Crankless Miniature Engine With Spring Energy Storage
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Solution Overview
Problem
Existing portable power generation technologies for remote locations are either heavy, noisy, inefficient, or unsuitable for frequent movement, and they struggle to provide continuous power with low-volatility fuels without complex fuel injection systems.
Innovation Solution
A miniature internal combustion engine (MICE) generator with a two-cycle operation, using a multi-helix spring for lateral stability, an alternator coil within a magnetic core, and a temperature-regulating assembly to maintain a predetermined temperature range, allowing for a close-tolerance ringless seal and self-lubrication, along with a preheater for low-volatility fuel use and sound dampening to reduce noise and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional fuel-powered motor-generators are used, then power generation capability is achieved, but weight and portability deteriorate
Solution Approach 1:
The engine is divided into separate functional modules: a two-stroke crankless engine for power generation, a spring mechanism for energy storage and delivery, and an alternator for electrical conversion. This segmentation allows each component to be optimized independently, reducing overall weight while maintaining power generation capability.
Solution Approach 2:
The patent replaces the traditional crankshaft-mechanical connection with a spring-based energy storage system coupled to an alternator. This substitution eliminates the need for heavy crankcase structures and mechanical linkages, significantly reducing weight while preserving the ability to deliver peak power.
2Power
If traditional motor-generators are used, then power output is achieved, but noise and portability deteriorate
Solution Approach 1:
The patent extracts and eliminates the noisy crankshaft mechanism from the system. By using a crankless two-stroke engine design with direct spring-alternator coupling, the primary source of mechanical noise and vibration is removed, achieving quiet operation while maintaining power output.
3Power
If battery assembly is used for peak power, then power availability is improved, but weight and size increase
Solution Approach 1:
The patent replaces the electrical battery-based peak power solution with a mechanical spring energy storage system. The spring absorbs and releases energy mechanically, providing peak power capability without the weight and size penalties of large battery assemblies required for automotive hybrid systems.
4Manufacturing precision
If close-tolerance ringless seal is used, then manufacturing precision is improved, but reliability deteriorates due to thermal expansion
Solution Approach 1:
The patent intentionally designs the piston with a deliberate clearance gap that accounts for thermal expansion. The piston is made slightly smaller than the cylinder bore, creating a thermal expansion compensation mechanism that maintains reliable sealing across temperature variations without requiring tight manufacturing tolerances.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The MICE generator provides a fuel-efficient, quiet, and portable power solution capable of generating 500 W to 2 kW of continuous electrical power, tolerant of dust and low-grade fuels, with reduced noise and vibration, suitable for field applications.
Implementation Method 1
The spring is constructed using a multiple-helix design for increased lateral stability, thereby reducing scoring
Implementation Method 2
reduced noise and vibration
Implementation Method 3
an alternator coil within a magnetic core
Implementation Method 4
maintain a post-startup, steady state operating temperature of the casing adjacent to the piston within a predetermined temperature range that optimizes a fit between the piston and a cylinder wall
Implementation Method 5
a preheater for low-volatility fuel use
Implementation Method 6
sound dampening to reduce noise and vibration
Data Source
AI summary
This invention overcomes the disadvantages of the prior art by providing a power generating system particularly suitable for field use in remote locations, which is fuel-efficient, relatively quiet, tolerant of dust, capable of operating on low grade logistics and diesel-like fuels and capable of generating between 500 W and 2 KW of continuous electrical power. This generator employs a miniature internal combustion engine/generator (MICE) having a piston moving within a cylinder arranged for two-cycle operation, and an interconnected, axially arranged piston shaft that oscillates an alternator coil within a magnetic core. The piston shaft is opposed by a strong, multiple-helix spring. The cylinder head, in which the piston operates, is cooled by moving (electrically pumped) fluid in a cooling head, or by another heat-transfer mechanism. The MICE generator's intake arrangement includes a preheater heated by a heated fluid flow thereon. The MICE generator is vibration-isolated using a base that supports the MICE on a plurality of soft coil springs. The MICE generator is encased in an acoustic enclosure having a shell composed of sheet metal or another stiff material extending from the base plate and being covered by a top side. Holes in the enclosure top are covered by porous discs that allow exhaust gasses from the internal muffler to pass therethrough. The acoustic enclosure resides in a large, typically portable, external package enclosure.