Note: Descriptions are shown in the official language in which they were submitted.
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AIR COMPRESSOR
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Patent Application
Serial Nos. 10/805,987, filed March 22, 2004, and 11/053,033, filed February
8,
2005, which are continuation-in-part applications of U.S. Patent Application
Serial
No. 10/630,090 filed July 30, 2003, which is a continuation of U.S. Patent
Application Serial No. 10/154,416 filed May 23, 2002. U.S. Patent Application
Serial No. 10/154,416 claimed the benefit of U.S. Provisional Application No.
60/366,676, filed March 22, 2002 and is a continuation-in-part of U.S.
Application
Serial No. 29/136,877 filed February 8, 2001. U.S. Application Serial No.
29/136,877 issued as U.S. Design Patent No. D461,196 on August 6, 2002.
Each of the aforementioned applications is incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates generally to the field of
portable air compressors and more particularly to hand portable air
compressors.
BACKGROUND OF THE INVENTION
[0003] Small air compressors have become common tools around the
home, workshop and work site. For home, recreation and other light duty uses
such as inflating sports or recreation equipment or for emergency use in
inflating
a car tire a number of very small and lightweight compressors are available.
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Such tasks require relatively low-pressure compressed air and/or relatively
low
airflow rates. Weight is kept low and portability is maximized in these
designs by
use of small, low volume and/or low-pressure compressors powered by small
lightweight electric motors. Additionally, significant weight, size and cost
savings
are achieved by the omission of a high-pressure vessel (i.e., air tank), as
well as
an oil lubrication system.
[0004] Many jobs, however, require higher air pressures, and/or greater
instantaneous air flow demands which typically exceed the capacity of the
hobby
or recreational use compressors. To satisfy the demands of higher air pressure
and higher airflow tasks it is necessary to increase the size of the
compressor
and the related motor or engine. Furthermore, rather than sizing the
compressor
to meet the maximum theoretical instantaneous air flow demand, it is common
design practice to include a compressed air reservoir in the form of an air
tank or
other pressure vessel. The tank, usually with an output regulator, can hold a
quantity of pressurized 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.
[0005] The air tank and the larger compressor that are typically required to
meet the desired pressure and airflow levels substantially increase the weight
and overall size of the compressor package. Units designed for high pressure
and high volume tasks can rapidly reach a weight and size where the well-known
motor vehicle mounted or towed trailer configuration is the only practical
form.
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Still, there are a range of intermediate capacity air compressors that are
common
tools around the construction site and which are man portable.
[0006] Current models of man portable air compressor packages comprise
a stand or supporting structure on or in which are mounted a motor or engine,
an
air compressor, an air tank, a discharge manifold and various valves,
instrumentation and controls. Many of the larger portable configurations are
provided with wheels, in what is often referred to as a wheelbarrow
configuration,
so that they can be moved by a single user. Examples of wheeled air
compressors include Models D55170 and D55270, which are marketed by The
Black & Decker Corporation under the DeWalt trade name.
[0007] Still, some users of intermediate capacity professional grade
compressors find it necessary or desirable to have a compressor that is
capable
of being lifted and carried by hand. One common approach taken by air
compressor manufacturers to improve the portability of such intermediate
capacity professional grade compressors has been to redesign the air
compressor so as to reduce its weight. Despite such efforts, intermediate
capacity professional grade compressors frequently weigh more than 50 pounds
and thus remain difficult to lift and move by hand, even for those users who
are
physically strong.
[0008] Aside from the issue of their weight, hand-portable intermediate
capacity professional grade compressors are also known to be quite
cumbersome to transport. In this regard, the configurations that use two
cylindrical tanks or a single pancake tank (i.e., a cylindrical tank of large
diameter
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but small height with convex ends) have become common, as have the mounting
schemes for mounting the compressor and the motor. For example,
configurations that use two cylindrical tanks typically mount the compressor
and
motor alongside the tanks, whereas configurations that use a single pancake
tank typically mount the compressor and motor on an end of the tank.
[0009] These conventional air compressor arrangements provide a
package with a relatively large base or footprint, and a center of gravity
that is
positioned in an approximately centered position within the footprint. While
such
arrangements provide the air compressor with a configuration that is
relatively
stable during its operation, lifting and carrying air compressors with these
configurations tends to be rather awkward and difficult. In this regard, these
configurations typically employ a handle (for lifting and carrying the air
compressor) that is attached to an appropriate structure, such as the stand or
the
air tank, at a location that is located vertically above the center of gravity
of the
entire air compressor package. The handle is generally oriented in a manner
that requires the air compressor package to be lifted vertically upwards and
carried in an orientation that is substantially the same as the orientation in
which
it is operated.
[0010] Lifting and carrying the known intermediate air compressor
packages in this manner, however, is relatively difficult, since the footprint
of
these air compressor packages tends to be relatively large and thus requires
the
user to hold the air compressor package with a somewhat outstretched arm such
that the wrist of the user is in a state of flexion. In an effort to bring the
air
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compressor package's center of gravity closer to the central axis of the user,
the
user will typically tilt their upper body away from the load of the air
compressor
package and thus will lift and transport the air compressor package with a
body
posture that is uncomfortable and awkward.
