Power box

• US 6,660,967 B2
• Filed: 08/28/2001
• Issued: 12/09/2003
• Est. Priority Date: 08/28/2001
• Status: Expired due to Fees

• Current Assignee: Joseph L. Colella, Senco Brands Incorporated (Kyocera Corporation)
• Original Assignee: Dynamic Power Source, LLC, Senco Products Incorporated (Kyocera Corporation)
• Inventors: Rieckers, Roger Lee, Brofft, Roger W., Cooper, William Roland
• Primary Examiner(s): Elve, M. Alexandra
• Assistant Examiner(s): MCHENRY, KEVIN L
• Application Number:
  US09/941,150
• Publication Number:
  US 20030042237A1
• Time in Patent Office: 833 Days
• Field of Search: 219/133, 219/134, 290/1.A, 290/1.R, 137/899.4
• US Class Current: 219/133
• CPC Class Codes: F02B 2075/1808 two
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02B 63/06 for pumps

Abstract

An integrated power unit for use in a bed of a pickup truck. A lower housing is sized to fit between the rear wheel wells of the pickup truck, and opposed upper housings extend over respective opposed sidewalls of the truck bed. The opposed upper housings are adjustable with respect to the lower housing, so that the integrated power unit may be used with various makes and models of pickup trucks. The lower housing contains an internal combustion engine for generating mechanical power, an alternator and electrically driven compressors. Ducting and baffles facilitate air flow and cooling in the lower housing. A fuel tank is formed by one of the upper housings, and a control panel is located in the other upper housing. Connections for electrical power and regulated and unregulated pneumatic power are available at the control panel.

Claims

1. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing having a front wall and adapted to be placed in the truck bed between the opposed sidewalls;

a power unit disposed within the lower housing;

a compressor disposed within the lower housing;

a compressed air tank disposed within the lower housing adjacent the front wall thereof, the compressed air tank being fluidly connected to the compressor for storing compressed air and providing compressed air to a connector fluidly connected to the compressed air tank;

a manual purge valve fluidly connected to the compressed air tank and operable to permit a liquid to be purged from the compressed air tank;

a purge outlet fluidly connected to the purge valve and extending through the front wall of the lower housing, the purge outlet directing the liquid from the purge valve to a location outside the lower housing; and

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed.

2. The integrated power unit of claim 1 wherein the purge outlet is located at a lower edge of the front wall of the lower housing.

3. The integrated power unit of claim 1 wherein the power unit is located adjacent a rear wall of the lower housing.

4. The integrated power unit of claim 1 further comprising an electric power generator electrically connected to the compressor.

5. The integrated power unit of claim 4 further comprising a welding power supply electrically connected to the electric power generator.

6. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a housing having a wall with ventilation openings, the housing adapted to be placed in the truck bed between the opposed sidewalls;

an electrical power generating unit disposed within the housing and generating electrical power; and

a plurality of electrically powered compressors disposed in the housing and connected to the electrical power generating unit, each of the plurality of compressors having a direct and unobstructed cooling air path between a respective compressor and the ventilation openings.

7. The integrated power unit of claim 6 wherein each of the plurality of compressors has a cooling air inlet located adjacent the ventilation openings so that there is a direct unobstructed cooling air path between the ventilation openings and the cooling air inlet.

8. The integrated power unit of claim 7 wherein the ventilation openings are in a front wall of the housing.

9. The integrated power unit of claim 6 further comprising at least three electrically powered compressors.

10. The integrated power unit of claim 6 further comprising four electrically powered compressors.

11. The integrated power unit of claim 6 wherein the electrical power generating unit further comprises an alternator.

12. The integrated power unit of claim 6 wherein the plurality of cooling air flow paths are substantially parallel cooling air flow paths in the housing.

13. The integrated power unit of claim 12 wherein the plurality of compressors have a plurality of respective centerlines oriented so that the plurality of respective centerlines are oblique to a longitudinal centerline of the truck.

14. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a housing adapted to be placed in the truck bed between the opposed sidewalls;

an engine having a muffler and disposed within the housing;

a power converting unit disposed within the housing and mechanically coupled to the engine;

a plenum disposed around the muffler;

the housing having internal structure forming

a first air flow path within the housing for receiving first cooling air from a first location outside the housing and directing the first cooling air past the engine, through the plenum and to a location outside of the housing; and

a separate second air flow path within the housing for receiving separate cooling air from a different location outside the housing and directing the separate cooling air past the power converting unit and then to a location outside of the housing, the separate cooling air not being used to cool the engine.

