U.S. patent application number 10/601225 was filed with the patent office on 2004-03-11 for air compressor assembly with continuous auto drain tank.
Invention is credited to Burkholder, Robert F., Curnel, Scott, Robenalt, David W., Russell, Kurt, Wood, Mark W., Wright, Matt.
Application Number | 20040047744 10/601225 |
Document ID | / |
Family ID | 34272312 |
Filed Date | 2004-03-11 |
United States Patent
Application |
20040047744 |
Kind Code |
A1 |
Burkholder, Robert F. ; et
al. |
March 11, 2004 |
Air compressor assembly with continuous auto drain tank
Abstract
An air compressor assembly having an air tank which, during air
usage, continuously discharges condensate accumulated in the air
tank into the compressed air being released. The air tank has an
air outlet port at its wall, through which compressed air and
condensate are released for use in air powered tools during air
usage.
Inventors: |
Burkholder, Robert F.;
(Jackson, TN) ; Curnel, Scott; (Jackson, TN)
; Wood, Mark W.; (Jackson, TN) ; Wright, Matt;
(Jackson, TN) ; Robenalt, David W.; (Jackson,
TN) ; Russell, Kurt; (Henderson, TN) |
Correspondence
Address: |
SUITER WEST PC LLO
14301 FNB PARKWAY
SUITE 220
OMAHA
NE
68154
US
|
Family ID: |
34272312 |
Appl. No.: |
10/601225 |
Filed: |
June 20, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60408860 |
Sep 6, 2002 |
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Current U.S.
Class: |
417/234 ;
417/360 |
Current CPC
Class: |
F04B 41/02 20130101 |
Class at
Publication: |
417/234 ;
417/360 |
International
Class: |
F04B 053/00 |
Claims
What is claimed is:
1. An air compressor assembly, comprising: an air tank for
containing air at an elevated pressure, the air tank having an air
inlet port and an air outlet port therein; an air compressor for
supplying air for storage in the air tank through a first tubing,
the first tubing connecting the air inlet port to the air
compressor; and a second tubing connecting the air outlet port to a
manifold assembly; wherein compressed air in the air tank is
discharged through the air outlet port, the second tubing, and the
manifold assembly during air usage.
2. The air compressor assembly of claim 1, wherein the air
compressor assembly is of a portable type.
3. The air compressor assembly of claim 2, wherein the portable air
compressor assembly is enclosed in a shroud.
4. The air compressor assembly of claim 3, wherein the shroud is
made of plastic.
5. The air compressor assembly of claim 3, wherein the shroud
includes a handle to allow the portable air compressor assembly to
be lifted and transported from place to place.
6. The air compressor assembly of claim 3, further comprises a
control panel to allow operation of the portable air compressor
assembly to be controlled.
7. The air compressor assembly of claim 1, wherein the air
compressor assembly is of a "pancake" type.
8. The air compressor assembly of claim 1, wherein the air
compressor assembly is of a "hot-dog" type.
9. The air compressor assembly of claim 1, wherein the air
compressor assembly is of a vertical "hot-dog" type.
10. The air compressor assembly of claim 1, wherein the air
compressor assembly is of a "double hot-dog" type.
11. The air compressor assembly of claim 1, wherein the air
compressor assembly is of a vertical stationary type.
12. The air compressor assembly of claim 1, wherein the air outlet
port is positioned at a bottom wall of the air tank.
13. The air compressor assembly of claim 1, wherein the air inlet
port is positioned at a top wall of the air tank.
14. The air compressor assembly of claim 1, wherein the air inlet
port includes a check valve for preventing air from flowing from
the air tank to the air compressor.
15. An air compressor assembly, comprising: an air tank for
containing air at an elevated pressure, the air tank having an air
access port therein; an air compressor for supplying air for
storage in the air tank; a first tubing connecting the air
compressor to a manifold assembly; and a second tubing connecting
the manifold assembly to the air access port; wherein compressed
air in the air tank is discharged through the air access port, the
second tubing, and the manifold assembly during air usage.
16. The air compressor assembly of claim 15, wherein the air
compressor assembly is of a portable type.
