U.S. patent application number 14/941723 was filed with the patent office on 2016-05-19 for air compressor assembly having a condensate management system.
The applicant listed for this patent is BLACK & DECKER INC.. Invention is credited to Gary D. WHITE, Christina WILSON.
Application Number | 20160138578 14/941723 |
Document ID | / |
Family ID | 54545044 |
Filed Date | 2016-05-19 |
United States Patent
Application |
20160138578 |
Kind Code |
A1 |
WHITE; Gary D. ; et
al. |
May 19, 2016 |
AIR COMPRESSOR ASSEMBLY HAVING A CONDENSATE MANAGEMENT SYSTEM
Abstract
An air compressor assembly including a condensate management
system that removes condensate from an air storage tank. Condensate
inside the storage tank descends to the lowest point in the tank,
where a single port is located. The port can serve as both an inlet
for compressed air to the storage tank and an outlet of compressed
air from the storage tank. The condensate is drawn from the storage
tank to the manifold assembly through an air conduit and out of the
air compressor assembly through a connected tool when the tool is
activated.
Inventors: |
WHITE; Gary D.; (Medina,
TN) ; WILSON; Christina; (Jackson, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BLACK & DECKER INC. |
New Britain |
CT |
US |
|
|
Family ID: |
54545044 |
Appl. No.: |
14/941723 |
Filed: |
November 16, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62080445 |
Nov 17, 2014 |
|
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|
Current U.S.
Class: |
417/63 ;
137/312 |
Current CPC
Class: |
F04B 41/02 20130101;
F04B 53/04 20130101; F04B 35/06 20130101; F04B 35/04 20130101; F04B
39/16 20130101 |
International
Class: |
F04B 39/16 20060101
F04B039/16; F04B 37/20 20060101 F04B037/20; F04B 53/14 20060101
F04B053/14; F04B 39/10 20060101 F04B039/10; F04B 39/12 20060101
F04B039/12; F04B 41/02 20060101 F04B041/02; F04B 35/04 20060101
F04B035/04; F04B 39/06 20060101 F04B039/06 |
Claims
1. An air compressor assembly comprising: at least one storage tank
configured to store compressed air; an air compressor that includes
a pump assembly configured to supply the compressed air to the at
least one storage tank and a motor configured to drive the pump
assembly; a manifold assembly including an inlet for receiving the
compressed air from the pump assembly, a tank pressure gauge
configured to display a pressure of the compressed air entering the
manifold assembly, a pressure regulator configured to regulate a
pressure of the compressed air being output from the manifold
assembly, and an outlet configured to deliver an output of the
compressed air to a pneumatic tool; and an air conduit connected
between the manifold assembly and the at least one storage tank to
deliver the compressed air and a condensate from the at least one
storage tank to the manifold assembly; and a port disposed in the
at least one storage tank, the port admitting the compressed air
into, and releasing the compressed air and the condensate from, the
at least one storage tank to the air conduit and the manifold
assembly.
2. The air compressor assembly according to claim 1, further
comprising a housing encasing the at least one storage tank, the
pump assembly, and the motor and at least partially encasing the
manifold assembly.
3. The air compressor assembly according to claim 1, further
comprising a second storage tank for storing additional compressed
air.
4. The air compressor assembly according to claim 1, further
comprising a handle coupled to the housing to assist in
transporting the air compressor assembly.
5. The air compressor assembly according to claim 1, wherein the
air conduit comprises a hose.
6. The air compressor assembly according to claim 1, wherein the
port is integral with the at least one storage tank.
7. The air compressor assembly according to claim 1, wherein the
port is valve-free.
8. The air compressor assembly according to claim 1, wherein the
port is arranged between a lower portion of the at least one
storage tank and the manifold assembly.
9. A condensate management system for removing a condensate from a
compressed air storage tank, the system comprising: an air storage
tank having a condensate removal member disposed below a plane
passing through a horizontal center portion of the air storage
tank; and an air conduit connected to the condensate removal
member.
10. The condensate management system according to claim 9, wherein
the condensate removal member is valve-free.
