U.S. patent application number 11/926681 was filed with the patent office on 2009-04-30 for air compressor.
This patent application is currently assigned to WARN INDUSTRIES, INC.. Invention is credited to Bryan M. Averill, Darren G. Fretz, Steven M. Schile, Eric J. Webb.
Application Number | 20090110567 11/926681 |
Document ID | / |
Family ID | 40583084 |
Filed Date | 2009-04-30 |
United States Patent
Application |
20090110567 |
Kind Code |
A1 |
Averill; Bryan M. ; et
al. |
April 30, 2009 |
Air Compressor
Abstract
A compact lightweight air compressor is provided with a DC motor
to provide versatile use in the field where no AC power source is
available. The air compressor includes a intercooler storage vessel
for cooling and storing the compressed air as well as a cooling fan
arrangement that allows cooling of all the air compressor
components.
Inventors: |
Averill; Bryan M.;
(Portland, OR) ; Schile; Steven M.; (Portland,
OR) ; Fretz; Darren G.; (Canby, OR) ; Webb;
Eric J.; (Vancouver, WA) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Assignee: |
WARN INDUSTRIES, INC.
Milwaukie
OR
|
Family ID: |
40583084 |
Appl. No.: |
11/926681 |
Filed: |
October 29, 2007 |
Current U.S.
Class: |
417/243 ;
417/410.3 |
Current CPC
Class: |
F04B 39/066 20130101;
F04B 39/12 20130101; F04B 35/04 20130101; F04B 27/053 20130101;
F04B 39/122 20130101; F04B 39/125 20130101 |
Class at
Publication: |
417/243 ;
417/410.3 |
International
Class: |
F04B 17/03 20060101
F04B017/03; F04B 35/04 20060101 F04B035/04 |
Claims
1. An air compressor, comprising: an electric motor including a
drive shaft; a crank assembly connected to a first end of said
drive shaft; a connecting rod attached to said crank assembly; a
piston connected to said connecting rod; a cylinder assembly
fixedly mounted relative to a first end of said electric motor and
receiving said piston therein; a fan drivingly attached to a second
end of said drive shaft; a shroud surrounding said fan for
directing cooling air axially along said motor housing from said
second end toward said first end; and an intercooler assembly
connected to said cylinder assembly for receiving compressed air
from said cylinder assembly.
2. The air compressor according to claim 1, wherein said
intercooler assembly includes a storage vessel and a plurality of
cooling fins disposed on a surface of said storage vessel.
3. The air compressor according to claim 1, wherein said
intercooler assembly is disposed above said electric motor.
4. The air compressor according to claim 1, wherein said
intercooler assembly is connected to said cylinder assembly by a
pipe attached to said cylinder assembly and extending a length of
said intercooler assembly and attached to an end of said
intercooler assembly furthest from said cylinder assembly.
5. The air compressor according to claim 4, further comprising a
cover plate covering said pipe.
6. The air compressor according to claim 1, further comprising a
base including a base wall and a plurality of sidewalls receiving
said electric motor therein.
7. The air compressor according to claim 6, further comprising a
handle assembly mounted to said base.
8. The air compressor according to claim 6, wherein said handle
assembly includes a pair of end support members mounted to opposite
ends of said base and a handle extending between said end support
members.
9. The air compressor according to claim 6, wherein said base
includes a plurality of vent openings therein.
10. The air compressor according to claim 1, wherein said motor is
a DC electric motor.
11. The air compressor according to claim 1, further comprising a
crankcase attached to said first end of said electric motor, said
cylinder assembly being mounted to said crankcase and said
intercooler assembly being mounted to said crankcase.
12. The air compressor according to claim 1, wherein said
compressor has a height of no greater than 12 inches, a length of
no greater than 14 inches and a width of no greater than 10
inches.
13. The air compressor according to claim 1, wherein said
compressor has a weight of no greater than 45 pounds.
14. An air compressor, comprising: an electric motor including a
drive shaft; a crank assembly connected to a first end of said
drive shaft; a connecting rod attached to said crank assembly; a
piston connected to said connecting rod; a cylinder assembly
fixedly mounted relative to a first end of said electric motor and
receiving said piston therein; and an intercooler assembly
connected to said cylinder assembly for receiving compressed air
from said cylinder assembly, said intercooler assembly including a
storage vessel and a plurality of cooling fins disposed on a
surface of said storage vessel.