15. The integrated power unit of claim 14 wherein the power converting unit comprises an alternator.

16. The integrated power unit of claim 14 wherein the power converting unit further comprises a compressor.

17. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing adapted to be placed in the truck bed between the opposed sidewalls, the lower housing having a lid movable with respect to the lower housing;

an engine disposed within the lower housing and generating electrical and/or mechanical power;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed; and

a switch disposed to detect closed and open positions of the lid, and the switch being electrically connected with the internal combustion engine to disable the internal combustion engine in response to the lid being opened.

18. The integrated power unit of claim 17 wherein the switch is disposed in the lower housing.

19. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing adapted to be placed in the truck bed between the opposed sidewalls;

an electrical power generating unit disposed within the housing and generating electrical power;

a plurality of electrical breakers disposed within the lower housing and electrically connected to the electrical power generating unit; and

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed.

20. The integrated power unit of claim 19 wherein the lower housing further comprises a lid movable with respect to the lower housing to provide access to the plurality of electrical breakers.

21. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing adapted to be placed in the truck bed between the opposed sidewalls;

a power unit disposed within the lower housing;

a compressor disposed within the lower housing and operatively connected to the power unit;

a compressed air tank disposed within the lower housing and fluidly connected to the compressor;

a control panel disposed in the upper housing and having a gauge fluidly connected to the compressed air tank for displaying fluid pressure within the compressed air tank; and

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed.

22. The integrated power unit of claim 21 wherein the control panel further has a switch for enabling and disabling the compressor.

23. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing adapted to be placed in the truck bed between the opposed sidewalls;

a power unit disposed within the lower housing;

a compressor disposed within the lower housing and operatively connected to the power unit;

a compressed airtank disposed within the lower housing and fluidly connected to the compressor;

a control panel having a compressed air connector fluidly connected directly to the compressed air tank without an intervening regulator; and

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed.

24. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing adapted to be placed in the truck bed between the opposed sidewalls;

a power unit disposed within the lower housing;

a compressor disposed within the lower housing and operatively connected to the power unit;

a compressed air tank disposed within the lower housing and fluidly connected to the compressor;

a control panel disposed in the upper housing and having a switch for enabling and disabling the compressor; and

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed.

25. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing having front, rear and opposed end walls and adapted to be placed in the truck bed between the opposed sidewalls;

an engine disposed within the lower housing;

a plurality of power converting units disposed within the lower housing and operatively connected to the engine;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed;

a first air flow path having vent openings in the front and rear walls of the lower housing and receiving cooling air from outside the lower housing and directing the cooling air past the engine to a location outside the lower housing; and

a second airflow path within the lower housing for receiving cooling air from a plurality of locations outside one of the housings and directing the cooling air from separate ones of the plural locations, respectively past separate ones of the power converting units and to a location outside one of the housings.

26. The integrated power unit of claim 25 wherein the lower housing has front, rear and opposed end walls and the first air flow path further comprises vent openings in one of the end walls and the front wall.

27. The integrated power unit of claim 25 wherein the lower housing has a top wall and the first air flow path further comprises a vent opening in the top wall.

28. The integrated power unit of claim 25 wherein the lower housing has a top wall and the second air flow path further comprises a vent opening in the top wall.

29. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing having front rear and opposed end walls and adapted to be placed in the truck bed between the opposed sidewalls;

an engine disposed within the lower housing;

a plurality of power converting units disposed within the lower housing and operatively connected to the engine;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed;

a first air flow path within the lower housing and having a vent opening in the upper housing for receiving cooling air from outside one of the housings and directing the cooling air past the engine to a location outside an other of the housings; and

a second airflow path within the lower housing for receiving cooling air from a plurality of locations outside one of the housings and directing the cooling air from separate ones of the plural locations, respectively past separate ones of the power converting units and to a location outside one of the housings.

30. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing having a bottom wall and adapted to be placed in the truck bed between the opposed sidewalls;

an engine disposed within the lower housing;

a plurality of power converting units disposed within the lower housing and operatively connected to the engine;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed;

a first air flow path comprises a vent opening in the bottom wall of the lower housing for receiving cooling air from outside one of the housings and directing the cooling air past the engine to a location outside one of the housings; and

a second airflow path within the lower housing for receiving cooling air from a plurality of locations outside one of the housings and directing the cooling air from separate ones of the plural locations, respectively past separate ones of the power converting units and to a location outside one of the housings.

31. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing having front, rear and opposed end walls and adapted to be placed in the truck bed between the opposed sidewalls;

an engine disposed within the lower housing;

a plurality of power converting units disposed within the lower housing and operatively connected to the engine;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed;

a first airflow path within the lower housing for receiving cooling air from outside one of the housings and directing the cooling air past the engine to a location outside one of the housings; and

a second air flow path comprises vent openings in the front and rear walls within the lower housing for receiving cooling air from a plurality of locations outside one of the housings and directing the cooling air from separate ones of the plural locations, respectively past separate ones of the power converting units and to a location outside one of the housings.

32. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing having front, rear and opposed end walls and adapted to be placed in the truck bed between the opposed sidewalls;

an engine disposed within the lower housing;

a plurality of power converting units disposed within the lower housing and operatively connected to the engine;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed;

a first air flow path within the lower housing for receiving cooling air from outside one of the housings and directing the cooling air past the engine to a location outside one of the housings; and

a second air flow path comprises vent openings in one of the end walls and the rear wall within the lower housing for receiving cooling air from a plurality of locations outside one of the housings and directing the cooling air from separate ones of the plural locations, respectively past separate ones of the power converting units and to a location outside one of the housings.

33. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing having front rear and opposed end walls and adapted to be placed in the truck bed between the opposed sidewalls;

an engine disposed within the lower housing;

a plurality of power converting units disposed within the lower housing and operatively connected to the engine;

an upper housing having a vent opening therein, the upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed;

a first air flow path within the lower housing for receiving cooling air from outside one of the housings and directing the cooling air past the engine to a location outside one of the housings; and

a second airflow path within the lower housing for receiving cooling air from a plurality of locations outside one of the housings and directing the cooling air from separate ones of the plural locations, respectively past separate ones of the power converting units and to a location outside one of the housings, one of the first and second air flow paths further comprises the vent opening in the upper housing.

34. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing having a bottom wall with a vent opening therein and adapted to be placed in the truck bed between the opposed sidewalls;

an engine disposed within the lower housing;

a plurality of power converting units disposed within the lower housing and operatively connected to the engine;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed;

a first air flow path within the lower housing for receiving cooling air from outside one of the housings and directing the cooling air past the engine to a location outside one of the housings; and

a second air flow path with in the lower housing for receiving cooling air from a plurality of locations outside one of the housings and directing the cooling air from separate ones of the plural locations, respectively past separate ones of the power converting units and to a location outside one of the housings, one of the first and second air flow paths further comprises the vent opening in the bottom wall.

35. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing adapted to be placed in the truck bed between the opposed sidewalls;

an engine disposed within the lower housing;

a power converting unit disposed within the lower housing and mechanically coupled to the engine;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed; and

an air vent located in a sidewall of one of the housings for receiving ventilation air from inside the one of the housings and directing the ventilation air in an upward direction outside the one of the housings, the air vent comprising

ventilation holes in the sidewall for directing the ventilation air outside the one of the housings, and

a louvered vent disposed adjacent the ventilation holes for directing the ventilation air in the upward direction, the louvered vent being located outward and away from the sidewall of the one of the housings.

36. The integrated power unit of claim 35 wherein the louvered vent is located outside the one of the housings and mounted to the one of the housings immediately adjacent to, but displaced from, the ventilation holes.

37. The integrated power unit of claim 36 wherein the louvers are angled with respect to the ventilation holes for directing the ventilation air in a substantially upward direction.

38. The integrated power unit of claim 37 wherein the air vent is located in a sidewall of the lower housing.

39. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing adapted to be placed in the truck bed between the opposed sidewalls;

an engine disposed within the lower housing;

a power converting unit disposed within the lower housing and mechanically coupled to the engine;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed; and

an air vent located in a rear wall of the lower housing for receiving ventilation air from inside the one of the housings and directing the ventilation air in an upward direction outside the one of the housings, the air vent comprising

ventilation holes in the sidewall for directing the ventilation air outside the one of the housings, and

louvers disposed adjacent the ventilation holes for directing the ventilation air in the upward direction.

40. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing adapted to be placed in the truck bed between the opposed sidewalls, the lower housing having a bottom wall;

an engine disposed within the lower housing;

a power converting unit disposed within the lower housing and mechanically coupled to the engine;

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed;

the lower housing forming a first air flow path within the lower housing for receiving cooling air from outside the housings and directing the cooling air past the engine to a location outside the housings; and

the lower housing forming a second air flow path within the lower housing for receiving cooling air from openings in the bottom wall of the lower housing and directing the cooling air past the power converting unit to a location outside of the housings.

41. An integrated power unit for use with a pickup truck having a truck bed with opposed sidewalls, the integrated power unit comprising:

a lower housing adapted to be placed in the truck bed between the opposed sidewalls, the lower housing having a top wall with a lip extending around a periphery of a hole in the top wall;

a lid movable over the opening in the top wall and having a peripheral groove disposable over the lip to seal the lid over the opening in the top wall;

an engine disposed within the lower housing;

a power converting unit disposed within the lower housing and mechanically coupled to the engine; and

an upper housing extending from the lower housing and adapted to extend over a sidewall of the truck bed.