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High Performance Free-Piston Stirling Engines Unrivalled Performance | Energy Efficient | Compact | Robust |

High Performance Free-Piston Stirling Engines

Unrivalled Performance | Energy Efficient | Compact | Robust | Long-Lived

Experience the Benefits of Unique Free-Piston Stirling Technology

Benefits of Patented Sunpower Technology Over Kinematic or Other Free-Piston Designs

Sunpower free-piston Stirling engines are based on patented design features which have evolved into todays technology and an array of available prototypes.

Sunpower designs are highly differentiated from conventional kinematic Stirling engines.Also, because Sunpower engines operate on gas bearings, use compact linear alternators and have a simple mechanical configuration, they offer significant benefits over other free-piston designs.

By comparison, kinematic Stirling engines are complicated and expensive to build, and require a lubricant, seals and mechanical bearings which combine to restrict performance and limit life. Also, power output is difficult to change in the kinematic design.offer significant benefits over other free-piston designs. Sunpower ’ s unique combination of gas bearings,

Sunpower ’ s unique combination of gas bearings, compliance and compact linear alternator delivers the highest s unique combination of gas bearings, compliance and compact linear alternator delivers the highest efficiency, lowest mass free-piston Stirling engines available.

Sunpower free-piston Stirling engine technology is protected by more than 30 United States patents and 80 international patents.lowest mass free-piston Stirling engines available. Product Development Support Sunpower ’ s free-piston

Product Development Support

Sunpower s free-piston Stirling engine manufacturing organization is supported by a vibrant R&D group who work closely with customers to develop new solutions or engineer Sunpower s engines into new products. Sunpower also maintains a healthy intellectual property/licensing business which can offer customers unique and exclusive positions to our intellectual property.

Sunpower s free-piston technology is being applied in areas such as cryocoolers and linear compressors, power generation and household refrigeration. Some applications include the world s most efficient refrigerator on sale internationally; natural gas-fueled household cogeneration systems scheduled to enter the market in 2007; and nuclear space power systems.

The commercialization of innovative new technologies enabling unique products requires partnerships and collabora- tion. For any new product, Sunpower s engineering team is available to work directly with partners at all stages, from proof-of-concept demonstration to design for manufacturer and manufacturing start-up.

Sunpower Free-Piston Stirling Engine Prototype Availability

 

Prototype

Power

Temperature

Efficiency

Heat Source

Heat Rejection

Hermetically

Mass

Dimensions, Diameter x Length in mm (nominal)

Model

(nominal)

Ratio (Th/Tc)

Sealed

EE-35

42W e

2.7

32%

Electric Heater

Air/Water Cooling

No

1.4

kg

52

x 157

EE-35-H

42W e

2.7

32%

Propane/JP-8

Air/Water Cooling

Yes

0.6

kg

50

x 142

Burner

 
       

Electric Heater/

       

EE-80

95W e

3.0

36%

Propane Burner

Air/Water Cooling

No

3.7

kg

69

x 193

EE-80-H(*)

95W e

3.0

36%

TBD

Air/Water Cooling

Yes

1.0

kg

65

x 186

EG-1000

1000W e

2.7

32%

Propane Burner

Water Cooling

No

35 kg

270 x 435

Source: SY Kim., James Huth, James G. Wood; Performance Characterization of Sunpower Free-Piston Stirling Engines, Sunpower Inc. (*) Projected Values.

For the latest information on Sunpower products, services, corporate news and our online library, visit our Web site at www.sunpower.com.

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Measured Performance, EE-35 and EE-35-H

Measured Performance, EE-35 and EE-35-H EE-35 engine with pressure vessel removed Measured Performance, EE-80 and EE-80-H
Measured Performance, EE-35 and EE-35-H EE-35 engine with pressure vessel removed Measured Performance, EE-80 and EE-80-H

EE-35 engine with pressure vessel removed

Measured Performance, EE-80 and EE-80-H EE-80 engines, opposed pair Measured Performance, EG-1000 EG-1000 engine with
Measured Performance, EE-80 and EE-80-H
EE-80 engines, opposed pair
Measured Performance, EG-1000
EG-1000 engine with
non-recuperative propane burner
EE-80 engines, opposed pair Measured Performance, EG-1000 EG-1000 engine with non-recuperative propane burner 3
EE-80 engines, opposed pair Measured Performance, EG-1000 EG-1000 engine with non-recuperative propane burner 3

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EE-80 engines, opposed pair Measured Performance, EG-1000 EG-1000 engine with non-recuperative propane burner 3

Sunpower Advantages Over Conventional Kinematic and Other Free-Piston Designs

Patented, non-contact gas bearing compliant designOver Conventional Kinematic and Other Free-Piston Designs Lightweight, compact size —Workplace diameter is

Lightweight, compact sizeDesigns Patented, non-contact gas bearing compliant design —Workplace diameter is independent of displacer spring

—Workplace diameter is independent of displacer spring

—Compliant displacer floats on gas bearings, allowing non-contact operation

—Eliminates lubrication

—Uses space-efficient planar spring

—Reduces number of critical alignments

—Simplifies manufacturing

—Improves efficiency

—Piston support on gas bearings enables non-contact operation

Highly efficient, low-mass linear alternator with permanent magnet for direct AC outputsupport on gas bearings enables non-contact operation Unmatched power-to-mass ratio Configurable to a variety of