11. The condensate management system according to claim 9, wherein
the condensate removal member comprises an outlet port in a bottom
of the air storage tank.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Application No. 62/080,445
entitled: Air Compressor Assembly Having a Condensation Management
System filed Nov. 17, 2014, which is hereby incorporated by
reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to the field of air
compressors and particularly to a condensate management system for
use with an air compressor assembly.
[0004] 2. Description of the Related Art
[0005] To meet instantaneous air flow demand, it is a common design
practice to include a compressed air reservoir in the form of an
air storage tank or other pressure vessel. The tank, usually with
an output regulator, can hold a quantity of compressed air to meet
peak demands from serviced loads, while allowing the use of a
smaller and lighter compressor that charges the tank and is capable
of meeting the average compressed air flow rate for the intended
use.
[0006] Air compressor assemblies typically include an air
compressor, having a motor driven pump assembly, mounted to a
compressed air storage tank, a manifold assembly in fluid
connection with the pump assembly, and a pressure switch assembly.
This configuration allows for the operation of an air-powered tool
from the reservoir of compressed air stored in the compressed air
storage tank. When the supply of compressed air in the compressed
air storage tank becomes depleted by the operation of the
air-powered tool, the air compressor may be operated for
repressurizing the compressed air storage tank. In this manner, air
compressor assemblies are further used to provide compressed air
for operating air-powered tools.
[0007] Traditional air compressors pump compressed air into the
tank through an inlet hose, then to a manifold and out to a
connected tool through a separate outlet hose. During the
utilization of a compressed air tank, it is common for water and
other liquids to condense from the air inside the air tank as a
consequence of the pressure and temperature differences inside the
tank and outside the tank. For example, due to the heat generated
by the pump during compression of the air and the subsequent
cooling of air in the tank, a condensate can accumulate within the
tank body. A primary source of the condensate is water vapor
naturally occurring in the supply of air. The condensate can cause
rust to develop within the tank resulting in reduced efficiency of
the compressor assembly. Air storage tanks, therefore, have a
separate drain valve for draining a condensate or water from the
tank. In order to remove the condensate, the operator manually
opens the drain valve, allowing the water to exit from the
tank.
[0008] Water and other liquids that may accumulate inside the air
tank may alternatively be removed through the installation of a
condensate removal device. Conventionally, a condensate removal
device is placed in proximity to a low point of a compressed air
tank within an air compressor assembly to remove condensate that
may form within a compressed air tank. Typically, condensate
removal devices known to the art are valves that may be opened and
closed easily yet are capable of maintaining a constant pressure
inside the air tank.
[0009] Since compressed air tanks tend to be large and heavy, they
may not be easily transported. As a result, typical mobile
compressed air tanks may be fitted to a frame comprising wheels and
handlebars. This allows a person or persons to lift the compressed
air tank and pull or push it to a desired location. While traveling
on a smooth surface, the design works well. However, in many
construction sites, movement to a remote location over an uneven
and unpaved surface may be necessary. A frequent problem that
occurs while moving the compressed air tank to a remote location is
that the drain valve for removing condensate from an air tank may
be damaged during transport to a remote location. Foreign objects
tend to come into contact with the valve during transport causing
damage to the valve. Another problem is that compressed air tanks
may be moved during the day and typically are placed upon the bed
of a pickup truck in order to transport the compressed air tank to
another worksite. Since typical compressed air tanks are heavy, it
is not easy for persons to use care and caution when placing the
compressed air tanks onto the bed of a pickup truck. Thus, the
compressed air tank may be lifted and pushed onto the bed in a
quick manner. Often, other items located on the bed of the truck
may come into contact with the drain valve damaging the valve when
the compressed air tank is placed upon the bed of a pickup truck.
Upon damage to the drain valve, the compressed air tank becomes
non-functional.
[0010] As such, there is a need for an air compressor assembly that
does not require a drain valve or the additional maintenance and
care of draining the air storage tank. Specifically, it would be
advantageous to have an air compressor assembly in which the
condensate drains from the tank automatically, so that the operator
would no longer need to manually drain water from the air storage
tank. In addition, there is a need to reduce the number of holes in
an air storage tank, which would improve the structural integrity
of the tank.
