Housing assembly for air compressor and the like

Abstract

A portable electric air compressor comprising a housing enclosing and supporting an air compressor sub-assembly. The housing includes separable upper and lower insulating members and an integral handle set into an annular recess for receiving and storing a compressor hose. The housing defines a neat and aesthetically pleasing appearance, and the handle is constructed and disposed for easy handling of the unit. The interconnection between the housing and the compressor sub-assembly is constructed for maximum vibration isolation and sound deadening, and is designed for ease of assembly and cool operation.

Description

SUMMARY OF THE INVENTION

The present invention is directed to a housing assembly for an air compressor or the like which encloses and efficiently supports an air compressor sub-assembly for quiet and cool operation. In addition, the housing assembly serves to help isolate the air compressor sub-assembly, and, in the case of an electric version, assists in electrical insulation so that the unit is relatively free from vibration and is double insulated. Furthermore, the housing includes an integral handle for ease in carrying, and the latter is set into and surrounded by an annular recess for convenient storage of the compressor hose when the unit is not in use. The described housing presents a neat and esthetically pleasing appearance which is devoid of unsightly fasteners and the like. Still further, the assembled unit is small, compact, and is well balanced for easy handling and storage, and is ideally suited for use by home owners as well as in more demanding environments.

The main objects, therefore, of the present invention are to provide a novel housing assembly for a portable, air compressor, or the like, including an electric powered, air compressor sub-assembly, wherein the housing construction neatly and efficiently encloses, supports, and electrically insulates and vibrationally isolates the air compressor sub-assembly.

Further important objects of the present invention are to provide a novel housing assembly of the above character which includes an integral, inset handle for easy handling of the unit, and which is disposed and balanced to achieve this, and further which includes an air hose receiving, annular recess surrounding the handle for convenient and out of the way storage of the compressor air hose when the unit is not in use.

Additional objects of the present invention are to provide a novel housing assembly of the above character which affords easy assembly of the air compressor sub-assembly, and which is relatively inexpensive to manufacture, rugged in construction, and reliable in use.

Other objects and advantages of the present invention will become more apparent from a consideration of the detailed description to follow, taken in conjunction with the drawings annexed hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating an air compressor housing assembly embodying the present invention;

FIG. 2 is an enlarged end view of the structure of FIG. 1;

FIG. 3 is a sectional view of FIG. 2, taken along the line 3--3 thereof;

FIG. 4 is an enlarged sectional view of FIG. 1 taken along the line 4--4 thereof;

FIG. 5 is a sectional view of FIG. 3, taken along the line 5--5 thereof;

FIG. 6 is a partially exploded, sectional view of FIG. 3 taken along the line 6--6 thereof; and

FIG. 7 is a sectional view of FIG. 4 taken along the line 7--7 thereof.

DETAILED DESCRIPTION

Referring now more specifically to the drawings, an air compressor housing assembly embodying the present invention is illustrated generally at 11 in FIG. 1 and is seen to include separable upper and lower members 13, 15. As shown in FIG. 3 an air compressor sub-assembly 17 is enclosed within the lower housing member 15 and is electrically powered such as, for example, from a conventional AC electric power source connected thereto through a line cord 19. The air compressor, when energized, is constructed to deliver compressed air through a hose 21 which extends upwardly through a fitting 22 disposed in an opening in the upper housing member 13. The hose 21, at its other end, is provided with a suitable fitting 25 for connection to a suitable output device. On/off control for the air compressor is afforded by a switch 26 having ears 28, 30 trapped between lugs 32, 34 integral with the housing members 13, 15, respectively. The switch 26 includes an externally accessible rocker type operator 27 for operation thereof. Suitable resilient feet 29 may be secured to the bottom of the lower housing member 15 to prevent surface marring, to enhance stability of the unit, and isolate vibration from the surface on which the unit is supported.