17. The air compressor assembly of claim 16, wherein the portable
air compressor assembly is enclosed in a shroud.
18. The air compressor assembly of claim 17, wherein the shroud is
made of plastic.
19. The air compressor assembly of claim 17, wherein the shroud
includes a handle to allow the portable air compressor assembly to
be lifted and transported from place to place.
20. The air compressor assembly of claim 17, further comprises a
control panel to allow operation of the portable air compressor
assembly to be controlled.
21. The air compressor assembly of claim 15, wherein the air
compressor assembly is of a "pancake" type.
22. The air compressor assembly of claim 15, wherein the air
compressor assembly is of a "hot-dog" type.
23. The air compressor assembly of claim 15, wherein the air
compressor assembly is of a vertical "hot-dog" type.
24. The air compressor assembly of claim 15, wherein the air
compressor assembly is of a "double hot-dog" type.
25. The air compressor assembly of claim 15, wherein the air
compressor assembly is of a vertical stationary type.
26. The air compressor assembly of claim 15, wherein the air access
port is positioned at a bottom wall of the air tank.
27. The air compressor assembly of claim 15, wherein the manifold
assembly includes a check valve for preventing air from flowing
from the manifold assembly to the air compressor.
28. An air compressor assembly, comprising: an air tank for
containing air at an elevated pressure having an air access port
thereof, the air access port being an open end of a centrally
hollow conduit positioned inside the air tank; an air compressor
for supplying air for storage in the air tank; a first tubing
connecting the air compressor to a manifold assembly; and a second
tubing connecting the manifold assembly to the air access port;
wherein compressed air in the air tank is discharged through the
conduit, the air access port, the second tubing, and the manifold
assembly during air usage.
29. The air compressor assembly of claim 28, wherein the air
compressor assembly is of a portable type.
30. The air compressor assembly of claim 29, wherein the portable
air compressor assembly is enclosed in a shroud.
31. The air compressor assembly of claim 30, wherein the shroud is
made of plastic.
32. The air compressor assembly of claim 30, wherein the shroud
includes a handle to allow the portable air compressor assembly to
be lifted and transported from place to place.
33. The air compressor assembly of claim 30, further comprises a
control panel to allow operation of the portable air compressor
assembly to be controlled.
34. The air compressor assembly of claim 28, wherein the air
compressor assembly is of a "pancake" type.
35. The air compressor assembly of claim 28, wherein the air
compressor assembly is of a "hot-dog" type.
36. The air compressor assembly of claim 28, wherein the air
compressor assembly is of a vertical "hot-dog" type.
37. The air compressor assembly of claim 28, wherein the air
compressor assembly is of a "double hot-dog" type.
38. The air compressor assembly of claim 28, wherein the air
compressor assembly is of a vertical stationary type.
39. The air compressor assembly of claim 28, wherein the air access
port is positioned at a top wall of the air tank.
40. The air compressor assembly of claim 28, wherein the manifold
assembly includes a check valve for preventing air from flowing
from the manifold assembly to the air compressor.
41. A method for discharging condensate within an air tank of an
air compressor assembly, comprising: supplying an air tank for
storing air at an elevated pressure; and discharging condensate
within the air tank into compressed air being released from the air
tank during air usage.
42. The method of claim 41, further comprising routing discharged
condensate and compressed air through air outlet tubing to an air
powered tool.
43. The method of claim 42, wherein the discharging step is
performed so that the condensate is discharged in small amounts not
harmful to the air powered tool.
Description
CROSS-REFERENCE TO RELATED DOCUMENTS
[0001] The present application claims the benefit under 35 U.S.C.
.sctn. 119(e) of U.S. Provisional Application Serial No.
60/408,860, filed Sep. 6, 2002. Said U.S. Provisional Application
Serial No. 60/408,860 is herein incorporated by reference in its
entirety.
[0002] The present application herein incorporates the following
United States patent applications by reference in their
entirety:
1 Attorney Docket Number "Express Mail" Mailing Label No. Filing
Date PTG 02-96-3 EV 338 284 614 US Jun. 20, 2003 PTG 02-96-4 EV 338
284 605 US Jun. 20, 2003
FIELD OF THE INVENTION
[0003] The present invention relates generally to the field of air
compressors, and particularly to an air compressor assembly having
an air tank which automatically and continuously discharges
condensate accumulated in the air tank during air usage.