15. The air compressor according to claim 14, wherein said
intercooler assembly is disposed above said electric motor.
16. The air compressor according to claim 14, wherein said
intercooler assembly is connected to said cylinder assembly by a
pipe attached to said cylinder assembly and extending a length of
said intercooler assembly and attached to an end of said
intercooler assembly furthest from said cylinder assembly.
17. The air compressor according to claim 16, further comprising a
cover plate covering said pipe.
18. An air compressor, comprising: an electric motor including a
drive shaft; a crank assembly connected to a first end of said
drive shaft; a connecting rod attached to said crank assembly; a
piston connected to said connecting rod; a cylinder assembly
fixedly mounted relative to a first end of said electric motor and
receiving said piston therein; a storage vessel connected to said
cylinder assembly for receiving compressed air from said cylinder
assembly; and a base including a base wall and a plurality of
sidewalls receiving said electric motor therein.
19. The air compressor according to claim 18, further comprising a
handle assembly mounted to said base.
20. The air compressor according to claim 19, wherein said handle
assembly includes a pair of end support members mounted to opposite
ends of said base and a handle extending between said end support
members.
21. The air compressor according to claim 18, wherein said base
includes a plurality of vent openings therein.
22. An air compressor, comprising: an electric motor including a
drive shaft; a crank assembly connected to a first end of said
drive shaft; a connecting rod attached to said crank assembly; a
piston connected to said connecting rod; a cylinder assembly
fixedly mounted relative to a first end of said electric motor and
receiving said piston therein; a vessel connected to said cylinder
assembly for receiving compressed air from said cylinder assembly,
wherein said compressor has a height of no greater than 12 inches,
a length of no greater than 14 inches and a width of no greater
than 10 inches.
23. The air compressor according to claim 22, wherein said
compressor has a weight of no greater than 45 pounds.
24. The air compressor according to claim 22, wherein said electric
motor is a DC electric motor.
25. The air compressor according to claim 23, further comprising a
base for receiving said electric motor and a handle mounted to said
base.
Description
FIELD
[0001] The present disclosure relates to air compressors and more
particularly, to a portable air compressor having a compact and
lightweight design.
BACKGROUND
[0002] The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
[0003] Air compressors have been found to be useful for numerous
tasks including inflating tires and rafts, providing compressed air
to power tools such as power nailers, impact wrenches, ratchets and
other uses. The availability of compressed air sources is generally
limited, based upon the common necessity for an AC power source.
Furthermore, the size and weight of typical air compressors can
prohibit the use of air compressors in certain instances.
SUMMARY
[0004] A portable air compressor is provided including a compact
lightweight construction which is provided with a DC electric motor
that allows the compressor to be driven by a vehicle battery or
other DC power sources. The air compressor can include a crank
assembly connected to a first end of the drive shaft of the
electric motor. A connecting rod can be attached to the crank
assembly. A piston is connected to the connecting rod. A cylinder
assembly is fixedly mounted relative to a first end of the electric
motor and receives the piston therein. A fan can be drivingly
attached to a second end of the drive shaft and a shroud can
surround the fan for directing cooling air axially along the motor
housing from the second end towards the first end. An intercooler
assembly is connected to the cylinder assembly for receiving
compressed air from the cylinder assembly.
[0005] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DRAWINGS
[0006] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
disclosure in any way.
[0007] FIG. 1 is a perspective view of an air compressor according
to the principles of the present disclosure;
[0008] FIG. 2 is a perspective view of the air compressor shown in
FIG. 1 with the optional handle removed;
[0009] FIG. 3 is a partially exploded perspective view of the
motor/compressor assembly and fan assembly according to the
principles of the present disclosure;
[0010] FIG. 4 is an end view of the motor/compressor assembly
according to the principles of the present disclosure;
[0011] FIG. 5 is a perspective view of the crank case according to
the principles of the present disclosure;
[0012] FIG. 6 is an exploded perspective view of the crank case
connecting rods and piston assemblies according to the principles
of the present disclosure;
[0013] FIG. 7 is a perspective view showing the assembly of the
connecting rods and pistons to the crank case and electric motor
according to the principles of the present disclosure;
[0014] FIG. 8 is a partial cross-sectional view of the assembly
shown in FIG. 7;
[0015] FIG. 9 is a partially exploded perspective view of the
cylinder assemblies being mounted to the crank case according to
the principles of the present disclosure;
[0016] FIG. 10 is a perspective view of the base of the compressor
according to the principles of the present disclosure;
[0017] FIG. 11 is a perspective view illustrating the mounting of
the solenoid to the base according to the principles of the present
disclosure;
[0018] FIG. 12 is a perspective view illustrating the mounting of
the compressor and the electric motor assembly into the base
according to the principles of the present disclosure;
[0019] FIG. 13 is a top plan view of the electric motor and
compressor mounted within the base according to the principles of
the present disclosure;
[0020] FIG. 14 is a perspective view illustrating the assembly of
the intercooler assembly onto the compressor unit according to the
principles of the present disclosure;
[0021] FIG. 15 is an exploded perspective view illustrating the
assembly of the handle assembly to the compressor according to the
principles of the present disclosure; and
[0022] FIG. 16 is a schematic diagram of the control circuit for
the air compressor according to the principles of the present
disclosure.