SUMMARY OF THE INVENTION
[0011] In one form, the present teachings provide an air compressor that
includes a support structure, a compressor and an air tank in fluid connection
with
the compressor. The air tank has a capacity of at least 0.5 gallons. The
support
structure includes a tubular frame that defines a pair side members and a
handle
that is disposed between and connects the side members. Each side member
includes a first leg, an arm and a second leg. The first leg is disposed under
a first
side of the compressor and secured to the air tank at a first location. The
second
leg has a first portion, which is generally parallel to the first leg, and a
second
portion that extends downwardly toward the first leg and outwardly toward the
handle. The air tank has a generally cylindrical shape and extends
longitudinally
between the side members. The air tank abuts the first legs and the second
portion
of the second legs. The handle is configured to be grasped by a hand of a user
so
that the air compressor can be rotated about an axis that is generally
parallel to a
longitudinal axis of the air tank between an operating position and a hand-
carried
transport position.
[0012] In another form, the present teachings provide a method that
includes: providing an air compressor apparatus having a support structure, a
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compressor, an air tank and a handle, the air tank being in fluid connection
with the
compressor and having a capacity that is greater than about 0.5 gallons, the
handle
being coupled to at least one of the support structure and the air tank; the
support
structure defining a base; placing the air compressor apparatus in an
operating
position wherein the base is disposed in a first orientation; and moving the
air
compressor apparatus to a hand-carried transport position by rotating the air
compressor apparatus by the handle about an axis that is generally parallel to
the
handle, the base being disposed in a second orientation that is generally
perpendicular to the first orientation when the air compressor apparatus is in
the
hand-carried transport position.
[0013] In still another form, the present teachings provide an air
compressor with a compressor, an air tank having a tank wall that defines a
tank
cavity, a regulator valve and a manifold. The manifold has a manifold body
that
includes an inlet port and an outlet port. The manifold body is threadably
coupled
to the air tank. The inlet port is coupled in fluid connection to tank cavity
and the
compressor, while the outlet port is separate from the inlet port and in fluid
connection with the tank cavity and the pressure regulator.
[0014] Further areas of applicability of the present invention will become
apparent from the detailed description provided hereinafter. It should be
understood that the detailed description and specific examples, while
indicating
the preferred embodiment of the invention, are intended for purposes of
illustration only and are not intended to limit the scope of the invention.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Additional advantages and features of the present invention will
become apparent from the subsequent description and the appended claims,
taken in conjunction with the accompanying drawings, wherein:
[0016] Figure 1 is a perspective view of a compressor package
constructed in accordance with the teachings of the prior art;
[0017] Figure 2 is a front view of a user transporting the compressor
package of Figure 1;
[0018] Figure 3 is a perspective view of an air compressor package
constructed in accordance with the teachings of the present invention;
[0019] Figure 4 is a left side elevational view of the air compressor
package of Figure 3 as positioned in an operational position;
[0020] Figure 5 is a rear elevational view of the air compressor package of
Figure 3;
[0021] Figure 6 is a bottom plan view of the air compressor package of
Figure 3;
[0022] Figure 7A is a left side elevational view of the air compressor
package of Figure 3 as it is being rotated into a transport position;
[0023] Figure 7B is a left side elevational view of the air compressor
package of Figure 3 as positioned in the transport position;
[0024] Figure 8 is a perspective view of an air compressor package
constructed in accordance with the teachings of an alternate embodiment of the
present invention;
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[0025] Figure 9 is a left side elevational view of the air compressor
package of Figure 8 as positioned in a transport position;
[0026] Figure 10 is a perspective view of an air compressor package
constructed in accordance with the teachings of another alternate embodiment
of
the present invention;
[0027] Figure 11 is a left side elevational view of an air compressor
package constructed in accordance with the teachings of still another
alternate
embodiment of the present invention;
[0028] Figure 12 is a front perspective view of another air compressor
package constructed in accordance with the teachings of the present invention;
[0029] Figure 13 is a rear perspective view of the air compressor package
of Figure 12;
[0030] Figure 14 is a left side elevation view of the air compressor
package of Figure 12;
[0031] Figure 15 is a perspective view of an air compressor package
constructed in accordance with the teachings of another alternate embodiment
of
the present invention;
[0032] Figure 16 is a left side elevational view of the air compressor
package of Figure 15 as positioned in an operational position;
[0033] Figure 17 is a top plan view of the air compressor package of
Figure 15;
[0034] Figure 18 is a bottom plan view of the air compressor package of
Figure 15;
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[0035] Figures 19 is rear elevational view of the air compressor package of
Figure 15;
[0036] Figure 20 is an exploded perspective view of a portion of the air
compressor package of Figure 15;
[0037] Figure 21 a left side elevational view of the air compressor package
of Figure 15 as it is being rotated into a transport position;
[0038] Figure 22 is a left side elevational view of the air compressor
package of Figure 15 as positioned in the transport position;
[0039] Figure 23 is a perspective view of another air compressor package
constructed in accordance with the teachings of the present disclosure;
[0040] Figure 24 is a side perspective view of the air compressor package
of Figure 22;
[0041] Figure 25 is a perspective view of a portion of the air compressor
package of Figure 23 with the cowling removed;
[0042] Figure 26 is an enlarged perspective view of a portion of the air
compressor package of Figure 23 illustrating the coupling of the manifold to
the
air tank in greater detail;
[0043] Figure 27 is a perspective view of the manifold;
[0044] Figure 28 is a longitudinal section view of the manifold taken
through the inlet and outlet ports;
[0045] Figure 29 is a section view perpendicular to the longitudinal axis of
the manifold through the outlet port, the pressure port and the relief port;
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[0046] Figure 30 is a longitudinal section view of the manifold taken
through the drain port;
[0047] Figure 31 is a section view similar to Figure 30 but taken through
the air tank and the manifold; and
[0048] Figure 32 is an enlarged view of a portion of Figure 32.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] With reference to Figures 1 and 2 of the drawings, a prior art air
compressor package 1 is illustrated to include a support structure 2, a
compressor mechanism 3, an air tank 4 and a handle 5. The compressor
mechanism 3 and the air tank 4, which are among the heavier components of the
air compressor package 1, are distributed horizontally about the support
structure
2 such that the center of gravity 6 of the air compressor package 1 is
disposed
well within the interior of an area bounded by the support structure 2. The
handle
is coupled to the support structure 2 in a manner that places a centerline 7
of
the handle 5 vertically in-line with the center of gravity 6 of the air
compressor
package 1.