The air compressor sub-assembly 17 illustrated in the drawings, while not limiting of the invention, is of the linear variety and includes a cylinder housing 31 having field laminations 33 rigid therewith. Windings 36 on a spool 38 are mounted on laminations 33 and are suitably connected to line cord 19. The field laminations 33 are supported upon a plurality of ribs 39 formed integral with the bottom housing member 15. At the top, the laminations 33 are engaged by a plurality of spaced, sponge rubber pads 41 carried by ribs 42 integral with the upper housing member 13 when the latter is in place on the lower housing member 15. As shown, the upper housing member 13 is fixed to the lower housing member 15 by screws 43, 45, 47.

An armature-piston (not shown) is slidably disposed within the cylinder housing 31 and is adapted to reciprocate upon energization of the field laminations 33. When this occurs, air is alternately drawn in through air inlet openings 35 formed in the lower housing member 15 and is discharged through a coupling 37 to which the air hose 21 is connected. Suitable valve means is provided in the cylinder housing 31 to control inlet and discharge of air thereto. For a more detailed description of this construction, reference may be made to the copending application of Martin O. Schrock, et al., Ser. No. 333,018, filed Feb. 16, 1973, and owned by the assignee hereof.

It has been learned that the design and construction of the housing 11 in the area of air inlet openings 35 is most critical from the standpoint of noise occurring during operation of the unit. Thus, a rubber, rubber-like, or foam sleeve 49 constructed of, for example, unsaturated propolymer ethylene propylene rubber, is interposed between the cylinder housing 31 at the intake valve assembly 51 and the air inlet openings 35. This sleeve 49 defines an expansion muffling chamber 53 which requires that the sound generated by the action of the intake valve 51 pass through this chamber and the small inlet openings 35 to the outside of the housing 11. This action serves to break up and greatly reduce the audibility of the valve noise. Furthermore, the sleeve 49 serves to assist in isolating vibration of the compressor cylinder 31 from the lower housing member 15. If desired, a removable filter 57 constructed of, for example, polyurethane foam or felt, can be disposed within an annular chamber 59 in the outer surface of the lower housing member 15 over the inlet openings 35 to filter the incoming air.

It will be appreciated that the housing members 13, 15, being formed of a relatively high strength, plastic material having good electrical insulating properties, such as, for example, Abson 89, manufactured by B. F. Goodrich, serves to electrically isolate and insulate the user from the electric air compressor sub-assembly 17. Furthermore, the compressor sub-assembly 17 is transversely and longitudinally clamped within the housing 11 by means integral with the upper and lower housing members 13, 15. This means includes tapered walls 58, 60 formed integral with ribs 39, and tapered walls 70, 72 formed integral with ribs 42. The tapered walls 58, 60 and 70, 72 clampingly engage the laminations 33 as shown when the upper and lower housing members 13, 15 are secured together. The pads 41, carried by ribs 42 and located between the tapered walls 70, 72 provide additional and resilient clamping forces on the laminations 33. Thus, when the upper housing member 13 is tightened on the lower housing member 15 by means of screws 43, 45, 47, the compressor sub-assembly 17 is securely mounted and supported both longitudinally and transversely within the housing 11.

At the opposite end of the compressor, there is provided a linear fan housing 61 provided with openings (not shown) and having a piston fan 63 therein coupled to the reciprocating armature-piston. This fan 62 draws cooling air inwardly through slots 64 in the housing 11 and circulates it over the air compressor sub-assembly 17. As shown, in FIGS. 3 and 6, the fan housing 31 is substantially cylindrical in shape and is resiliently supported by means of a band of foam material 63 wrapped therearound and trapped in place between baffles 66, 68 integral with the upper and lower housing member 13, 15. Furthermore, this resilient band of material 63 serves as a seal so that cooling air drawn into the housing 11 by the fan 62 and to the left of the resilient band 63, as seen in FIG. 3, is caused to continuously recirculate over those parts of the compressor sub-assembly 17 subject to heating during operation of the unit.