BACKGROUND OF THE INVENTION
[0004] An air compressor assembly is used to provide compressed air
for operating air powered tools such as nailing tools, socket
driving tools, material shaping tools, sanding tools, spray
painting tools, inflation chucks, and the like. During the
utilization of an air compressor assembly, moisture in compressed
air may build up at the bottom of an air tank of an air compressor
assembly. Since condensate accumulation in the air tank, if not
drained timely, may cause tank corrosion, a drain valve is
conventionally provided at the bottom of the air tank to open up
after a certain operating time of the air compressor assembly to
release condensate (e.g., condensed moisture) accumulated therein.
Such a drain valve requires constant monitoring, must be attended
by a dedicated person, and is therefore not practical in terms of
labor cost and working efficiency.
[0005] Thus, it would be desirable to provide an air compressor
assembly that is free from the drain valve, requires less
maintenance time, and has less tank corrosion.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention is directed to an air
compressor assembly having an air tank which, during air usage,
continuously discharges condensate accumulated in the air tank into
the compressed air being released for use in air powered tools.
[0007] In one embodiment of the present invention, the air tank has
an air outlet port, through which compressed air and discharged
condensate may be released from the air tank.
[0008] In a further embodiment of the present invention, the air
tank has a centrally hollow conduit inside the air tank through
which compressed air and discharged condensate may be released from
the air tank. The conduit, whose top open end is an air outlet port
of the air tank, protrudes downward from the air outlet and has a
lower open end positioned in a vicinity of the bottom of the air
tank.
[0009] According to the present invention, during air usage, the
compressed air being released may push condensate out of the tank
through the air outlet or through the conduit. The compressed air
being released may mix with the discharged condensate and be used
in air powered tools. Because condensate within the air tank is
continuously discharged during air usage, the condensate may be
discharged in small amounts not harmful to the air powered
tools.
[0010] The air tank according to the present invention may be part
of air compressor assemblies in various styles, including a
"pancake" type air compressor assembly, a "hot-dog" type air
compressor assembly, a vertical "hot-dog" type air compressor
assembly, a vertical stationary type air compressor assembly, a
"double hot-dog" type air compressor assembly, and the like.
[0011] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention as
claimed. The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate an embodiment of
the invention and together with the general description, serve to
explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The numerous advantages of the present invention may be
better understood by those skilled in the art by reference to the
accompanying figures in which:
[0013] FIG. 1 is an isometric view illustrating a portable air
compressor assembly in accordance with an exemplary embodiment of
the present invention;
[0014] FIG. 2 is a front elevation view of the portable air
compressor assembly shown in FIG. 1;
[0015] FIG. 3 is a side elevation view of the portable air
compressor assembly shown in FIG. 1;
[0016] FIG. 4 is an isometric view of an exemplary embodiment of
the portable air compressor assembly shown in FIGS. 1 through 3,
wherein the front shell of the shroud is removed for illustration
of the air tank, air compressor and manifold assembly;
[0017] FIG. 5 is an isometric view of the portable air compressor
assembly shown in FIG. 4, further illustrating manifold assembly,
air compressor, and the air tank within the shroud of the portable
air compressor assembly, wherein the air tank is shown in a
cross-sectional view;
[0018] FIG. 6 is an isometric view of a further exemplary
embodiment of the portable air compressor assembly shown in FIGS. 1
through 3, wherein the front shell of the shroud is removed for
illustration of the air tank, air compressor and manifold
assembly;
[0019] FIG. 7 is an isometric view of the portable air compressor
assembly shown in FIG. 6, further illustrating manifold assembly,
air compressor, and the air tank within the shroud of the portable
air compressor assembly, wherein the air tank is shown in a
cross-sectional view;
[0020] FIG. 8 is an isometric view of an additional exemplary
embodiment of the portable air compressor assembly shown in FIGS. 1
through 3, wherein the front shell of the shroud is removed for
illustration of the air tank, air compressor and manifold
assembly;
[0021] FIG. 9 is an isometric view of the portable air compressor
assembly shown in FIG. 8, further illustrating manifold assembly,
air compressor, and the air tank within the shroud of the portable
air compressor assembly, wherein the air tank is shown in a
cross-sectional view;
[0022] FIG. 10 is an isometric view illustrating a "pancake" type
air compressor assembly in accordance with an exemplary embodiment
of the present invention;
[0023] FIG. 11 is an isometric view illustrating a "hot dog" type
air compressor assembly in accordance with an exemplary embodiment
of the present invention;
[0024] FIG. 12 is an isometric view illustrating a vertical "hot
dog" type air compressor assembly in accordance with an exemplary
embodiment of the present invention; and
[0025] FIG. 13 is an isometric view illustrating a vertical
stationary type air compressor assembly in accordance with an
exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Reference will now be made in detail to the presently
preferred embodiments of the invention, examples of which are
illustrated in the accompanying drawings.