SUMMARY OF THE INVENTION
[0011] The air compressor assembly of the embodiments described
herein is designed to pump compressed air through a regulating
manifold assembly and to a connected tool. If the operator does not
use all of the air flowing into the manifold assembly, the excess
compressed air will flow into the storage tank for later use.
However, the longer the compressed air stays in the storage tank,
the more likely condensation is to occur. As such, the air
compressor assembly of the present invention includes a condensate
management system that provides at least one storage tank having a
single port at the bottom of the storage tank body that is
connected to a single air hose that allows entry and exit of the
compressed air to and from the air storage tank. Condensate
accumulated in the storage tank during operation of the pump
assembly flows to the bottom of the storage tank. Through gravity,
the condensate flows out of the storage tank body into the air
hose. As a result, the air compressor assembly of the embodiments
described herein allows condensate removal through the air pressure
hose, thereby eliminating the need for a drain valve and a separate
second air inlet in the storage tank. In addition, as a drain valve
and separate air inlet are no longer necessary, the condensate
management system also results in a reduction in manufacturing
costs.
[0012] Accordingly, in an embodiment, the present invention is
directed to a compressor assembly including a pump assembly of an
air compressor, a manifold assembly, and an air storage tank of an
air compressor. The present invention includes a condensate
management system between the pump assembly, manifold assembly and
air storage tank that directs condensate out of the compressor
assembly.
[0013] In an embodiment, an air compressor assembly includes at
least one storage tank configured to store compressed air; an air
compressor that includes a pump assembly configured to supply the
compressed air to the at least one storage tank and a motor
configured to drive the pump assembly. A manifold assembly includes
an inlet for receiving the compressed air from the pump assembly. A
tank pressure gauge is configured to display a pressure of the
compressed air entering the manifold assembly and a pressure
regulator is configured to regulate a pressure of the compressed
air being output from the manifold assembly. An outlet, such as a
tool connect member, is provided at one end of the manifold
assembly to deliver an output of the compressed air to a connected
tool. An air conduit, such as a hose, is connected between the
manifold assembly and the at least one storage tank to deliver the
compressed air and a condensate from the at least one storage tank
to the manifold assembly. A port is disposed in the at least one
storage tank. The port admits the compressed air into, and releases
the compressed air and the condensate from, the at least one
storage tank to the air conduit and the manifold assembly. The port
thereby serves as both an inlet port and an outlet port for
compressed air.
[0014] The air compressor assembly can have a housing that encases
the at least one storage tank, the pump assembly, and the motor.
The housing can at least partially encase the manifold assembly.
The housing can have a handle to assist in transporting the air
compressor assembly.
[0015] A second storage tank can be added to the air compressor
assembly in order to store additional compressed air.
[0016] The port can be integral with the at least one storage tank
and be valve-free.
[0017] The port serves as a condensate management system and can be
arranged between a lower portion of the at least one storage tank
and the manifold assembly. The condensate management system
provides for the removal of a condensate from the air storage tank
and the entire air compressor assembly.
[0018] In another embodiment, a condensate management system is
provided for removing a condensate from a compressed air storage
tank of the air compressor assembly. The condensate management
system includes an air storage tank having a condensate removal
member disposed below a plane passing through a horizontal center
portion of the air storage tank; and an air conduit connected to a
valve-free condensate removal member. The valve-free condensate
removal member includes an outlet port in a bottom of the air
storage tank.
[0019] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not necessarily restrictive of the
invention as claimed. The accompanying drawings, which are
incorporated in and constitute a part of the specification,
illustrate embodiments of the invention and together with the
general description, serve to explain the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The numerous advantages of the present invention may be
better understood by those skilled in the art by reference to the
accompanying Figures. In the Figures, like reference numerals
designate corresponding parts throughout the several views.
[0021] FIG. 1 is a perspective view of an embodiment of an air
compressor assembly housing having the condensate management system
in accordance with an embodiment of the present invention;
[0022] FIG. 2 is an internal rear perspective view of the air
compressor assembly within the housing, in accordance with an
embodiment of the present invention;
[0023] FIG. 3 illustrates the pump assembly and condensate
management system of the air compressor assembly in accordance with
an embodiment of the present invention;
[0024] FIG. 4 illustrates the manifold assembly and condensate
management system of the air compressor assembly in accordance with
an embodiment of the present invention;
[0025] FIG. 5 is a left side view of the air compressor assembly in
accordance with an embodiment of the present invention; and
[0026] FIG. 6 is a right side view of the air compressor assembly
in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Reference will now be made in detail to the presently
preferred embodiments of the invention, examples of which are
illustrated in the accompanying drawings.