[0050] With additional reference to Figure 2, the configuration of the
handle 5 is such that it permits the air compressor package 1 to be lifted
vertically and transported in the same orientation as it is operated. The size
of
the footprint or base 8 of the air compressor package 1, however, is
relatively
large, which necessitates that the user 9 transport the air compressor package
1
with a somewhat outstretched arm 9a. Consequently, the user's wrist 9b is
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maintained in a state of flexion, which tends to be uncomfortable for the user
and
fatiguing.
[0051] In Figures 3 through 5, an air compressor package constructed in
accordance with the teachings of the present invention is generally indicated
by
reference numeral 10. The air compressor package 10 is illustrated to include
a
compressor mechanism 12, an air tank 14, a support structure 16, a handle 18
and a gauge package 20. The compressor mechanism 12 is conventional in its
construction and operation and as such, need not be discussed in detail
herein.
Briefly, the compressor mechanism 12 includes a compressor 22, which is
operable for intaking and compressing ambient air, and a power source, such as
an electric motor 24 or an engine, for providing power to the compressor 22.
The
compressed air that exits the compressor 22 is discharged to the air tank 14,
which serves as a reservoir for the compressed air.
[0052] The air tank 14 has a capacity of at least 0.5 gallons and in the
particular example provided, is illustrated as having a single cylindrically
shaped
tank structure. The air tank 14, however, preferably has a capacity of about 1
to
about 8 gallons, and more preferably a capacity of about 3 to about 5 gallons.
Those skilled in the art will understand that the air tank 14 may be
configured
somewhat differently, as with a conventional pancake-style (i.e., a relatively
short
and large diameter cylinder with convex ends) tank structure (not shown) or
with
a plurality of tank structures that are coupled in fluid connection.
[0053] The support structure 16 is illustrated to be configured in a"roll-
cage" manner that extends around both the compressor mechanism 12 and the
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gauge package 20 to protect these components should the air compressor
package 10 be overturned or impacted by another object. In the particular
embodiment illustrated, the support structure 16 includes a tubular frame 30
having opposite laterally extending sides 32 that are interconnected by a
mounting plafform 34 and a plurality of strut members 36, as well as an
optional
shield or cover 38. In the example provided, the cover 38 is formed from a
sheet
material, such as steel, aluminum or plastic, and is removably fastened with,
for
example, conventional threaded fasteners (not shown) to the tubular frame 30.
While the primary purpose of the cover 38 is to protect components such as the
compressor mechanism 12 and the gauge package 20 from damaging contact
with, for example, falling tools and workpieces, those skilled in the art will
understand that the relatively smooth outer surface of the cover 38, when
abutted
against the lateral side of the user during transport, is relatively more
comfortable
and less likely to interfere with the movement of the user as compared to the
tubular frame 30, the compressor mechanism, the air tank 14 and/or the gauge
package 20.
[0054] In the example provided, the laterally extending sides 32 are
constructed in an open manner, such that the ends 42 of the laterally
extending
sides 32 do not intersect one another but rather intersect the air tank 14.
The
ends 42 are coupled to the air tank 14 through a conventional coupling means,
such as welds. In the particular embodiment illustrated, the air tank 14
extends
through the laterally extending sides 32 but those skilled in the art will
understand
that the air tank 14 could alternatively be configured to terminate flush or
inboard
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of the laterally extending sides 32 so that the support structure 16 would
also
protect the opposite ends of the air tank 14. The gauge package 20, which
conventionally includes an air tank pressure gauge 46, a regulator 48, a
regulator
gauge 50 and an outlet manifold 52, is coupled to a gauge panel 54 that is
mounted between the laterally extending sides 32 of the support structure 16.
The gauge panel 54 may be a discrete component or may be integrally formed
with the cover 38. Preferably, the gauge panel 54 is mounted in a rearwardly
sloped orientation, which is best illustrated in Figures 3 and 4, as opposed
to the
substantially vertical orientation that is illustrated in the prior art air
compressor
package 1 of Figure 1, so as to position the air tank pressure gauge 46, the
regulator 48, the regulator gauge 50 and the outlet manifold 52 in a manner
that
is relatively more comfortable for the user of the air compressor package 10
to
read and/or access. As those skilled in the art will appreciate from this
disclosure, the improved readability of the air tank pressure gauge 46 and the
regulator gauge 50 and the improved accessibility of the regulator 48 that
result
from the positioning of the gauge panel 54 in a rearwardly sloped orientation
improves the accuracy with which the user is able to control the air pressure
that
is delivered to the outlet manifold 52. Pegs 58, which are coupled to one of
the
laterally extending sides 32 and extend outwardly therefrom, are optionally
provided so as to permit items, such as a power cord 60 or an air hose 62, to
be
coiled (around the pegs 58) for storage.
[0055] The mounting platform 34, which is illustrated to be fabricated from
a sheet material, such as steel, aluminum or plastic, serves as the base 66 of
the
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support structure 16. The compressor mechanism 12 is coupled to the mounting
platform 34 via a plurality of threaded fasteners (not specifically shown). A
plurality of rubber feet 68 are affixed to the corners of the mounting
platform 34
and serve to dampen vibrations that are transmitted through the support
structure
16 as well as to provide the support structure 16 with a degree of skid
resistance.