[0027] Referring generally now to FIGS. 1 through 9, exemplary
embodiments of a portable air compressor assembly 100 in accordance
with the present invention are shown. It is understood that a
portable air compressor assembly means an air compressor assembly
that can be carried and/or moved with ease, and not as a structural
limitation. The portable air compressor assembly 100 includes an
air tank 102 (or 202), an air compressor 104, and a manifold
assembly 106 assembled within a shroud or housing 108. The shroud
108, which is preferably formed of plastic, may include a handle
118 allowing an operator to lift and transport the portable air
compressor assembly 100 from place to place, and a control panel
120 for providing controls for the portable air compressor assembly
100.
[0028] In the exemplary embodiments illustrated in FIGS. 1 through
3, the control panel 120 may include an on/off switch 122, a
pressure regulator 124, a pressure gauge 126, a pressure relief
safety valve 128, and a speed control switch 116. However, it is
understood that the control panel 120 may provide other controls
depending on design preferences.
[0029] As shown in FIGS. 4 through 9, the air compressor 104 may
include a compressor 110 having one or more pistons 112 driven by a
motor or engine 114. For example, in the exemplary embodiments
illustrated, the air compressor 104 may include a single piston
compressor 110 having a single piston driven by a universal
electric motor 114. By employing a universal electric motor 114,
the speed at which the motor 114 operates, and thus the speed at
which the piston 112 is reciprocated, may be varied by controlling
the voltage supplied to the motor 114. In this manner, the air flow
rate supplied by the air compressor 104 through connecting piping
or tubing 136 and/or manifold assembly 106 to the air tanks 102,
202 may be varied. For example, in the embodiments illustrated, the
speed control switch 116 shown in FIGS. 1 and 2 may allow an
operator to select between a high speed operation mode wherein
maximum air flow is supplied to the air tanks 102, 202, and a low
speed operating mode wherein the compressor 110 runs more slowly
reducing the noise generated by the air compressor 104.
[0030] FIG. 4 is an isometric view of an exemplary embodiment of
the portable air compressor assembly 100 shown in FIGS. 1 through
3, wherein the front shell of the shroud 108 is removed. FIG. 5 is
an isometric view of the portable air compressor assembly 100 shown
in FIG. 4, wherein the air tank 102 is shown in a cross-sectional
view.
[0031] As shown in FIGS. 4 and 5, the air tank 102 of the air
compressor assembly 100 has an air inlet port 130 and an air outlet
port 132, both positioned at the wall of the air tank 102. In the
exemplary embodiments shown in FIGS. 4 and 5, the air inlet port
130 is located at an upper wall of the air tank 102, and the air
outlet port 132 is located at a lower wall of the air tank 102. It
is understood that the locations of the air inlet port 130 and the
air outlet port 132 at the wall of the air tank 102 may change,
without departing from the scope and spirit of the present
invention. The air inlet port 130 and the air outlet port 132 are
openings extending through the wall of the air tank 102.
