Horizontal Shaft Electric Powerhead for Engine Replacement

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Solution Overview

Problem

Existing outdoor power equipment relies on small internal combustion engines, which are inefficient and environmentally harmful, lacking a compact and efficient electric power solution that can replace these engines effectively.

Innovation Solution

The development of a horizontal shaft electric powerhead with a 2,500 watts or fewer electric motor, coupled with a lithium-ion battery system, housed in a compact form factor that matches the volume of a comparable small internal combustion engine, allowing for direct replacement and integration with existing outdoor power equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If small internal combustion engines are used to power outdoor equipment, then sufficient power and torque are achieved, but environmental harm increases and efficiency decreases

Engineering Contradiction:

ImproveemissionsVSAvoidefficiency

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by moving object

Solution Approach 1:

The patent replaces the internal combustion engine (mechanical/thermal system) with an electric motor system. The electric motor converts electrical energy directly to mechanical energy, eliminating combustion processes that produce harmful emissions. This substitution maintains the power output capability while removing the source of environmental pollution and improving energy efficiency through direct electromagnetic conversion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the energy source parameter from chemical energy (fuel combustion) to electrical energy (battery power). This fundamental parameter change transforms the power generation mechanism, allowing for zero-emission operation and higher energy efficiency by eliminating thermal losses associated with combustion engines.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If electric motors are designed to replace internal combustion engines, then environmental friendliness improves, but maintaining the same volume and form factor becomes challenging

Engineering Contradiction:

ImproveemissionsVSAvoidpowerhead volume

Core Design Contradiction:

Object-affected harmful factorsVSVolume of moving object

Solution Approach 1:

The patent integrates the battery pack, motor controller, and electric motor into a nested compact assembly. The battery cells are arranged in a space-efficient configuration within the housing, with the motor and control electronics integrated into the same volume. This nesting approach allows the entire electric powerhead to fit within the volume constraints of traditional small engines while providing sufficient power output.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent employs a horizontal shaft configuration for the electric motor, which changes the spatial orientation of the power output. This dimensional reconfiguration allows for more efficient space utilization within the housing, enabling the motor to deliver power in a direction that matches traditional engine mounting patterns while maintaining a compact overall volume.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If the electric powerhead uses a horizontal output shaft configuration, then compatibility with existing equipment mounting patterns is achieved, but the battery and motor integration becomes more complex

Engineering Contradiction:

Improvemounting compatibilityVSAvoidintegration complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent designs the electric powerhead with a horizontal output shaft that replicates the mounting interface and dimensional characteristics of traditional small internal combustion engines. This universal design allows the electric powerhead to directly replace conventional engines in existing outdoor equipment without requiring modifications to mounting brackets, drive shafts, or associated components, thereby achieving broad adaptability across different equipment applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This solution provides a compact, efficient, and environmentally friendly alternative to small internal combustion engines, offering comparable power and torque while reducing emissions and operational costs.

Implementation Method 1

a battery including a plurality of lithium-ion battery cells, the battery coupled to the electric motor

Methodology Applied

Scientific EffectBattery (electricity): Battery (electricity)

Implementation Method 2

an electric motor with a horizontal output shaft configured to rotate about a horizontal axis of rotation

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12328055B2Electric powerhead

Publication Date: 2025.06.10 BRIGGS & STRATTON CORP

AI summary

An electric powerhead includes an electric motor including an output shaft configured to rotate about an axis of rotation, a battery including a plurality of lithium-ion battery cells, the battery coupled to the electric motor, a housing having a cross-sectional footprint substantially the same as 174.5 in2, and a base plate configured to be fastened to a mounting surface, the base plate including a plurality of openings arranged in an engine support pattern.