DETAILED DESCRIPTION
[0023] The following description is merely exemplary in nature and
is not intended to limit the present disclosure, application, or
uses. It should be understood that throughout the drawings,
corresponding reference numerals indicate like or corresponding
parts and features.
[0024] With reference to the attached Figures, the air compressor
10 will now be described. The air compressor 10 can include a base
12, an electric motor and compressor assembly 14, a compressed air
storage vessel 16 and an optional handle assembly 18.
[0025] With reference to FIG. 3, the motor and compressor assembly
14 will now be described. The motor and compressor assembly 14
includes an electric motor 20 that can be a DC powered series wound
field motor. The electric motor 20 includes a drive shaft 22 (best
shown in FIG. 8) that can be accessible from both ends of the
electric motor 20. A crank case 24 is mounted to a first end of the
electric motor 20. As shown in FIG. 5, the crank case 24 includes a
radially extending bearing support wall 26 which is disposed
against the electric motor 20 in the assembled position. The
bearing support wall 26 supports a bearing assembly 28 for
receiving and supporting the drive shaft 22 of the electric motor
therein. The crank case 24 includes a pair of legs 30 that include
a threaded bore therein for mounting the crank case 24 to the base
12.
[0026] The crank case 24 includes at least one and optionally two
cylinder mounting flanges 34 for mounting the cylinder assemblies
36 thereto as illustrated in FIG. 4. The cylinder mounting flanges
34 can include a plurality of threaded apertures 38 for receiving
fasteners for mounting the cylinder assemblies 36 thereto. In
addition, a pair of apertures 40 can be provided for receiving
dowel pins 42 for precisely locating the cylinder assemblies 36
relative to the crank case 24. The crank case 24 includes apertures
44 provided in each of the cylinder mounting flanges 34 for
receiving a connecting rod 46 therein. The connecting rods 46 are
mounted to a crank assembly 48 which is drivingly connected to the
drive shaft 22, as best illustrated in FIGS. 6-8.
[0027] The crank assembly 48 can include a counterweight member 50
having an aperture 52 with a pair of flats 54 for receiving the
drive shaft 22 of the electric motor 20. The counterweight member
50 includes a slot 56 extending from the aperture 52 to a perimeter
surface of the counterweight member 50. A fastener 58 is provided
in an aperture 60 that traverses the slot 56 so as to allow the
counterweight member 50 to be clamped onto the driveshaft 22 by
tightening the fastener 58 and drawing the slot 56 closed. An
offset crank pin 64 is connected to the counterweight member 50 and
is received in the connecting rods 46. A pair of spacers 65 are
provided between the connecting rods 46 and a rotor clip 66 secures
the connecting rods 46 on the crank pin 64.
[0028] As shown in FIG. 6, a piston assembly 68 is mounted to the
connecting rod 46 for receipt in the cylinder assembly 36. The
present disclosure provides an exemplary compressor device that
includes a V-twin (two) piston-cylinder arrangement, although it
should be understood that a single piston air compressor is also
contemplated as being within the scope of the present disclosure.
