire resistant materials (e.g. fabric, etc.), and may have any suitable shape. In some constructions, the housing504may be formed from hard materials such as plastic or a combination of soft and hard materials. The backpack generator500may include two padded shoulder straps506, one or more electrical outlets508, engine510configured and designed to operate on gaseous fuel, alternator511, pressure regulators512, recoil manual start mechanism514, and other appurtenances and accessories for a fully functional generator system.

FIGS. 105-108depict various non-limiting examples of “suitcase” style compact portable generators520fueled by one or more gas canisters or cylinders containing a compressed liquid fuel such as propane. Multiple gas canisters502or larger cylinders522can be used to extend the run time of the generators. The gas canisters502may be standard 16 ounce replaceable propane canisters. In one non-limiting example shown inFIG. 107, a single larger replaceable or permanent refillable gas cylinder522(e.g. 5 pound or other) may be used. The gas canisters502or cylinder(s)522may be partially or completed contained in an outer case524which may include a carrying handle526in some examples. One or more pressure regulators512may be provided for each generator. The generator520shown inFIG. 106may include a gas-fueled folding pivotable cooking range521which can be deployed to provide the ability to both cook with gas and produce electric power. The range521may be fueled by the gas canister(s)502or cylinder(s)522.

The compact generators520each include an engine (not shown) configured to operate on gaseous fuel which may be mounted inside the outer case524. The engine may be similar to the engine510shown inFIG. 104or different.

In various configurations of the liquid or gaseous fueled generators disclosed herein, it will be appreciated that the power generation units may be configured as either a conventional generator (i.e. drawing AC electric power directly off the wire coil) or an inverter generator (i.e. transforming electric power off the coil into DC power and then back into AC).

While the foregoing description and drawings represent some example systems, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. In addition, numerous variations in the methods/processes. One skilled in the art will further appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed examples are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims and equivalents thereof, and not limited to the foregoing description or examples. Rather, the appended claims should be construed broadly, to include other variants and examples of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.