[0028] Referring generally to FIGS. 1-6, exemplary embodiments of
the present invention are shown.
[0029] Briefly, as shown in FIGS. 1 and 2, the air compressor
assembly 10 includes a housing 12 that encases a compressor or pump
assembly 14, which is operable for intaking and compressing ambient
air, a power source, such as an engine or electric motor 16, for
providing power to the pump assembly. The motor 16 may be of any
known type, such as an induction motor or a universal motor and, in
the example provided, includes a power cord 28 that permits the
motor 16 to be coupled to a source of alternating current power,
such as a conventional outlet. A pressure vessel, such as a storage
tank 18 is coupled to a manifold assembly 20, and a pressure switch
assembly 22 is operatively connected to the manifold assembly. The
compressed air that exits the pump assembly 14 is discharged
through the manifold assembly 20 and delivered to a tool connect
member 24 for powering air-powered tools. Excess compressed air is
delivered to the storage tank 18, which serves as a reservoir for
the compressed air. The excess compressed air is delivered to the
storage tank 18 through a port 19, which can serve as an inlet
port. The port 19 can be a tubular member attached to or integrally
formed with the storage tank. Compressed air can be drawn from the
storage tank 18 through the same port 19, in this capacity, serving
as an outlet port. Any condensate within the storage tank 18 is
drawn out with the compressed air, allowing the port 19 to also
serve as a condensate removal member.
[0030] A conduit is connected between the port 19 of the storage
tank and an inlet of the manifold assembly 20. The conduit is used
to deliver the compressed air and condensate from the storage tank
18 to the manifold assembly.
[0031] The manifold assembly 20 is operatively fitted to the
storage tank 18 allowing compressed air to be drawn from storage
tank, as needed, for inflating sports or recreation equipment, or
for emergency uses such as inflating vehicle tires or powering air
powered tools. Air-powered tools include, but are not limited to
pneumatic fasteners or nailers, impact wrenches, ratchet wrenches,
sprayers, grinders, socket driving tools, material shaping tools,
sanding tools, spray painting tools, inflation chucks, and the
like. Herein the term "tool" is used to designate an air-powered or
pneumatic tool, or inflatable member.
[0032] The motor 16 includes a fan 17 that can be coupled to the
output shaft (not shown) of the motor 16. The fan 17 can circulate
cooling air over the motor 16 and the pump assembly 14 by drawing
ambient air into the housing 12. Ambient air enters the housing 12
through louvered openings 25 in front of the motor fan 17. The
housing 12 includes a handle 26 to facilitate portability of the
air compressor assembly 10. The housing can be made from any
material including, but not limited to plastic or other resinous
material.
[0033] As shown in FIGS. 2 and 3, the pump assembly 14, driven by
the electric motor 16, is configured to supply compressed air
through the manifold assembly 20 to the tool connect member 24 and
any connected tool or pressurized air member. Alternatively, the
pump assembly 14 can be configured to supply compressed air only
through the manifold assembly 20 to the storage tank 18, instead of
directly to the air storage tank. As shown in FIG. 2, the pump
assembly 14 can have a pump cylinder 30, a cylinder head 32, a
valve plate assembly 34 mounted between the pump cylinder 30 and
the cylinder head 32, and a piston (not shown) which is
reciprocated in the pump cylinder 30 by an eccentric drive 36. The
eccentric drive 36 can include a sprocket 38 which can drive a
drive belt 40 which can drive a pulley 42. A bearing 44 can be
eccentrically secured to the pulley 42 by a rod bolt or a screw 46,
and to a connecting rod 48. Preferably, the sprocket 38 and the
pulley 42 can be spaced around their perimeters and the drive belt
40 can be a timing belt. The pulley 42 can be linked to the
sprocket 38 by the drive belt 40. As the pulley 42 rotates about
its axis, the bearing 44 and an attached end of the connecting rod
48 are moved around a circular path.