[0032] As shown in FIGS. 4 and 5, the air compressor 104 may
provide air to the air tank 102 through the tubing 136 and the air
inlet port 130. There may exist a check valve (not shown) inside
the air inlet port 130, which allows air to flow from the air
compressor 104 to the air tank 102 but prevents air from flowing
from the air tank 102 to the air compressor 104. The air tank 102
may be connected to the manifold assembly 106 through outlet tubing
134. During air usage, compressed air being released from the air
tank 102, because of its high pressure, may drive condensate
accumulated in the tank 102 out through the air outlet port 132.
The compressed air being released may mix with the discharged
condensate and be used in air powered tools. Preferably, the
discharged condensate is routed through the outlet tubing 134, the
manifold assembly 106 and any attached air hose to the air powered
tools.
[0033] FIG. 6 is an isometric view of a further exemplary
embodiment of the portable air compressor assembly 100 shown in
FIGS. 1 through 3, wherein the front shell of the shroud 108 is
removed. FIG. 7 is an isometric view of the portable air compressor
assembly 100 shown in FIG. 6, wherein the air tank 202 is shown in
a cross-sectional view.
[0034] As shown in FIGS. 6 and 7, the air tank 102 of the air
compressor assembly 100 has an air access port 132 positioned at
the wall of the air tank 102. In the exemplary embodiments shown in
FIGS. 6 and 7, the air access port 132 is located at a lower wall
of the air tank 102. It is understood that the location of the air
access port 132 at the wall of the air tank 102 may change, without
departing from the scope and spirit of the present invention. The
air access port 132 is an opening extending through the wall of the
air tank 102.
[0035] As shown in FIGS. 6 and 7, the air compressor 104 is
connected to the manifold assembly 106 through the tubing 136, and
the air tank 102 is connected to the manifold assembly 106 through
the air access port 132 and tubing 134. There may exist a check
valve (not shown) inside the manifold assembly 106, which allows
air to flow from the air compressor 104 to the manifold assembly
106 but prevents air from flowing from the manifold assembly 106 to
the air compressor 104. Thus, the air compressor 104 may supply air
to the air tank 102 through the tubing 136, the manifold assembly
106, the tubing 134 and the air access port 132. Compressed air may
be released from the air tank 102 through the air access port 132,
the tubing 134, the manifold assembly 106, and any attached air
hose to the air powered tools. During air usage, compressed air
being released from the air tank 102, because of its high pressure,
may drive condensate accumulated in the tank 102 out through the
air access port 132. The compressed air being released may mix with
the discharged condensate and be used in air powered tools.
[0036] FIG. 8 is an isometric view of an additional exemplary
embodiment of the portable air compressor assembly shown in FIGS. 1
through 3, wherein the front shell of the shroud is removed for
illustration of the air tank, air compressor and manifold assembly.
FIG. 9 is an isometric view of the portable air compressor assembly
shown in FIG. 8, further illustrating manifold assembly, air
compressor, and the air tank within the shroud of the portable air
compressor assembly, wherein the air tank is shown in a
cross-sectional view;
[0037] As shown in FIGS. 8 and 9, the air tank 202 of the air
compressor assembly 100 may have an air access port 150 (often
referred to as a "spud") positioned at a wall of the air tank 202.
For example, in the exemplary embodiments, the air access port 150
is located at an upper wall of the air tank 202. However, it is
understood the air access port 150 may be located at a different
position at the wall of the air tank 202, without departing from
the scope and spirit of the present invention. The air access port
150 is an opening that extends through the wall of the air tank
202.
[0038] As shown in FIG. 8, the air access port 150 is connected to
a pressure switch assembly 118 which in turn is connected to the
manifold assembly 106 via connecting pipe or tubing 116. The
pressure switch assembly 118 is used for regulating pressure within
the air tank 202 by alternately starting and stopping the air
compressor 104 to periodically replenish the supply of air in the
tank 202. When pressure within the tank 202 reaches a preset low
pressure point, or "kick-in pressure", the pressure switch assembly
118 starts the air compressor 104 to re-pressurize the tank 202. As
the pressure within the tank 202 reaches a preset high pressure
point, or "kick-out pressure", the pressure switch assembly 118
stops the air compressor 104 to prevent over-pressurization of the
tank 202. In this manner, the pressure of the compressed air in the
compressed air storage tank 202 is maintained within a range
generally suitable for powering one or more air powered tools.