Unmatched power-to-mass ratiolinear alternator with permanent magnet for direct AC output Configurable to a variety of heat sources

Configurable to a variety of heat sources depending on application requirementsmagnet for direct AC output Unmatched power-to-mass ratio New designs can be developed and engineered into

New designs can be developed and engineered into unique new productsof heat sources depending on application requirements Current commercial, military and aerospace applications use

Current commercial, military and aerospace applications use three different prototypes that are available for purchasecan be developed and engineered into unique new products —Reduced weight through use of efficient copper

—Reduced weight through use of efficient copper coil with no end turns and zero mean lamination flux

—Minimal power loss because moving magnets never leave poles

Sunpower Products and Fuel Source Alternatives

Product Development Potential

Automotive pre-warmer, battery charger

Autonomous consumer and commercial appliances

Electric generation, biomass

Electric generation, distributed, grid connected

Electric generation, off-grid

Electric generation, solar thermal

Fuel-fired battery

Fuel-fired UPS (uninterruptible power supply)

Heat pump, biomass fueled

Heat pump, residential

Vehicle APU (auxiliary power supply)

Fuel Source

Gasoline, diesel

Natural gas, LPG, propane

Wood pellets, unprocessed biomass

Natural gas, LPG, propane

Natural gas, LPG, propane

Solar, solar/natural gas hybrid

Butane, propane, methanol, kerosene/diesel

Butane, propane, kerosene/diesel

Wood pellets, unprocessed biomass

Natural gas, LPG, propane

Gasoline, diesel

Sunpower free-piston Stirling engines now in use or in process offer many product development opportunities in diverse markets using a variety of fuels.

now in use or in process offer many product development opportunities in diverse markets using a

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For more than 30 years Sunpower, Inc., the originator of free-piston Stirling engines, has developed and delivered fully engineered prototypes and preproduction engines for a variety of applications in aerospace, military, household appliance and research industries.

Milestones in Free-Piston Stirling Engine Development at Sunpower

William Beale invents the free-piston Stirling engine and is awarded U.S. Patent 3,552,120

RE-1000, the first mature free-piston Stirling engine; delivered

Design, development and testing of machines from 35W to 7.5kW, and proven operation on numerous heat sources including solar, gaseous and liquid fossil fuels, biomass and heat pipes

First demonstration of a tuned dynamic vibration absorber

Demonstration of stand-alone diesel fueled free-piston Stirling engine generator to the US Army, First use of a heat pipe heater head

Demonstration of high-frequency engine operation (115Hz)

Demonstration of balanced opposed configuration engine arrangement

First successful application of on-sun solar powered free-piston Stirling engine (development units run through 1994)

Licensee completes field trial for first free-piston Stirling engine-based household cogeneration appliance

Manufactured cryocooler launched on the 2002 RHESSI mission

Demonstration of and improvement on highest efficiency of small free-piston Stirling engine achieved to date

Demonstration of and improvement on the highest power per unit mass of small free-piston Stirling engine achieved to date

Receipt of NASA funded program to develop next generation Advanced Stirling Convertor (ASC)

Free-piston linear alternator technology available in household refrigerators

Demonstration of dual opposed, low vibration free-piston Stirling engine configuration at Space Technology and Applications International Forum

Free-piston Stirling cooler technology commercially available

Demonstration of 20% efficiency of JP-8 to electric power out in a prototype Wearable Power Supply for the US Department of Defense (DoD)

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1971

1978

1980 to

present

1985

1987

1988

1989

1989-

1994

2001

2002

2003-

2005

2003 -

2005

2003

2003

2004

2004

2005

Working with Sunpower

Sunpower s free-piston Stirling engine prototypes, R&D services and intellectual property are sold direct from our corporate development center in Athens, Ohio USA. Evaluation prototypes for selected products are available to qualified customers. For information please contact Sunpower, Inc.

182 Mill Street,Athens, Ohio 45701 USA | P: 740-594-2221 | F: 740-593-7531 | www.sunpower.com | info@sunpower.com

F: 740-593-7531 | www.sunpower.com | info@sunpower.com Sunpower products are precision manufactured and tested in a

Sunpower products are precision manufactured and tested in a modern production facility adjacent to our research, development and administrative center in Athens, Ohio USA. Manufacturing proximity provides our customers with the highest level of flexibility to meet customization demands.

Sunpower is a world-leading developer of energy efficient, environmentally friendly, free-piston machines for power generation and cooling.These machines include free-piston Stirling engines and cryocoolers, pulse tube cryocoolers, and linear compressors.The company is comprised of manufacturing, contract R&D, and intellectual property licensing departments. Sunpower is privately held and is situated in Athens, Ohio USA.

is privately held and is situated in Athens, Ohio USA. This brochure meets EPA and FTC

This brochure meets EPA and FTC guidelines for recycled coated paper.

'2005 Sunpower Inc. 09/05 OW7743
'2005 Sunpower Inc.
09/05 OW7743

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