Furthermore, the addition of further cylinders could also be
utilized within the scope of the present disclosure. With reference
to FIG. 9, the cylinder assemblies 36 can include a cylinder body
70 that can include exterior cooling fins 72. A first cylinder
gasket 74 is disposed on the cylinder mounting flange 34 and the
cylinder body 70 includes apertures 76 for receiving the dowel pins
42 for properly locating the cylinder body 70 on the cylinder
mounting flange 34. A second cylinder gasket 80 is provided on the
upper end of the cylinder body 70 and a valve plate assembly 82 is
disposed above the second cylinder gasket 80. A head gasket 84 is
provided above the valve plate assembly 82 and a head 86 is
provided above the head gasket 84. The head 86 includes a plurality
of mounting apertures 88 for receiving threaded fasteners 90
therethrough that extend through corresponding apertures in the
head gasket 84, valve plate assembly 82, second cylinder gasket 80,
cylinder body 70, first cylinder gasket 74 and are threadedly
engaged with threaded apertures 38 provided in the cylinder flange
34 of the crank case 24.
[0029] With reference to FIG. 4, the head 86 of the cylinder
assembly 36 can include an inlet fitting in the form of an elbow 92
providing suction air to the cylinder assembly 36. A filter 94 can
be attached to the fitting 92 for preventing dust and debris from
entering the compressor. A discharge fitting in the form of an
elbow 96 is provided in communication with an exhaust passage of
the cylinder assembly 36. As shown in FIG. 14, the discharge
fittings 96 are connected to elongated copper tubes 98 which extend
a length of the compressed air storage vessel 16 and are connected
to inlet fittings 100 provided on the opposite end of the
compressed air storage vessel 16. The elongated copper tube 98
provides a cooling function for the compressed air being discharged
from the cylinder assemblies 36 prior to introduction into the
compressed air storage vessel 16. The tubing 98 can be made from
copper, but can also be made from additional materials that may
exhibit good heat conduction properties.
[0030] The compressed air storage vessel 16 can be in the form of
an intercooler which provides a storage vessel combined with a
plurality of cooling fins to assist in cooling the compressed air
received in the storage vessel 16. The vessel body can be formed by
extrusion or casting with the end walls being webbed to the finned
body. The storage vessel 16 can be provided with an outlet fitting
104 which serves as a quick connect for connection to various air
hose and accessories which are known in the air compressor art. The
intercooler 16 can also be provided with a pressure relief valve
106 and a pressure switch as will be described in greater detail
herein.
[0031] With reference to FIG. 3, a fan 110 is mounted to a second
end of the electric motor 20. A spacer 112 can be provided between
an end of the drive shaft 22 and the fan 110. A fastener 114 can be
inserted through an aperture 116 in the fan 110 and an aperture 118
in the spacer 112 to threadedly engage a threaded aperture 120
provided in the end of the drive shaft 22. An additional bushing
122 and spring lock washer 124 can be utilized for securing the fan
110 to the drive shaft 22. A shroud 128 can include an annular wall
portion 130 that can surround the fan 110 to direct air flow from
the fan 110 in an axial direction along the surface of the motor 20
toward the cylinder assemblies 36 and also along a bottom surface
of the intercooler storage vessel 16. The shroud 128 includes a
inlet aperture 132 that allows air to be drawn into the shroud 128
and then to be expelled axially along the motor.
[0032] With reference to FIG. 4, it is noted that an end cap 136
can be mounted to the open end of the crank case 24. The end cap
can be mounted to the crank case 24 by a plurality of fasteners 138
which engage threaded apertures 140 provided in the open end of the
crank case 24, as best illustrated in FIG. 9.
[0033] With reference to FIGS. 10 and 11, the base 12 can include a
base wall 144 and a plurality of side walls 146 a-c. The side walls
146 a-c can be provided with vent holes 150 for allowing cooling
air to pass into the base for cooling the motor and compressor
assembly 14 as well as cooling the compressed air storage vessel 16
and the compressor electronics. The vent holes 150 can be arranged
to provide for sufficient cooling air to enter the base 12 for
cooling the air compressor components. The base 12 includes a
mounting aperture 160 for mounting a switch solenoid device 154.
The use of threaded fasteners 156 and threaded nuts 158 are one
exemplary method of mounting the solenoid 154, although other
methods of mounting the solenoid 154 can be utilized. The switch
rocker 152 is inserted through an opening 160 provided in sidewall
146c.