[0034] The ambient air 100 can be compressed in the pump cylinder
30 by the piston. The cylinder head 32 defines an inlet for the
ambient air, and an outlet 50 for the compressed air 102.
Compressed air 102 can exit the cylinder head 32 via the compressed
air outlet 50 and can flow through a first pressure hose 52 to
enter the storage tank and flow through a second pressure hose 54
to enter the manifold assembly 20. Heat generated by the pump
assembly 14, and in particular, the heat from the cylinder head 32,
can be exhausted through louvered openings 33 in the housing 12,
adjacent to the cylinder head.
[0035] The pump assembly 14 is connected to the pressure switch 22,
that can be located in a gauge header 82 (see FIG. 4) that supports
the manifold assembly 20. Preferably, the pump assembly 14 is
connected to the manifold assembly 20 and the pressure switch 22
via a one-way valve, such as a check valve 56, or the like. The
check valve 56 ensures that the air from the storage tank 18 does
not leak out toward the pump assembly 14. The pressure switch 22
operates the pump assembly 14 for supplying compressed air to a
connected tool.
[0036] Excess compressed air, as determined by the pressure switch
22, is delivered to the storage tank 18. When the storage tank 18
has been fully pressurized (i.e., when the compressed air capacity
has been reached), the pressure switch 22 operates to stop the pump
assembly 14 from supplying compressed air to the storage tank 18,
thereby preventing overpressurization of the storage tank.
Specifically, the pressure switch 22 regulates pressure within the
storage tank 18 by alternately starting and stopping the pump
assembly 14 to supply compressed air. In one embodiment, the
pressure switch 22 is coupled with the pump assembly 14 for
electrically actuating the pump assembly. The pressure switch 22
causes the pump assembly to operate until the compressed air
storage tank is full. When the storage tank is full, the air
pressure in the tank will be sensed by sensors (not shown) within
the pressure switch 22 that open sensor contacts to stop the motor
16, and trigger the pressure switch to turn off. When the pressure
switch 22 is turned off, air is no longer pumped into the storage
tank 18. In this manner, the pressure of the compressed air in the
storage tank 18 is maintained within a range generally suitable for
powering one or more air powered tools.
[0037] The stored air is available for use when a connected tool is
turned on so that the air leaves the storage tank and flows out of
the air compressor assembly though the tool connect member 24 of
the manifold assembly 20.
[0038] The manifold assembly 20 may also include a safety pressure
relief valve 58 for relieving pressure within the manifold assembly
20 and the storage tank 18. In accordance with an exemplary
embodiment, the pressure relief valve 58 may be opened by a
operator by pulling outward on an enlarged ring 60 having a tab or
"fob" 62 attached thereto. Preferably, the ring 60 and fob 62 are
sized to be easily gripped by the operator of the air compressor 10
to open the safety pressure relief valve 58.
[0039] In an embodiment of the present invention, as illustrated in
FIGS. 2-6, the air compressor assembly 10 includes a plurality of
air conduits or hoses for delivering compressed air throughout the
assembly. The air conduits include a first pressure hose 52
disposed between the pump assembly 14 and the storage tank 18, and
a second pressure hose 54 disposed between the storage tank and the
manifold assembly 20.
[0040] As shown in FIG. 3, the pump assembly 14 is operatively
connected to the manifold assembly 20 through the first pressure
hose 52 and a second pressure hose 54. The first pressure hose 52
delivers compressed air from the pump assembly 14. A first end 66
of the first pressure hose 52 is connected to the outlet port 50 of
the cylinder head 32 and a second end 68 of the first pressure hose
is connected to an inlet port 70 of an adaptor assembly connector,
such as a splitter valve 72. The splitter valve 72 can direct the
compressed air into at least two directions. For example, the
splitter valve 72 can direct one stream of compressed air to enter
the second pressure hose 54 and direct another stream of compressed
air to enter the storage tank 18. The second pressure hose 54 has a
first end 74 that is connected to an outlet port 76 of the splitter
valve 72 and a second end 78 that is connected to an inlet port 80
in the gauge header 82 of the manifold assembly 20.