With specific reference to Figure 6, an access aperture 70 is formed through
the
mounting platform 34 and permits the user to access a valve mechanism 72 to
manually drain the air tank 14.
[0056] With renewed reference to Figure 4, those skilled in the art will
appreciate that the air tank 14 and the compressor mechanism 12 are coupled to
the support structure 16 such that their centers of gravity, CGAT and CGAC,
respectively, are positioned relatively close to the base 66 when the air
compressor package 10 is oriented in its operational position (Figures 3
through
5). As the air tank 14 and the compressor mechanism 12 account for a majority
of the weight of the air compressor package 10, configuration in this manner
is
advantageous in that it provides the air compressor package 10 with a
relatively
low center of gravity CGACP. As those skilled in the art will understand, the
center
of gravity CGACP acts along a plane 80 that is skewed to the base 66. In the
particular embodiment illustrated, the plane 80 is substantially perpendicular
to
the base 66 since the base 66 is situated on a flat surface 82, such as a
floor.
[0057] With reference to Figures 3 and 7, the handle 18 is configured to be
gripped by a palmar surface 90 of the hand 92 of a user 94 when the user 94 is
transporting the air compressor package 10. The handle 18 may be of any type
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and may be mounted to any appropriate structure, such as the support structure
16 or the air tank 14. In the particular embodiment illustrated, the handle 18
is
fixedly mounted to air tank 14 and includes a grip portion 96 that is
contoured to
receive the fingers of the user when the user is transporting the air
compressor
package 10. The grip portion 96 is formed about a centerline 98 that lies in
(or is
positionable into) a plane 100 that includes the center of gravity CGACP of
the air
compressor package 10.
[0058] The handle 18 permits the user of the air compressor package 10
to reposition the air compressor package 10 from the operational position that
is
illustrated in Figure 4 to a transport position that is illustrated in Figure
7A. To
facilitate repositioning of the air compressor package 10 in this manner, a
protective stop 69 may be fastened with, for example, conventional threaded
fasteners (not shown) to each of the laterally extending sides 32 of the
tubular
frame 30. The protective stops 69 are preferably comprised of rubber or some
other type of material having an adhesive characteristic. In some instances,
the
user may roll air compressor package onto its side as shown in Figure 7B. In
these instances, the protective stops 69 prevent any unwanted slippage of the
air
compressor package away from the user. When positioned in the transport
position, the plane 100 that includes the centerline 98 of the handle 18 and
the
center of gravity CGACP of the air compressor package 10 is located in a
substantially vertical orientation that is generally parallel to a vertical
(longitudinal) axis 104 of the user 94, as well as generally parallel to the
base 66
and the top 108 of the air compressor package 10.
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[0059] Furthermore, since the center of gravity CGACP of the air
compressor package 10 is relatively close to the base 66 when the air
compressor package 10 is oriented in the operational position, the user 94 is
able
to transport the air compressor package 10 such that the base 66 is proximate
a
lateral side 110 of the user 94 (i.e., within about 10 inches of the lateral
side 110,
and preferably about 3 inches to about 7 inches) and the user's wrist 112 is
not in
a state of flexion. When placed in the transport position, the air compressor
package 10 is preferably configured such that the centers of gravity CGAT and
CGAC of the air tank 14 and the compressor mechanism 12 are disposed in the
plane 100, or oppositely offset therefrom by substantially equal distances.
With
the handle 18 thus positioned, the user 94 is able to comfortably carry the
air
compressor package 10, as well as to easily pivot the air compressor package
10
between the operational position and the transport position without releasing
the
handle 18.
[0060] While the air compressor package 10 has been described thus far
as including an air tank 14 with a single cylindrically shaped tank structure
and a
handle 18 that is fixedly coupled to the air tank 14, those skilled in the art
will
appreciate that the invention, in its broader aspects, may be constructed
somewhat differently. For example, the handle 18a may be incorporated into the
support structure 16a as illustrated in Figures 8 and 9. In this embodiment,
the
support structure 16 extends around the air tank 14 on a side opposite the
compressor mechanism 12 and upwardly from the base 66. A grip structure 96a
is formed on the front strut member 36a that interconnects the opposite
laterally
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extending sides 32a. Like the handle 18 of the air compressor package 10 that
is
illustrated in Figure 3, the handle 18a is positioned such that a centerline
98a of
the grip structure 96a is positioned in a plane that contains the center of
gravity
CGACP of the air compressor package 10a when the air compressor package 10a
is positioned in the transport position.
[0061] In the arrangement of Figure 10, the handle 18a is similar to that of
the embodiment of Figure 8 in that it is incorporated with the support
structure
16a. The air tank 14b, however, includes first and second generally
cylindrical
tank structures 150a and 150b which are stacked vertically relative to one
another when the air compressor package 10b is placed in the operating
position. In the arrangement illustrated, the first and second generally
cylindrical
tank structures 150a and 150b are disposed equidistantly on opposite sides of
the plane (not specifically shown) that includes the centerline 98a of the
handle
18a and the center of gravity CGACP. The longitudinal axes 152a and 152b of
first and second generally cylindrical tank structures 150a and 150b,
respectively,
are illustrated to contained in a plane that is skewed to the base 66 to
thereby
minimize the amount by which the first and second generally cylindrical tank
structures 150a and 150b are offset from the plane that includes the
centerline
98a of the handle 18a and the center of gravity CGACP. In this arrangement,
the
mounting platform 34b may be elevated slightly relative to the mounting
platform
34 of the air compressor package 10 so as to more easily and compactly
package the air tank 14b and the compressor mechanism 12 so that the
centerline 98a of the handle 18a is positioned in the manner described above.
