Gas compressor

Abstract

A gas compressor device (2) comprising a motor having a rotatable motor shaft (18), a rotating disk (6) attached to the motor shaft (18), and a compressor (10) comprising pistons (8), piston rods (62), cylinders (50), and the rotating disk (6) has a top contour such that, as the disk (6) turns, a piston rod (62) having a roller (78) which is in moveable contact with the top contour of the disk (6) will start at a low elevation (42), pass gradually to a higher elevation (44), reach a peak (46), and pass rapidly back to the low elevation (42).

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from International PCT Application PCT/US2004/03 1921, entitled “Gas Compressor”, filed on Sep. 29, 2004.

SEQUENCE LISTING OR PROGRAM

Not Applicable

FEDERALLY SPONSORED RESEARCH

Not Applicable

TECHNICAL FIELD OF THE INVENTION

This invention is directed to gas compressors. More specifically, the invention is directed to gas compressors wherein the compression is carried out by the action of pistons in cylinders and the pistons are made to reciprocate by being contact with a revolving contoured disk.

INDUSTRIAL APPLICABILITY

The gas compressor of the present invention may be used for the compressing of gas for a variety of applications. It may be used to compress coolants for refrigerators and air conditioners. It may be used as a compressor in air pumps for a wide variety of inflatable objects.

BACKGROUND OF THE INVENTION

The prior art is replete with disclosures of compressors wherein pistons reciprocate in cylinders and the cause of the reciprocation is the pistons' contact with the surface of a revolving oblique disk, generally called a swash plate. Samples of recent US patents having such disclosures are: U.S. Pat. No. 6,224,349 issued to Iwanami et al May 1, 2001; U.S. Pat. No. 6,302,658 issued to Seipel et al Oct. 16, 2001; U.S. Pat. No. 6,312,231 issued to Kuhne et al Nov. 6, 2001; U.S. Pat. No. 6,318,502 issued to Unger Nov. 20, 2001; U.S. Pat. No. 6,368,073 issued to Kanai Apr. 9, 2002; U.S. Pat. No. 6,390,787 issued to Herder 5/21/20Q2> and U.S. Pat. No. 6,406,271 issued to Valentin Jun. 18, 2002. These compressors share the common features of a rotating motor shaft which rotates a swash plate which has a surface oblique to the axis of the motor shaft. The outer edges of the swash plate are connected to one or more pistons. As the swash plate rotates, the pistons are forced to reciprocate in the pistons and the reciprocal movement of the pistons operates the compressor in a known manner.

Such compressors are prolific in the literature, but not in commerce. These compressors require lubrication, which is undesirable when the compressed gas is to be breathed by a human subject. There is a problem in many of these devices which causes the pistons to be out of line with the cylinders. The rate of speed of the piston in the expansion phase is the same as the rate of speed of the piston in the compression phase. It has been discovered that following compression, it is desirable for the piston to exit the cylinder as quickly as possible. The existing swash plate type compressors do not make provision for the difference in reciprocating speeds.

SUMMARY OF THE INVENTION

This invention relates to gas compressors. Gas compressors find a variety of utilities, such as in refrigerators, running pneumatic tools, and supplying air pressure to fill tires and other air-filled devices. The gas compressors of the present invention are run by motors which provide rotary motion. These are preferably electrical motors. The motor shaft is connected to a rotatable disk.

The side of the disk facing the motor is flat and the side of the disk facing away from the motor contains a ramp. This side contains a low area. The height of the disk gradually increases to a peak and then rapidly decreases to the height of the low area. The portion of the disk which is of increased height is hollow so as to maintain a uniform weight throughout the disk.

The air compressor is situated on the opposite side of the motor from the disk and a frame mount connects the motor and the compressor. For the purpose of this description, the motor will be “down” and the compressor will be “up” although any arrangement is possible. Preferably, the compressor contains at least two cylinders and a piston fits into each cylinder. Each piston is attached to a piston rod. The lower end of each piston rod is attached to a roller. Each roller rolls freely along the turning disk and rises and falls as it passes over the ramp on the disk.

The rising and falling motion of the rollers causes alternating up and down motion of the pistons. When the pistons rise, gas in the cylinder is compressed and expelled from the piston. When the pistons fall, a new supply of gas enters the cylinder.

The piston rod passes through a spring. The upper end of the spring attaches to the lower end of the piston and the lower end of the spring attaches to the frame mount. The spring biases the piston rod, causing the piston to be biased toward the lower part of the cylinder.