[0039] As shown in FIG. 9, the air access port 150 is an upper open
end of a centrally hollow conduit 138 which is located inside the
air tank 202. The conduit 138 protrudes downward from the air
access port 150 and has a lower open end 140 positioned in a
vicinity of the bottom of the air tank 202. Through the air access
port 150 and the conduit 138, compressed air may be provided to the
air tank 202 by the air compressor 104. For example, the air
compressor 104 may supply air to the air tank 202 through the
tubing 136, the manifold assembly 106, the connecting tubing 116,
the pressure switch assembly 118, the air access port 150, and the
conduit 138. There may exist a check valve (not shown) inside the
manifold assembly 106, which allows air to flow from the air
compressor 104 to the manifold assembly 106 but prevents air from
flowing from the manifold assembly 106 to the air compressor
104.
[0040] Compressed air may be released from the air tank 102 through
the conduit 138, the air access port 150, the connecting tubing
116, the pressure switch assembly 118, the manifold assembly 106,
and any attached air hose to the air powered tools. During air
usage compressed air being released from the air tank 202, because
of its high pressure, may push condensate accumulated inside the
air tank 202 out through the lower open end 140, the conduit 138
and the air access port 150. The compressed air being released may
mix with the discharged condensed moisture and be used in air
powered tools.
[0041] As shown in FIGS. 1 through 9, because condensate within the
air tanks 102, 202 is continuously discharged during air usage, the
condensate is discharged in small amounts not harmful to the air
tool. Accordingly, the air tanks 102, 202 do not require a drain
valve such as is commonly found in the air tanks of conventional
air compressor assemblies for draining condensate from the tank.
Thus, the drain valve may be eliminated. Furthermore, the time
required for maintenance of the air compressor assembly 100 is
reduced compared to that of a conventional air compressor assembly,
since the air tanks 102, 202 do not have to be manually drained on
a periodic basis. Moreover, tank corrosion is reduced because
condensate removal is continuous and not dependent on operator
maintenance actions.
[0042] In the exemplary embodiments illustrated in FIGS. 1 through
9, if moisture-free air is required (e.g., for paint spraying or
the like), a moisture separator may be coupled to an air hose that
is connected to the air compressor assembly 100. However, such
moisture separators are also required by a conventional air
compressor assembly for applications such as paint spraying, since
it is known that moisture condenses in air hoses as well as in the
air tank of a compressor assembly. Thus, compared to a conventional
air compressor assembly, the air compressor assembly 100 of the
present invention would require no additional equipment if used for
applications requiring removal of moisture (e.g., such as providing
air to spray paint).
[0043] In the exemplary embodiments illustrated in FIGS. 1 through
9, the air tanks 102, 202 are enclosed within and supported by the
shroud 108. The shroud 108 may also enclose the air compressor 104,
the manifold assembly 106, the connecting piping or tubing 136, and
electrical wiring. Because the air tanks 102, 202 are typically not
visible to viewers of the shroud 108 from outside of the assembled
shroud, the air tanks 102, 202 may be fabricated and assembled into
the unit without first being painted. In this manner, processing
through an expensive and time consuming paint process is
eliminated, improving manufacturing efficiencies to lower cost.
Moreover, all potentially hot tubing between the air compressor 104
and the air tanks 102, 202 is enclosed in the shroud 108, thereby
reducing the risk of operator burn injuries from hot tubing
surfaces. An additional advantage of the enclosed air tanks 102,
202 is that the air tanks 102, 202 may warm up more quickly than an
exposed tank by absorbing heat from the air compressor 104. The air
tanks 102, 202 may also retain heat longer because of reduced
convection and radiation cooling to the outside air. By keeping the
air tanks 102, 202 warmer, the tanks 102, 202 are less likely to
condense moisture, resulting in reduced tank corrosion.
[0044] Referring generally now to FIGS. 10 through 13, exemplary
embodiments of air compressor assemblies in various styles in
accordance with the present invention are shown. Referring to FIG.