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[0062] The arrangement of Figure 11 is generally similar to that of Figure
3, except that the handle 18c is pivotably coupled to the support structure
16c on
a side opposite the air tank 14. When positioned into the transport position,
the
compressor mechanism 12 is situated above the air tank 14. This arrangement
also illustrates that the air compressor package of the present invention may
be
rotated about a generally horizontal axis between the operational and
transport
positions in any direction. For example, the embodiment of Figures 6 and 7
illustrate that the air compressor package 10 may be rotated from the front F
of
the air compressor package 10 to the bottom B (or top T) of the air compressor
package 10, whereas the embodiment of Figure 11 illustrates that the air
compressor package 10c may be rotated from the rear R of the air compressor
package 10c to the bottom B (or top T) of the air compressor package 10c.
Those skilled in the art will understand that the air compressor package may
alternatively be configured to rotated from a side of the air compressor
package
to the bottom (or top) of the air compressor package via handle 18c.
[0063] With reference to Figures 12 and 13, another air compressor
package constructed in accordance with the teachings of the present invention
is
generally indicated by reference numeral 10d. The air compressor package 10d
is somewhat similar to the air compressor package 10 illustrated in Figure 3
and
may include a compressor mechanism 12, an air tank 14, a support structure 16,
a handle 18 and a gauge package 20. The compressor mechanism 12 may
include an oil-less or oil-free compressor 22d and a power source, such as an
electric motor 24 or an engine, for providing power to the oil-less compressor
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22d. The oil-less compressor 22d includes a piston 300 that reciprocates along
an axis 302 to intake and compress ambient air. The term oil-less is used
herein
to describe an air compressor that that does not use sump for holding a liquid
oil
for lubrication of the piston 300 as it reciprocates. Preferably, the entire
compressor 22d, including the crankcase (not shown), may be operated without
a liquid lubricating oil. The compressed air that exits the compressor 22d is
discharged to the air tank 14, which serves as a reservoir for the compressed
air.
[0064] The air tank 14 may have a capacity of at least 0.5 gallons and in
the particular example provided, is illustrated as having a single
cylindrically
shaped tank structure. The air tank 14, however, may have a capacity of about
1
to about 8 gallons, and more preferably a capacity of about 3 to about 5
gallons.
[0065] The support structure 16 may include a pair of tubular supports 30d
and a mounting platform 34d. The mounting platform 34d may include a base
member 310 and a pair of side members 312 that may be coupled to and extend
outwardly from the base member 310. With additional reference to Figure 14,
each side member 312 may include an arcuate end surface 314 that is
configured to abut a portion of the perimeter of the air tank 14 when the base
member 310 is abutted against the air tank 14. While the base member 310 may
be abutted against the air tank 14 at any location in the lower quadrant 320
of the
air tank, an upper surface 322 of the base member 310 may be positioned such
that it is generally parallel to a first plane 324 that extends longitudinally
through
and bisects the air tank 14 and an edge 326 of the base member 310 terminates
at
a point that is included in a second plane 328 that is generally perpendicular
to the
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first plane 324 and which extends longitudinally through and bisects the air
tank 14.
Configuration in this manner positions a center of gravity of the air tank 14
(i.e.,
CGAT) relatively close to the base member 310 and prevents the air tank 14
from
extending below the mounting platform 34d. Those of ordinary skill in the art
will
appreciate that exact alignment of the edge 326 to the plane 328 cannot be
reliably
accomplished on a mass-production basis and as such, it will be understood for
the
purposes of this disclosure and the appended claims that the edge 326 is
positioned in the plane 328 when a deviation between the edge 326 and the
plane
328 is less than or equal to 0.25 inch (i.e., 0.25 inch on either side of the
plane
328).
[0066] A first end of the tubular supports 30d may be coupled to the base
member 310 and a second, opposite end of the tubular supports 30d may be
coupled to the air tank 14. The tubular supports 30d are positioned on
opposite
sides of the compressor mechanism 12 to thereby protect the compressor
mechanism 12 should the air compressor package 10d be overturned or
impacted by another object.
[0067] In the example provided, a shroud 330, which may be formed from
a sheet metal or plastic material, may be removably coupled to the support
structure 16 and/or the compressor mechanism 12. While the primary purpose of
the shroud 330 is to protect components such as the compressor mechanism 12
and the gauge package 20 from damaging contact with, for example, falling
tools
and workpieces, those skilled in the art will understand that the relatively
smooth
outer surface of the shroud 330, if abutted against the lateral side of the
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during transport, is relatively more comfortable and less likely to interfere
with the
movement of the user as compared to other portions of the air compressor
package 10d.
[0068] The gauge package 20 may conventionally include an air tank
pressure gauge (not shown), a regulator (not shown), a regulator gauge (not
shown) and an outlet manifold 52, and may be mounted to any convenient point,
such as to the air tank 14, the support structure 16 or the compressor 22d.
[0069] The compressor mechanism 12 may be coupled to the mounting
platform 34d via a plurality of threaded fasteners (not specifically shown). A
plurality of rubber feet 68 may be affixed to the corners of the mounting
platform
34d to dampen vibrations that are transmitted through the support structure 16
as
well as to provide the support structure 16 with a degree of skid resistance.
An
access aperture (not specifically shown), similar to the access aperture 70 in
Figure 6, may be formed through the mounting platform 34d to permit the user
to
access a valve mechanism 72 to manually drain the air tank 14.