For ease in handling the unit, the upper housing member 13 is provided with a handle 65 formed integral therewith. As shown, the handle 65 is set into a recess 67 in the housing member 13 and which is annular in configuration. Thus, the handle 65 protrudes only slightly from the top of the upper housing 13. Furthermore, the annular recess 67 defines an annular storage chamber for the compressor hose 21, and the handle 65 forms somewhat of a winding reel about which the loops of hose 21 may be wrapped, substantially as shown in FIGS. 1 and 3. Furthermore, the handle 65 is disposed with respect to the center of gravity of compressor unit so that the unit is well balanced and easy to handle and transport by the user. Finally, the particular construction and inset relation of the handle 65, together with the annular recess 67 provides a highly inexpensive, and yet neat and aesthetically pleasing appearance.

To assemble the compressor sub-assembly 17 to the housing, it is seen that the sub-assembly, with foam band 63 in place, is dropped into housing member 15 onto ribs 39. After connection of line cord 19, switch 32, and hose 21, housing member 13 is positioned and secured in place by screws 43, 45, 47.

By the foregoing, there has been disclosed a novel housing configuration and construction for an electric air compressor or the like calculated to fulfill the inventive objects hereinabove recited. While a preferred embodiment has been illustrated and described above in detail, various additions, substitutions, or modifications and omissions may be made thereto without departing from the spirit of the invention.

Claims

I claim:

1. A housing assembly for an air compressor of the type comprising a portable, power driven air compressor, housing means enclosing and supporting said air compressor, said air compressor having inlet valve means for admitting air thereto, said housing assembly comprising a housing having inlet openings formed therein adjacent said inlet valve means, resilient sleeve means engaging said housing and said air compressor adjacent said inlet openings and said inlet valve means, said resilient sleeve forming a resilient shock absorbing mounting for said compressor adjacent said housing and forming an expansion muffling chamber for said inlet valve means, whereby to substantially reduce operational noise of said compressor, said compressor having discharge means, air hose means connected to said discharge means and extending through said housing.

2. A housing assembly for a portable, electric, air compressor as claimed in claim 1 wherein said housing comprises separable housing members adapted to entrappingly contain said air compressor therein, said housing members being formed of an electrically insulating material, said housing members forming a container whose top is provided with a substantially annular recess therein, a central handle integral with said top and disposed in said recess and forming carrying means for said compressor, said compressor having air hose means connected thereto and extending through an opening in said housing within said recess, said air hose being adapted to be stored within said recess about said handle.

3. A housing assembly for a portable, electric, air compressor comprising upper and lower separable housing members, said air compressor including laminations disposed in said lower member and transversely supported upon and longitudinally clamped by ribs integral therewith, said upper member being formed with ribs which transversely support and longitudinally clamp said laminations when secured to said lower member, said housing members being formed of an electrically insulating material, and said housing members forming a container for said air compressor.

4. A housing assembly for a portable electric air compressor comprising upper and lower housing members arranged to receive and support a self-contained air compressor therebetween, said upper and lower members respectively including internal partitions extending vertically within said members and shaped to provide a seat for said compressor, resilient means interposed between said compressor and said partitions to tightly clamp said compressor to said housing, said air compressor having inlet valve means for admitting air thereto, inlet openings formed in at least one of said upper and lower housing members adjacent said inlet valve means, resilient sleeve means extending between and engaging said housing and said air compressor respectively adjacent said inlet openings and said inlet valve means, said resilient sleeve forming a resilient shock absorbing mounting for said compressor adjacent said housing and forming an expansion muffling chamber for said inlet valve means to substantially reduce operating noise of said valves transmitted through said inlet opening, said compressor having discharge means, and air hose means connected to said discharge means and extending through said housing.

5. A housing assembly for a portable, electric, air compressor comprising a pair of separable housing members arranged to receive and support a self-contained air compressor therebetween, each of said members including an internal rib for receiving said compressor, each of said ribs including a slot-shaped region defined between a pair of tapered walls, said compressor including an external portion received within said slot-shaped regions and clamped therein by said tapered walls to securely mount said compressor within said housing.