10, an exemplary "pancake" type air compressor assembly 800 in
accordance with the present invention is shown. The air compressor
assembly 800 may include an air tank 802, an air compressor 804,
and a manifold assembly 806. The air tank 802 is a flattened oval
tank, often referred to informally in the art as a "pancake" style
tank. The air tank 802 may be made of plastic, metal such as steel,
or the like. The air tank 802 has an air inlet port which is
connected to the air compressor 804 through tubing 834. There may
exist a check valve (not shown) inside the air inlet port, which
allows air to flow from the air compressor 804 to the air tank 802
but prevents air from flowing from the air tank 802 to the air
compressor 804. An air outlet port 832 is located at the wall of
the air tank 802. Preferably, air outlet port 832 is located at the
bottom of the air tank 802. The air outlet port 832 is an opening
that extends through the tank wall and is connected to the manifold
assembly 806 through outlet tubing. The air compressor assembly 800
may also include a wheel assembly 860 for transporting the air
compressor assembly 800.
[0045] Referring to FIG. 11, an exemplary "hot-dog" type air
compressor assembly 900 in accordance with the present invention is
shown. The air compressor assembly 900 may include an air tank 902,
an air compressor 904, and a manifold assembly 906. The air tank
902 is a horizontally disposed, cylindrical compressed air tank,
typically referred to informally in the art as a "hot-dog" style
tank. The air tank 902 may be made of plastic, metal such as steel,
or the like. The air tank 902 has an air inlet port which is
connected to the air compressor 904 through tubing 934. There may
exist a check valve (not shown) inside the air inlet port, which
allows air to flow from the air compressor 904 to the air tank 902
but prevents air from flowing from the air tank 902 to the air
compressor 904. An air outlet port 932 is located at the wall of
the air tank 902. Preferably, air outlet port 932 is located at the
bottom of the air tank 902. The air outlet port 932 is an opening
that extends through the tank wall and is connected to the manifold
assembly 906 through outlet tubing. The air compressor assembly 900
may also include a wheel assembly 960 for transporting the air
compressor assembly 900.
[0046] Referring to FIG. 12, an exemplary vertical "hot-dog" type
air compressor assembly 1000 in accordance with the present
invention is shown. The air compressor assembly 1000 may include an
air tank 1002, an air compressor 1004, and a manifold assembly
1006. The air tank 1002 is a vertically disposed, cylindrical
compressed air tank, typically referred to informally in the art as
a vertical "hot-dog" style tank. The air tank 1002 may be made of
plastic, metal such as steel, or the like. The air tank 1002 has an
air inlet port which is connected to the air compressor 1004
through tubing 1034. There may exist a check valve (not shown)
inside the air inlet port, which allows air to flow from the air
compressor 1004 to the air tank 1002 but prevents air from flowing
from the air tank 1002 to the air compressor 1004. An air outlet
port 1032 is located at the wall of the air tank 1002. Preferably,
air outlet port 1032 is located at the bottom of the air tank 1002.
The air outlet port 1032 is an opening that extends through the
tank wall and is connected to the manifold assembly 1006 through
outlet tubing. The air compressor assembly 1000 may also include a
wheel assembly 1060 for transporting the air compressor assembly
1000.
[0047] Referring to FIG. 13, an exemplary vertical stationary type
air compressor assembly 1100 in accordance with the present
invention is shown. The air compressor assembly 1100 may include a
vertically disposed air tank 1102, an air compressor 1104, and a
manifold assembly 1106. The air compressor assembly 1100 is
stationary, that is, it may not be easily transported. The air tank
1102 may be made of plastic, metal such as steel, or the like. The
air tank 1102 has an air inlet port which is connected to the air
compressor 1104 through tubing 1134. There may exist a check valve
(not shown) inside the air inlet port, which allows air to flow
from the air compressor 1104 to the air tank 1102 but prevents air
from flowing from the air tank 1102 to the air compressor 1104. An
air outlet port 1132 is located at the wall of the air tank 1102.