[0070] With specific reference to Figure 14, the air tank 14 and the
compressor mechanism 12 may be coupled to the support structure 16 such that
their centers of gravity, CGAT and CGAC, respectively, are positioned
relatively
close to the base member 310. As the air tank 14 and the compressor
mechanism 12 account for a majority of the weight of the air compressor
package 10d, configuration in this manner is advantageous in that it provides
the
air compressor package 10d with a center of gravity CGACP that is located
relatively close to a surface onto which the air compressor package 10d has
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been placed, thereby rendering the air compressor package 10d relatively
resistant to tipping.
[0071] The handle 18 may be of any type and may be mounted to any
appropriate structure, such as the support structure 16 or the air tank 14. In
the
particular embodiment illustrated, the handle 18 is fixedly mounted to air
tank 14
and includes a grip portion 96 (Fig. 12) that is contoured to receive the
fingers of
the user when the user is transporting the air compressor package 10d. The
grip
portion 96 (Fig. 12) is formed about a centerline 98 that lies in (or is
positionable
into) a plane (e.g., plane 324) that includes the center of gravity CGACP of
the air
compressor package 10d.
[0072] The handle 18 permits the user of the air compressor package 10d
to reposition the air compressor package 10d from the operational position
that is
illustrated in Figure 14 to a transport position that is similar to that which
is
illustrated for the air compressor package 10 in Figure 7. In the transport
position, the user may carry the air compressor package 10d with the lower
surface of the base member 310 positioned proximate their lateral side or in
the
alternative, with the shroud 330 is positioned proximate their lateral side.
In the
particular example provided, the dimension between the first plane 324 and the
tubular supports 30d is not equal to the dimension between the first plane 324
and
the lower surface of the base member 310. Construction in this manner permits
the
user to transport the air compressor package 10d in two distinct manners.
Since
the air tank 14 is placed directly onto the base member 310 of the mounting
platform 34d, the center of gravity CGACP of the air compressor package 10d is
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relatively closer to the base member 310 as compared to the embodiments of
Figures 3 through 11 and as such, some users will find the air compressor
package 10d more easy to transport than the air compressor package 10 of
Figure 3, since this configuration permits the air compressor package 10d to
be
transported relatively closer to the lateral side of a user.
[0073] As will be apparent to one of ordinary skill in the art in light of
this
disclosure, placement of the air compressor package 10d in the operating
position places the axis 302 along which the piston 300 (Fig. 12) reciprocates
in a
generally horizontally orientation, while placement of the air compressor
package
10d in the transport position places the axis 302 in a generally vertical
orientation.
[0074] An alternative arrangement for an air compressor package 120
constructed in accordance with the teaching of the present invention is
depicted
in Figures 15 through 20. In this embodiment, an air compressor mechanism 122
is mounted between a pair of cylindrically shaped air tanks 124. As shown, the
air tanks are spaced apart laterally from each other and supported on the
underside by a pair of skid bars 126. The skid bars 126 are likewise spaced
apart
laterally from each other, but mounted transversely to the two air tanks 124.
A
rubber foot 128 is affixed to each end of each skid bar 126. These rubber feet
128 serve to dampen vibrations that are transmitted through the support
structure
during operation as well as provide a degree of skid resistance when placed in
an operational position.
[0075] As described above, the air compressor mechanism 122 further
comprises a compressor 132 operable to intake and compress ambient air and a
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power source 134, such as an electric motor or an engine, for providing power
to
the compressor. The compressor mechanism is again of a conventional
construction and operation and as such does not need to be described in
further
detail.
[0076] A shroud assembly 140 protects the compressor mechanism and
associated components should the air compressor package 120 be overturned or
impacted by another object. In an exemplary embodiment, the shroud assembly
140 includes a protective plate 142 extending between a pair of inverted u-
shaped tubular members 144. Ends of the tubular members 144 are coupled by
conventional means, such as welds, to the top surface of the air tanks 124.
The
protective plate is in turn coupled to the tubular members 144. The protective
plate is formed from a sheet or material, such as steel, aluminum, plastic or
other
suitable material, and is removably fastened with, for example, conventional
threaded fasteners to the tubular frame.
[0077] A portion of the protective plate serves as a gauge panel 146 which
supports conventional compressor accessory components, such as pressure
gauges, a pressure regulator and one or more outlet manifolds. The gauge panel
146 is preferably sloped rearwardly in a manner that improves readability and
accessibility of the gauges housed in the panel.
[0078] To transport the air compressor package 120, a handle extends
outwardly from either side of the air compressor package 120. In the exemplary
embodiment, the handle 150 is a tubular member which extends between the two
u-shaped tubular members 144. It is contemplated that the handle 150 may
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include a grip portion that is contoured to receive the user's fingers. It is
also
contemplated that the handle may have other configurations and be mounted to
other appropriate support structure, such as one of the air tanks. Again, the
grip
portion is preferably formed about a centerline that lies in (or is
positionable into)
a plane that includes the center of gravity CGACP of the air compressor
package
120. The handle 150 enables the user to rotate the air compressor package 120
to an intermediate position as shown in Figure 21 prior to reaching a
transport
position as shown in Figure 22.
[0079] Protective stops 152 are again used to prevent any unwanted
slippage of the air compressor package away from the user. In this embodiment,
the protective stops 152 are fastened to the air tank disposed on an opposite
side from the handle 150. More specifically, the protective stops 152 are
fastened
to a mounting bracket 154 which in turn is coupled to the air tank by
conventional
means, such as welds, as best seen in Figure 20. The protective stops 69 are
preferably comprised of rubber or some other type of material having an
adhesive characteristic. The protective stops 152 also protect the air tank
from
the rough surface and/or abrupt landings which may be encountered as the air
compressor package is returned to an operational position.