The compressor contains a self-operated Mower which helps to pre-pressurize air entering the pistons. This blower and an optional fan below the motor serve to keep the compressor from overheating.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.

FIG. 1 is an exploded elevational perspective cut-away view of the rotary pump of the present invention showing one view of the rotating disk;

FIG. 2 is an exploded elevational perspective cut-away view of another rotary pump of the present invention showing one view of the rotating disk;

FIG. 3 is an exploded elevational perspective cut-away view of the rotary pump of the present invention showing another view of the rotating disk;

FIG. 4 is an exploded elevational perspective enlarged view showing the gearing mechanism, the disk and the motor mount in detail;

FIG. 5 is an elevational view of one angle of the rotating disk;

FIG. 6 is a side elevational view in cut-away showing the slope of the rotating disk and the relationship of the gears to each other;

FIG. 7 is a side cross-sectional view showing the relationship between the rotating disk and more than one piston rod;

FIG. 8 is a side cross-sectional view showing the relationship between the rotating disk and a single piston rod; and

FIG. 9 is an elevational perspective cut-away view of the rotary pump of the present invention showing one view of the rotating disk. This Figure is similar to FIG. 1, but does not show the lower fan or the turbine.

DETAILED DESCRIPTION AND BEST MODE OF THE INVENTION

In the following detailed description of the invention of exemplary embodiments of the invention, reference is made to the accompanying drawings (where like numbers represent like elements), which form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced.

These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, but other embodiments may be utilized and logical, mechanical, electrical, and other changes may be made without departing from the scope of the present invention. The following detailed description is therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.

In the following description, numerous specific details are set forth to provide a thorough understanding of the invention. However, it is understood that the invention may be practiced without these specific details. In other instances, well-known structures and techniques known to one of ordinary skill in the art have not been shown in detail in order not to obscure the invention.

The device 2 of the present invention is made up of a motor (not shown) in a motor housing 4, a rotatable disk 6 to drive pistons 8, and a compressor 10 which uses the pistons 8 to compress gas. In the preferred embodiment, the motor housing 4 contains a fan 12 located at the lower surface 14 of the motor housing 4, which fan 12 is useful in lowering the temperature of the motor and the compressor 10 and preventing overheating. Any conventional motor is suitable, although an electric motor is preferred. The motor fits within a motor housing 4 which is preferably cylindrical in shape and has a flat top surface 16.

The relationship between the motor and the rotatable disk 6 is better understood with reference to FIGS. 1, 4, and 6. The rotatable motor shaft 18 protrudes from the center of the top surface 16 of the motor housing 4.

The relationship between the gears and the motor shaft is better understood with reference to FIG. 6. The rotatable motor shaft 18 is centrally located in and is fixedly connected to a first, central gear 20. The first gear 20 meshes with a second, transfer gear 22 as shown in FIGS. 4 and 6. The second gear 22 meshes with a third, disk drive gear 24 shown in FIG. 6, but omitted from FIG. 4 for clarity. The third gear 24 is fixedly located in the lower section 26 of a rotating disk 6. The purpose of the gears 20, 22, 24 is to transfer a fast rotational speed of the motor shaft is to a slower rotational speed of the disk 6.

In one embodiment, as shown in FIGS. 1 and 2, support rollers 28 are fixedly attached to the top surface 16 of the motor housing 4. These rollers 28 abut with the lower surface 30 of the rotatable disk 6 and support the rotatable disk 6 while giving it complete freedom to rotate.

In another embodiment, as shown in FIG. 6, the rotatable disk 6 is attached to the inner surface 32 of the device wall 34 and is supported by two sets of collars 36 which contain bracelet bearings 38. This allows the disk 6 to be firmly supported by the wall 34, yet given complete freedom to rotate freely.

The top contour 40 of the rotating disk 6 is such that, as the disk 6 turns, an object which is in moveable contact with the disk 6 will start at a low elevation 42, pass gradually to a higher elevation 44, reach a peak 46, and pass rapidly down a steep incline 48 to the low elevation 42. This configuration allows for the rapid passage of the cylinder 50 into the expansion phase.

A frame mount 52, best shown in FIG. 4, is connected to the motor housing 4. The lower end 54 of the frame mount 52 is attached to the motor housing 4 by any mechanical means, preferably bolts. The upper end 56 of the frame mount 52 has a horizontal member 58 which serves as an attachment base for the cylinders 50 of the gas compressor 10. The horizontal member 58 contains an opening 60 for each piston rod 62.