[0041] The pressure hoses 52, 54 include hose couplings that attach
the hoses to the splitter valve inlet port 70 and outlet port 76,
and to the manifold assembly inlet port 80. In an embodiment of the
present invention, the second pressure hose 54 can also have a
threaded coupling that can be screwed onto the port 19 of the
storage tank 18, that may also be threaded. A hose clamp 68, as
shown in FIGS. 3 and 5 can further secure the second pressure hose
54 and the coupling to the storage tank 18.
[0042] Compressed air can be drawn from the storage tank 18 through
the manifold assembly 20 to a connected tool. Compressed air that
enters the storage tank 18 can include excess air that cannot
immediately be used by a connected tool, but can be drawn out for
later use. As such, the second pressure hose 54 can be arranged
delivering compressed air from the pump assembly 14 and/or the
storage tank 18 to the manifold assembly 20 and to a connected
tool. In this arrangement, the second pressure hose 54 serves as a
drain for delivering air and any liquid condensate from the storage
tank 18 through the same compressed air inlet port in the storage
tank. In operation, compressed air is supplied from the pump
assembly 14 through the first pressure hose 52 to the splitter
valve 72. The splitter valve 72 is connected to the tank port 19.
The splitter valve 72 is also connected to the manifold assembly 20
by the first pressure hose 54. When the pump assembly 14 is
operating, compressed air is pumped through the first pressure
hose, through the manifold assembly 20, and out of the tool connect
member 24 to the connected tool. If the connected tool requires
less compressed air than is being created by the pump assembly 14,
or the connected tool is not being used, compressed air will also
pass from the splitter valve 72 through the port 19 and into the
storage tank 18 until the pressure reaches the limit of the
pressure switch 22 and the motor 16 stops. When compressed air is
required again, the compressed air will flow out of the storage
tank 18 through the port 19, through the splitter valve 72 and out
of the port 74 and into the hose 54, leading to the manifold
assembly 20 and the tool connect member 24. As compressed air flows
out of the storage tank 18, any moisture that condensed while the
compressor was cooling will also flow or drain out.
[0043] In an alternate embodiment of the present invention, a first
pressure hose can be configured to directly deliver compressed air
from the pump assembly 14 to the manifold assembly 20, and a second
pressure hose can be configured to deliver compressed air from the
manifold assembly to the storage tank 18. Likewise, in this
arrangement, the second pressure hose can serve as both a feed for
delivering air to the storage tank and a drain for delivering air
and any liquid condensate from the storage tank through a same port
in the storage tank.
[0044] Although a hose is disclosed, an air conduit of any material
for conveying a gas or air, such as a metal pipe, can be used.
[0045] Referring to FIG. 4, the manifold assembly 20 can include a
tank pressure gauge 90 and a pressure regulator or pressure
adjustment knob 92. The tank pressure gauge 90 displays the
pressure of the compressed air in the storage tank and the pressure
regulator/pressure adjustment knob 92 adjusts and displays the
pressures delivered by the air compressor 10 through the tool
connect member 24 to a connected tool. The pressure
regulator/adjustment knob 92 controls an internal regulator (not
shown) that is set within an output pressure guide. The knob 92 is
rotatable to a position that corresponds to the desired air output
pressure to a connected tool. The desired air output pressure guide
can be located on the face of the air compressor to be readable by
the operator. Alternatively, the manifold assembly 20 can include a
tank pressure gauge 90 and a separate regulator gauge.
[0046] The tank pressure gauge 90 and the regulator gauge may be
configured to monitor and provide readings on storage tank pressure
and manifold assembly outlet pressure, respectively. It is
contemplated that the gauges 90, 92 may provide a variety of
readouts, such as needle, digital readouts, plasma readouts, and
the like. As shown, the pressure regulator/adjustment knob 92 has a
dial or like control for selecting the pressure of air to be
delivered by the air compressor assembly 10 to a connected tool.
Those of skill in the art will appreciate that other dials and
controls, such as a depression switch, digital controller, and the
like may be provided for regulating the pressure of air delivered
by the air compressor assembly and/or the pressure of the air in
the compressed air storage tank.