[0080] When positioned in the transport position, the plane 160 that
includes the centerline 162 of the handle 150 and a center of gravity CGACP of
the air compressor package 120 is located in a substantially vertical
orientation
that is generally parallel to a vertical (longitudinal) axis 104 of the user
94, as well
as generally parallel to a base and a top 108 of the air compressor package
120.
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Furthermore, since the center of gravity CGACP of the air compressor package
120 is relatively close to the base when the air compressor package 120 is
oriented in the operational position, the user 94 is able to transport the air
compressor package 120 such that the base is proximate a lateral side 110 of
the user 94 (i.e., within about 10 inches of the lateral side 110, and
preferably
about 3 inches to about 7 inches) and the user's wrist 112 is not in a state
of
flexion. With the handle 150 thus positioned, the user 94 is able to
comfortably
carry the air compressor package 120, as well as to easily pivot the air
compressor package 120 between the operational position and the transport
position without releasing the handle 150.
[0081] With reference to Figures 23 through 25, another air compressor
package constructed in accordance with the teachings of the present disclosure
is generally indicated by reference numeral 500. The air compressor package
500 can include a compressor mechanism 512, an air tank 514, a support
structure 516, a handle 518 and a gauge package 520. The compressor
mechanism 512 can be conventional in its construction and operation and as
such, need not be discussed in detail herein. In the particular example
provided,
the compressor mechanism 512 is generally similar to the compressor
mechanism 12 associated with the embodiment of Figures 12 and 13. In this
regard, the compressor mechanism 512 includes an oil-less compressor that is
driven by an electric motor.
[0082] The air tank 514 may have a capacity of at least 0.5 gallons and in
the particular example provided, is illustrated as having a single
cylindrically
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shaped tank structure. The air tank 514, however, may have a capacity of about
1 to about 8 gallons, e.g., a capacity of about 3 to about 5 gallons.
[0083] The support structure 516 can be configured in a "roll-cage"
manner that extends around both the compressor mechanism 512 and the air
tank 514 to protect these components should the air compressor package 500 be
overturned or impacted by another object. In the particular embodiment
illustrated, the support structure 516 includes a tubular frame 530 having
opposite laterally extending sides 532 and the handle 518, which interconnects
the opposite laterally extending sides 532. The support structure 516 can
further
include a plurality of strut members 536, as well as an optional shield or
cover
538 and a plurality of fastening tabs 539 (Fig. 25). The strut member 536 can
be
welded to the laterally extending side members 532 and can be fixedly but
removably coupled to the compressor mechanism 512 via threaded fasteners
(not shown) in a conventional and well known manner.
[0084] In the example provided, the laterally extending sides 532 are
constructed to include a first leg 580, a second leg 582 and an arm 584 that
is
disposed between and interconnects the first and second leg 582. The first leg
580 can be received under a first side of the compressor mechanism 512 and
under the air tank 514 to support compressor mechanism 512 and air tank 514.
The second leg 582 can include a first portion 586, which can be coupled to
the
arm 584 and which can be generally parallel to the first leg 580, and a second
portion 588 that interconnects the handle 518 and the first portion 586. The
second portion 588 can extends downwardly toward the first leg 580 and
outwardly
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beyond the air tank 514 toward the handle 518. It will be appreciated that the
air
tank 514 has a generally cylindrical shape and extends longitudinally between
the
side members 532 such that the air tank 514 abuts the first legs 580 and the
second portion 588 of the second legs 582.
[0085] The cover 538 can be formed from a sheet material, such as steel,
aluminum or plastic. The fastening tabs 529 can be welded to the tubular frame
530 and can include a threaded aperture (not shown). In the alternative, the
fastening tabs 529 can include a through-hole (not specifically shown) that
can
be aligned to a thread form (not specifically shown) that is defined by a
sheet
metal clip 541 (Fig. 25) that can be engaged to an associated fastening tab
529.
In either arrangement, the cover 538 can be coupled to the tubular frame 530
via
conventional fasteners (not specifically shown), but the sheet metal clips 541
(Fig. 25) are advantageous in that they are relative less expensive and more
tolerant of manufacturing variation. While the primary purpose of the cover
538
is to protect components such as the compressor mechanism 512 and the gauge
package 520 from damaging contact with, for example, falling tools and
workpieces, those skilled in the art will understand that the relatively
smooth
outer surface of the cover 538, when abutted against the lateral side of the
user
during transport, is relatively more comfortable and less likely to interfere
with the
movement of the user as compared to the tubular frame 530, the compressor
mechanism, the air tank 514 and/or the gauge package 520.
[0086] The gauge package 520 can include an air tank pressure gauge
546, a user-adjustable regulator valve 548, a regulator gauge 550 and an
outlet
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manifold 552, is coupled to a gauge panel 554 that is mounted between the
laterally extending sides 532 of the support structure 516. The gauge panel
554
may be a discrete component or may be integrally formed with the cover 538.
Preferably, the gauge panel 554 is mounted in a rearwardly sloped orientation,
which is best illustrated in Figure 23, as opposed to the substantially
vertical
orientation that is illustrated in the prior art air compressor package 1 of
Figure 1,
so as to position the air tank pressure gauge 546, the regulator 548, the
regulator
gauge 550 and the outlet manifold 552 in a manner that is relatively more
comfortable for the user of the air compressor package 500 to read and/or
access. As those skilled in the art will appreciate from this disclosure, the
improved readability of the air tank pressure gauge 546 and the regulator
gauge
550 and the improved accessibility of the regulator 548 that result from the
positioning of the gauge panel 554 in a rearwardly sloped orientation improves
the accuracy with which the user is able to control the air pressure that is
delivered to the outlet manifold 552. Pegs 558, which are coupled to one of
the
laterally extending sides 532 and extend outwardly therefrom, are optionally
provided so as to permit items, such as a power cord 560 or an air hose (not
shown), to be coiled around the pegs 558 for storage.
