Flex fuel field generator

Patent No. US9175601 (titled "Flex fuel field generator") on Jan 4, 2012. The application was issued on Nov 3, 2015.

What is this patent about?

’601 is related to the field of portable power generation, specifically focusing on small-scale internal combustion engines adapted for remote field operations. Traditional portable generators are often limited by their reliance on specific fuels like gasoline, their production of hazardous exhaust, and their inability to capture waste energy, making them inefficient for long-term off-grid use where logistical footprints must be minimized.

The underlying idea behind ’601 is the transformation of a standard generator into a multi-functional utility hub that produces not just electricity, but also potable water and thermal energy. By recognizing that hydrocarbon combustion produces water vapor as a byproduct, the invention utilizes a condenser mechanism to harvest liquid water from exhaust gases, effectively allowing fuel to serve as a dual-purpose resource for both power and hydration.

The claims of ’601 focus on a generator system equipped with a fuel selector and a manual choke configured to optimize combustion across diverse fuel types, specifically including rubbing alcohol and propane. The independent claims further define hardware configurations that integrate an exhaust-linked condenser, a heat exchanger with a dedicated pump and hosing for water heating, or a long flexible pipe for safe indoor venting.

In practice, the system leverages the chemistry of combustion to solve logistical hurdles in the field. Because the weight of water produced by the condenser is roughly equivalent to the weight of fuel consumed, operators can transport alcohol instead of water to reduce load. The manual choke adjustment is critical here; by restricting air intake to an intermediate position, the system allows standard engines to run efficiently on high-water-content fuels like 70% isopropanol that would otherwise cause stalling.

This approach differs from prior solutions by treating exhaust not as waste, but as a source of raw materials. While conventional generators focus solely on electrical output and require strict outdoor placement, this system uses flexible exhaust routing and catalytic conversion to enable safer operation near or inside shelters. It replaces the need for separate water purifiers and heaters by consolidating these functions into the engine's thermal management cycle.

How does this patent fit in bigger picture?

Technical Landscape

In the early 2010s when ’601 was filed, portable power generation for remote field operations was typically implemented using small-scale internal combustion engines designed for gasoline or propane. At a time when these systems commonly relied on high-volume fuel consumption and basic air-cooling, providing both electrical power and life-sustaining resources like potable water or heat was treated as separate logistical challenges requiring distinct equipment. Furthermore, hardware constraints in portable generator design made the safe indoor operation of such units non-trivial, as standard architectures lacked integrated mechanisms to manage thermal signatures or toxic exhaust byproducts beyond simple mufflers.

Prosecution Position

The disclosed invention represents a meaningful technical advancement through the architectural integration of resource recovery systems into a portable internal combustion generator. By incorporating a condenser and heat exchanger directly into the exhaust flow, the system achieves a dual-purpose technical effect: the generation of electricity is coupled with the simultaneous production of potable water and thermal energy from exhaust gases. This integration overcomes the technical constraint of logistical weight in remote operations by enabling a near 1:1 conversion of fuel weight to water weight. Additionally, the shift toward a modular exhaust management architecture—utilizing flexible piping, catalytic conversion, and unit-measure fuel adapters—enables the safe and efficient use of alternative fuels like rubbing alcohol in environments where traditional gasoline is unavailable or hazardous.

Claims

The patent includes a total of 23 claims, with claims 1, 10, and 14 serving as the independent claims. These independent claims focus on a generator system featuring an internal combustion engine with a manual choke and a fuel selector capable of optimizing operation for rubbing alcohol and propane, while incorporating various exhaust management components such as condensers, heat exchangers, or flexible piping. The dependent claims serve to add specific functional and structural details, including water management systems, safety sensors, catalytic converters, ventilation fans, fuel bottle adaptors, and timing controls to further refine the generator's operation and exhaust processing.

Key Claim Terms New

Definitions of key terms used in the patent claims.

Term (Source)Support for SpecificationInterpretation
Condenser
(Claim 1)
A water condenser may be attached to the exhaust, to reduce the thermal signature and condense and capture the water vapor as liquid water. Since the water is condensed from the gas phase, the water is clean and free of microorganisms, and is therefore potable. A water condenser functions as a heat exchanger, by removing heat from the exhaust gasses.A component connected to the engine exhaust that removes heat from exhaust gases to transition water vapor into liquid water for collection.
Flexible pipe
(Claim 14)
A flexible pipe for transporting exhaust gasses, which may included carbon dioxide and carbon monoxide, away from the generator (which may be indoors or in a tent) to a location away from the users (such as outside or into a body of water). The pipe has a length of at least 5 feet. This allows the generator to be operated indoors while venting dangerous gases externally.An elongated conduit of at least 5 feet in length attached to the exhaust outlet to transport exhaust gases away from the generator's immediate environment.
Fuel selector
(Claim 1, Claim 10, Claim 14)
A fuel selector is used for adjusting settings of the generator for optimal operation of any one of a variety of liquid or gaseous fuels. The present invention adapts and improves a commercial generator including an internal combustion engine for remote field location operations. Adaptations include a fuel selector for adjusting settings of the generator for optimal operation.A mechanism or control interface that modifies engine settings to optimize performance for different fuel types, specifically including rubbing alcohol and propane.
Manual choke
(Claim 1, Claim 10, Claim 14)
When the engine is first started (cold start), the choke is pulled out (air restricting) to minimize the amount of air mixed with the fuel, so that the cold fuel will combust properly. When the engine warms, the choke is pushed in (air non-restricting) so that the correct amount of air is mixed with fuel for proper combustion. A gasoline or propane generator is a generator including a carburetor and manual choke.A user-operated valve in the carburetor that restricts air intake to enrich the fuel-air mixture, typically used for starting a cold engine.
Rubbing alcohol
(Claim 1, Claim 10, Claim 14)
If the remote field generator is operated with rubbing alcohol, in unit measures, then it may provide the logistical advantage of not requiring the transport or supply of a unique fuel for the generator. The generator operates with rubbing alcohol as fuel, and the rubbing alcohol is supplied in bottles, each bottle containing a unit measure of rubbing alcohol. The fuel selector adjusts the engine to operate more efficiently on at least rubbing alcohol.An alcohol-based liquid fuel used as a logistical alternative to gasoline or diesel in remote field operations.

Litigation Cases New

US Latest litigation cases involving this patent.

Case NumberFiling DateTitle
3:25-cv-00239May 14, 2025Champion Power Equipment, Inc. V. Westinghouse Electric Corporation

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US9175601

Application Number
US13343597A
Filing Date
Jan 4, 2012
Publication Date
Nov 3, 2015
External Links
Slate, USPTO , Google Patents