Preferably, air outlet port 1032 is located at the bottom of the
air tank 1002. The air outlet port 1132 is an opening that extends
through the tank wall and is connected to the manifold assembly
1106 through outlet tubing.
[0048] In the exemplary embodiments illustrated in FIGS. 10 through
13, the air compressors 804, 904, 1004, 1104 may provide air to the
air tanks 802, 902, 1002, 1102 through tubing 834, 934, 1034, 1134,
respectively. During air usage, compressed air being released from
the air tanks 802, 902, 1002, 1102, because of its high pressure,
may drive condensate accumulated in the tanks 802, 902, 1002, 1102
out through the air outlet ports 832, 932, 1032, 1132,
respectively. The compressed air being released may mix with the
discharged condensate and be used by air powered tools.
[0049] It is understood that the air tanks 802, 902, 1002, 1102 of
the air compressor assemblies 800, 900, 1000, 1100 may have the
configuration shown in FIGS. 6 and 7, without departing from the
scope and spirit of the present invention. That is, instead of
having an air inlet port and a separate air outlet port, the air
tank may have a single air access port, through which air may be
supplied to the air tank from the air compressor, and compressed
air and condensate accumulated in the air tank may be released for
use by air tools.
[0050] It is understood that the air tanks 802, 902, 1002, 1102 of
the air compressor assemblies 800, 900, 1000, 1100 may have the
configuration shown in FIGS. 8 and 9, without departing from the
scope and spirit of the present invention. That is, the air tank
may have a centrally hollow conduit located inside the air tank.
Through the conduit, compressed air may be supplied to the air tank
from the air compressor, and compressed air and condensate
accumulated in the air tank may be released for use by air
tools.
[0051] In the exemplary embodiments illustrated in FIGS. 10 through
13, because condensate within the air tanks 802, 902, 1002, 1102 is
continuously discharged during air usage, the condensate is
discharged in small amounts not harmful to the air tool.
Accordingly, the air tanks 802, 902, 1002, 1102 do not require a
drain valve such as is commonly found in the air tanks of
conventional air compressor assemblies for draining condensate from
the tank. Thus, the drain valve may be eliminated. Furthermore, the
time required for maintenance of the air compressor assembly 800,
900, 1000, 1100 is reduced compared to that of a conventional air
compressor assembly, since the air tanks 802, 902, 1002, 1102 do
not have to be manually drained on a periodic basis. Moreover, tank
corrosion is reduced because condensate removal is continuous and
not dependent on operator maintenance actions.
[0052] In the exemplary embodiments illustrated in FIGS. 10 through
13, if moisture-free air is required (e.g., for paint spraying or
the like), a moisture separator may be coupled to an air hose that
is connected to the air compressor assembly 800, 900, 1000, 1100.
However, such moisture separators are also required by a
conventional air compressor assembly for applications such as paint
spraying, since it is known that moisture condenses in air hoses as
well as in the air tank of a compressor assembly. Thus, compared to
a conventional air compressor assembly, the air compressor assembly
800, 900, 1000, 1100 of the present invention would require no
additional equipment if used for applications requiring removal of
moisture (e.g., such as providing air to spray paint).
[0053] It is understood that the air compressor assembly according
to the present invention may also have air tanks of other
configurations without departing from the scope and spirit of the
present invention. For example, it may have two horizontally
disposed cylindrical compressed air tanks, positioned side by side
in a vertically oriented "double hot-dog" configuration.
[0054] It is also understood that the specific order or hierarchy
of steps in the methods disclosed are examples of exemplary
approaches. Based upon design preferences, it is understood that
the specific order or hierarchy of steps in the method can be
rearranged while remaining within the scope of the present
invention. The accompanying method claims present elements of the
various steps in a sample order, and are not meant to be limited to
the specific order or hierarchy presented.
[0055] It is believed that the present invention and many of its
attendant advantages will be understood by the foregoing
description. It is also believed that it will be apparent that
various changes may be made in the form, construction and
arrangement of the components thereof without departing from the
scope and spirit of the invention or without sacrificing all of its
material advantages, the form herein before described being merely
an explanatory embodiment thereof. It is the intention of the
following claims to encompass and include such changes.
* * * * *