[0087] A plurality of resilient feet 568 can be affixed to the corners of the
tubular frame 530 and serve to dampen vibrations that are transmitted through
the support structure 516 as well as to provide the support structure 516 with
a
degree of skid resistance.
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[0088] With reference to Figures 24 and 26, the air compressor package
500 is also shown to include a manifold 600. The manifold 600 can include a
manifold body 602 that can have a threaded portion 604 that is adapted to be
threadably coupled to the air tank 514. The manifold body 602 can define an
inlet port 610, an outlet port 612, a pressure port 614, a relief port 616,
and a
drain port 618. The inlet port 610 is coupled in fluid connection to the
compressor mechanism 512 and the air tank 514. Outlet port 612 is coupled in
fluid connection to the air tank 514 and the pressure regulator valve 548.
Pressure port 614 is coupled in fluid connection to the air tank 514 and a
pressure switch 615 that is associated with the compressor mechanism 512.
Relief port 616 is coupled in fluid connection to the air tank 514 and a
relief valve
617. Drain port 618 is coupled in fluid connection to the air tank 514 and a
drain
valve 619. In the particular example provided, the manifold body 602 is
unitarily
formed from a suitable material, such as zinc, e.g., in a casting process
(e.g., die
casting) and can be, e.g., machined as necessary thereafter.
[0089] With reference to Figures 27 and 28, the inlet port 610 can include
a first coupling 650 and an outlet zone 652 that is disposed within an annular
cavity 654 that is defined by a wall member 656 of the manifold body 602. The
first coupling 650 is illustrated to include female pipe threads, but those of
ordinary skill in the art will appreciate that any other coupling means (e.g.,
male
pipe threads, quick couplings, a hose barb, flare fittings or interfaces) may
be
employed.
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[0090] The outlet port 612 can include an inlet zone 662, which is
disposed within the annular cavity 654, and a second coupling 664, which is
illustrated to include a male hose barb. Those of ordinary skill in the art
will
appreciate that any other coupling means (e.g., male pipe threads, quick
couplings, a hose barb, flare fittings or interfaces) may be employed. In the
example provided, the outlet port 612 is segregated or separate from the inlet
port 610 (e.g., the hole formed in the manifold body 602 that defines the
inlet port
610 can be formed separately from the hole in the manifold body 602 that
defines
the outlet port 612). Construction in this manner permits air from the
compressor
mechanism 512 (Fig. 22) to be directed into the air tank 514 (Fig. 22) rather
than
toward the outlet port 612.
[0091] With reference to Figures 27 and 29, the pressure port 614 can
include a third coupling 670, such as a male hose barb, and can intersect the
outlet port 612 or the cavity 654 to permit air from the air tank 514 (Fig.
24) to
operate the pressure switch 615 (Fig. 26) that is associated with the
compressor
mechanism 512 (Fig. 24). As those of ordinary skill in the art will
appreciate, the
pressure switch 615 (Fig. 26) is employed to actuate the power source that
operates the compressor mechanism 512 (Fig. 24) when the air pressure in the
air tank 514 (Fig. 24) is less than a predetermined air pressure threshold.
[0092] The relief port 616 can include a fourth coupling 674, such as
female pipe threads, and can intersect the outlet port 612 or the cavity 654
to
permit air from the air tank 514 (Fig. 24) to act on the relief valve 617
(Fig. 26).
As those of ordinary skill in the art will appreciate, the relief valve 617
(Fig. 26)
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can be a normally closed valve that opens when the air pressure that is acting
on
it is greater than a predetermined air pressure.
[0093] With reference to Figures 27 and 30, the drain port 618 can be
formed in the manifold body 602 such that drain port 618 is fluidly isolated
from
the inlet port 610, the outlet port 612, and the cavity 654. In the particular
example provided, the drain port 618 is formed in a portion of the manifold
body
602 so as not to intersect the cavity 654 that is defined by the wall member
656.
The drain port 618 includes a central portion 680, which extends
longitudinally
through the manifold body 602, an inlet 682, which is formed through a portion
of
the wall member 656, and an outlet 684. The outlet 684 can include a fifth
coupling 686, such a female pipe threads.
[0094] With reference to Figures 31 and 32, the manifold 600 is installed to
the air tank 514 such that the inlet 682 of the drain port 618 is disposed
below an
end 700 of the manifold body 602 through which the inlet port 610 and the
outlet
port 612 (Fig. 27) communicate with the air tank 514 when the air compressor
package 500 (Fig. 24) is positioned in an operating position, which is
illustrated in
Figure 22. The drain valve 619, which can be a conventional ball valve, can be
coupled to the outlet 684 of the drain port 618. Configuration of the manifold
600
in this manner permits fluids that have accumulated in the air tank 514 to
drain
into the drain port 618 and not into the inlet port 610, the outlet port 612
(Fig. 27),
the pressure port 614 (Fig. 27) or the relief port 616. As such, the various
ports
may be combined into a single manifold that is attached to the air tank 514 at
a
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single location, which is relatively less expensive to manufacture than an air
tank
that employs multiple mounting locations for the various ports.
[0095] 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 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 this disclosure, but
that the
scope of the present disclosure will include any embodiments falling within
the
foregoing description and the appended claims.
33