[0047] As illustrated in FIG. 4, for example, the tank pressure
gauge 90, pressure regulator/adjustment knob 92 and tool connect
member 24 are coupled to the gauge header 82. The tool connect
member is located at one end of the gauge header 82. Alternatively,
the manifold assembly inlet port 80 can be located at one end of
the manifold assembly 20 and the tool connect member 24 can be
located at an axially opposite end of the gauge header 82 and
provide a means for connecting a tool.
[0048] The pressure regulator/adjustment knob 92 is connected to
the tank pressure gauge 90 and the second pressure hose 54 for
delivering compressed air to the connected tool. The manifold
assembly 20 includes an adapter assembly 84 providing for the
functional coupling of the first and second pressure hoses, with
the air compressor. In an embodiment, the adapter assembly 84 can
include a connector member for coupling each of the first and
second pressure hoses 52, 54 and the tank assembly with the
splitter 72 and the gauge header 82 of the manifold assembly 20,
respectively. It is contemplated that the adapter assembly 84 may
comprise a variety of fastening assemblies, such as a threaded
fastener, a compression fastener, and the like, without departing
from the scope and spirit of the present invention.
[0049] As illustrated in the Figures, the air compressor assembly
10 can have a single "pancake" shaped (i.e., a relatively short and
large diameter cylinder with convex ends) compressed air storage
tank structure. However, it will be appreciated that other shaped
tanks may be used for storing compressed air, including but not
limited to cylindrical tanks having a horizontal orientation, and
tanks having specialized shapes. Further, it should be noted that
the air compressor assembly 10 may include more than one compressed
air storage tank, such as two air storage tanks mounted
top-to-bottom or side-by-side, or the like. The use of air storage
tanks having configurations other than those specifically
illustrated herein is well known in the art. Consequently, the
substitution of such tanks in place of the compressed air storage
tanks specifically illustrated in the Figures does not depart from
the scope and intent of the present invention.
[0050] The storage tank 18 is appropriately sized for containment
within the air compressor assembly housing 12, while providing a
minimum volume to keep the pressure switch operating to supply
compressed air from the pump assembly 14. In an embodiment of the
present invention, the storage tank 18 can have a maximum capacity
of about 1 gallon, 2 gallons, 5 gallons, 10 gallons or more. Those
skilled in the art will understand that the storage tank may be
configured somewhat differently, as with a conventional cylindrical
style (not shown) or with a plurality of tank structures that are
coupled in fluid connection.
[0051] In the air compressor assembly 10 of an embodiment of the
present invention, the storage tank 18 is provided to reserve a
predetermined amount of compressed air sufficient to trigger the
pressure switch 22 to turn the pump assembly 14 off. As the source
of the predetermined amount of compressed air is ambient air which
includes water vapor, upon pressurization, additional water vapor
is introduced. Further, condensation occurs when heated gas cools,
such as when the gas is exposed to a lower temperature, such as in
the storage tank.
[0052] In an exemplary embodiment, when an air storage tank holds a
small amount of air, such as, for example, one gallon or less, and
a connected tool is drawing air from the air compressor assembly,
the stored air is used quickly and exhausted before being heated by
additional compressed air from the pump assembly, or before cooling
down as a result of the air remaining in the storage tank. In
operation, the compressed air is not given time to significantly
heat up or cool down therefore, the condensate does not have an
opportunity to accumulate. Due to the small size of the storage
tank, the condensate is continually forced or blown out of the air
compressor assembly by being drawn out to a connected tool. If
compressed air remains in the storage tank, the amount of
condensate is insignificant, such that when operation resumes, the
condensate is blown out of the air compressor assembly by being
drawn out to a connected tool.
[0053] In order to facilitate the draining of the condensate from
the storage tank 18, the tank is suspended within the air
compressor assembly housing 12, as shown in FIG. 2, for example.
Gravity causes the condensate to flow to the bottom of the storage
tank and to the port 19. In an embodiment, the port 19 can be
located on the bottom center portion of the storage tank 18. The
condensate is forced out of the storage tank through the second
pressure hose 54, when the connected tool is activated. When the
pressure regulator/adjustment knob 92 is rotated to its open and
predetermined position, at a set point controlled by a
spring-loaded piston (not shown), to maintain the desired pressure,
a connected tool draws the compressed air from the storage tank.