[0034] With reference to FIG. 12, the motor and compressor assembly
14 can be inserted into the base 12 and secured to the bottom wall
144 by threaded fasteners 162 and nuts 164. The bottom wall 144 is
provided with apertures 166 for receiving the threaded fasteners
162. In the assembled condition, the fan shroud 128 can be opposite
to the side wall 146c which can be provided with vent holes 150 to
allow sufficient air flow to be drawn into the fan 110 for cooling
the components of the air compressor. As illustrated in FIG. 13,
the shroud 128 is disposed near the solenoid 154 so that air being
drawn into the shroud 128 passes over the solenoid 154 to cool the
electronic components. The fan 110 then directs the air axially
along the surface of the motor 20 for further cooling of the motor
20 and compressor components.
[0035] With reference to FIG. 5, the crank case 24 includes
mounting bosses 170 each provided with threaded apertures 172. As
illustrated in FIG. 14, a pair of elongated fasteners 174 are
provided for insertion through mounting apertures 176 provided in
the end side wall 146c and insertion through apertures or slots 180
provided in the compressed air storage vessel 16 and then are
threadedly received in the bosses 170 for securing the compressed
air storage vessel 16 above the motor 20.
[0036] As illustrated in FIG. 2, a cover plate 184 is provided over
top of the elongated tubes 98 which are disposed above the
compressed air storage vessel 16. The cover 184 provides a guard
against a user inadvertently contacting the elongated tubes 98. The
cover 184 is mounted to the base 12 by threaded fasteners 186 as
illustrated in FIG. 2. At the opposite end, the cover 184 is
mounted to a projecting portion 190 of the crank case 24 as
illustrated in FIG. 4. The projecting portion 190 includes a pair
of threaded apertures 192 for receiving fasteners 194 (see FIG. 2)
for securing the cover 184 to the crank case 24.
[0037] With reference to FIG. 15, the handle assembly 18 will now
be described. The handle assembly 18 is mounted to the base 12 and
includes first and second end support members 200. The end support
members can have a generally U-shape and can be formed from
circular tubing. Each end support 200 includes a pair of feet 202
which can be mounted to the base 12 utilizing threaded fastener 204
and nuts 206. In addition, a bumper 208 can be mounted to the
bottom of the feet 202 to provide a cushion to the bottom of the
air compressor 10. The end support members 200 each include an
upper cross bar portion 210 that are provided with a pair of
apertures 212 extending therethrough. Upper and lower handle
members 214, 216, respectively can be sandwiched around the cross
bar portion 210 and can receive threaded fasteners 218 therethrough
to secure the handle portions 214, 216 to the end support members
200. Additional threaded fasteners 220 can be utilized for securing
the upper handle portion 214 to the lower handle portion 216.
[0038] The handle assembly 18 can be utilized for lifting and
moving the compressor 10 in a convenient manner so that the
components of the compressor 10 do not have to be contacted by a
user. The air compressor 10 of the present disclosure has a total
weight no greater than 45 lbs and has a compact package having a
height no greater than 12 inches, a length of no greater than 14
inches and a width of no greater than 10 inches. Thus, the entire
air compressor can fit within a 14 inch cube which is far more
compact than commercially available air compressors. It is noted
that in a single piston compressor arrangement, the size and weight
of the air compressor can be further reduced so that the weight of
the air compressor can be less than 35 lbs. As illustrated in FIG.
1, the air compressor 10 is provided with a power cable 230 having
a cable quick connect 232 that can be utilized for connection to a
vehicle battery or other power source such as a 12 volt vehicle
battery 234 as illustrated in FIG. 16. The air compressor
electronics as illustrated in FIG. 16 includes an on/off switch 152
which is in communication with the vehicle battery 234. The
solenoid 154 provides a relay for connecting the battery source to
the motor 20 when the on/off switch 152 is closed. A pressure
switch 240 is provided for interrupting supply of current to the
solenoid 154 when the pressure in the compressed air storage vessel
16 exceeds a pre-determined level. The pressure switch 240 is
provided in communication with the compressed air storage vessel 16
so as to automatically turn off the air compressor when a
pre-determined pressure level is reached within the compressed air
storage vessel 16.
[0039] With the air compressor 10 of the present disclosure, the
compact and lightweight arrangement of the components provide for
easy portability of the air compressor 10 while the DC electric
motor 20 provides greater versatility by allowing the compressor 10
to be utilized wherever there is a DC power source such as a work
vehicle nearby. The air compressor 10 also provides unique cooling
features including a combined storage vessel and cooling function
in the intercooler storage vessel. The arrangement of the cooling
fan 110 for cooling all components of the air compressor 10 also
provides for greater efficiency.
* * * * *