The force of the compressed air pushes the condensate through the
manifold assembly 20 and out of the air compressor assembly 10.
With the storage tank port 19 at the bottom center of the storage
tank 18, the tank does not have to be tilted or manipulated in
order to drain the condensate. Moreover, the port 19 is valve-free
allowing the condensate to be readily removable, without operator
intervention by powering ON on the air compressor assembly 10 and
activating the connected tool.
[0054] The amount of air drawn from the storage tank 18 is
controlled by the regulator/pressure adjustment knob 92. It is
commonly the case, with typical air compressor assemblies, that the
storage tank must comprise multiple ports and an inlet port must be
physically separated from the outlet port in order to prevent the
quick turn of air from inlet to outlet. With the port 19 serving as
both the feed and drain hose, the storage tank 18 need only use a
single port to accomplish both compressed air inlet and outlet.
[0055] An ON/OFF power switch 88 controls operation of the air
compressor. As shown in FIG. 1, the ON/OFF switch 88 is illustrated
as mounted on the air compressor housing, for example, and is
operationally coupled with the pressure switch assembly. The ON/OFF
switch 88 is located remotely from the pressure switch of the
pressure switch assembly 22. The ability to remotely locate the
ON/OFF switch 88 provides greater flexibility to the operator for
access to the switch for turning the compressor on and off and
increases the ease of use of the air compressor 10. It is
contemplated that the ON/OFF switch 88 may be lighted to show when
a circuit providing electricity to the pressure switch is
complete.
[0056] For example, when the ON/OFF switch 88 is lit the operator
knows that the pressure switch 22 is monitoring the pressure within
the storage tank so that when the pressure passes a threshold value
the pressure switch will activate or de-activate the pump assembly
as indicated by the threshold value. In operation, the air
compressor may have 200 PSI of air within the storage tank 18 and
through use of the air compressor, the air pressure may drop to 150
PSI. The pressure switch 22 may have a threshold value of 175 PSI,
whereupon the pressure switch activates the pump assembly when
pressure within the storage tank drops below 175 PSI. When the
ON/OFF switch 88 is not lit, the operator knows that the pressure
switch 22 is not monitoring the air pressure within the storage
tank, thus, by the present example, the air pressure would continue
to drop below the 175 PSI value, if the pump assembly 14 is not
activated to increase the pressure. It is further contemplated that
the ON/OFF switch 88 may include a protective covering, such as a
plastic boot for extreme environment operation. The ON/OFF switch
88 may be enabled as a two-position switch. However, it is
contemplated that a variety of switch assemblies may be employed
with the present invention.
[0057] The arrangement of the pump assembly 14, manifold assembly
20, and storage tank 18 works together to force water out of the
air compressor assembly 10. If compressed air does condensate
inside the storage tank, gravity forces the condensate to descend
to the bottom of the tank. At the bottom of the storage tank, the
port 19 receives the condensate and allows it to flow to the
connected air conduit such that, at the initial next operation of
the air compressor, the compressed air drawn from the tank forces
the condensate out of the tank and through the air conduit to the
manifold assembly.
[0058] While aspects of the present invention are described herein
and illustrated in the accompanying drawings in the context of an
air compressor, those of ordinary skill in the art will appreciate
that the invention, in its broadest aspects, has further
applicability.
[0059] It will be appreciated that the above description is merely
exemplary in nature and is not intended to limit the present
disclosure, its application or uses. While specific examples have
been described in the specification and illustrated in the
drawings, it will be understood by those of ordinary skill in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the present disclosure as defined in the claims. Furthermore,
the mixing and matching of features, elements and/or functions
between various examples is expressly contemplated herein, even if
not specifically shown or described, so that one of ordinary skill
in the art would appreciate from this disclosure that features,
elements and/or functions of one example may be incorporated into
another example as appropriate, unless described otherwise, above.
Moreover, many modifications may be made to adapt a particular
situation or material to the teachings of the present disclosure
without departing from the essential scope thereof. Therefore, it
is intended that the present disclosure not be limited to the
particular examples illustrated by the drawings and described in
the specification as the best mode presently contemplated for
carrying out the teachings of the present disclosure, but that the
scope of the present disclosure will include any embodiments
falling within the foregoing description and the appended
claims.
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