The disk 6 contains a lower face 30 and an upper contour 40. The surface of the lower face 30 is preferably flat. The disk 6 is supported by rotatable supports 28. The rotatable supports 28 are attached to, and supported by, the frame mount 52. The surface of the upper contour 40 is curved as described above. It can readily be seen that as the motor shaft 18 causes the disk 6 to rotate, a fixed point over the disk 6 will be subjected to alternating up and down motion. The disk 6 is hollow as shown in FIG. 7 so that the weight of the disk 6 is uniformly distributed throughout its area.

The gas compressor 10 contains at least one cylinder 50. Each cylinder 50 contains a piston 8. Each piston 8 contains an upper surface 64 and a lower surface 66. In the device of the present invention, the user may change the number of pistons and cylinders to fit his or her needs at the time. A change in gearing may be necessary so that the same motor (gasoline or electric) may be used. The change in gearing allows the device to compensate for the increased load put on the motor by providing a slow disk rotation with increased torque or a rapid disk rotation with decreased torque.

In a first embodiment as shown in FIG. 1, a spring 68 contains an upper end 70 and a lower end 72. The upper end 70 of the spring 68 is connected to the horizontal member 58 of the frame mount 52 and the lower end 72 of the spring 68 is connected to the piston rod 62. The spring 68 biases the piston rod G2 downwardly to draw the piston 8 out of the compressing position in the cylinder 50.

In a second embodiment as shown in FIG. 2, a spring 68 contains an upper end 70 and a lower end 72. The upper end 70 is fixedly connected to the lower surface 66 of the piston 8 and the lower end 72 is fixedly connected to the horizontal member 58 of the frame mount 52. This spring 68 stretches as the piston 8 is pushed upwardly when the piston rod 62 is pushed upwardly by an area of the disk 6 having a high elevation 44. The spring 68 contracts when this upward force is removed and this contraction forces the piston rod 62 downwardly.

Each piston 8 is connected to a piston rod 62. The piston rod 62 passes through an aperture 60 in an insert 74 which has reduced friction in the horizontal member 58 of the frame mount 52. This insert 74 having reduced friction is preferably made of Teflon®. The lower end 76 of the piston rod 62 is connected to a roller 78 by means of an axle 80 passing through the roller 78 and attaching to the lower end 76 of the piston rod 62. The roller 78 is so directed that it will revolve as the disk 6 rotates. The cross-section of the piston rods 62 are non-circular in shape and the aperture 60 in the insert 74 in the frame mount 52 is of a similar shape. Square is a preferable shape. The non-circular shape prevents turning of the piston rod 62 and thus keeps the rollers 78 in proper alignment.

Each cylinder 50 contains conventional one-way inlet 84 and outlet valves 86 to permit the intake of gas and the outlet of pressurized gas.

The upper end 88 of the compressor 10 contains a blower fan 90 as shown in FIG. 3 having its own energy source. The blower fan or turbine 90 is preferably within a housing container 92. The purpose of the fan or turbine 90 is to enable gas entering the cylinders 50 to have a pressure which is greater than ambient pressure. This pressure build-up takes place in a holding container 92 between the fan or turbine 90 and the cylinders 50. The housing cap 94 also contains a filter 96 for the gas. The turbine may be replace with any similar device which forces air at a rate of more than 150 liters per minute, preferably 450 liters per minute.

In operation, as best shown in FIGS. 4 and 6, the motor rotates a motor shaft IS and causes the disk 6 to rotate around the shaft 18 through a series of speed transmission gears 20, 22, 24. The disk 6 is supported by support rollers 28 or by attachment to the device wall 34. The upper face 96 of the disk 6 rises and falls in relation to any given point above the disk 6 as the disk 6 rotates. As shown in FIG. 9, the rollers 7S of the piston rods 62 remain in a fixed position relative to the rotating disk 6 and rise and fall as they move with the changing height of the disk 6. The piston rods 62 and pistons 8 follow the rising and falling of the rollers 78. As a piston 8 rises, it compresses gas in its cylinder 50. As a piston 8 falls with the help of the spring 68, the gas enters the cylinder 50 under higher than ambient pressure because of the blower fan 90 in the housing cap 92. The repeated up and down movement of the pistons 8 causes a continuous flow of pressurized gas from the compressor 10.

Although the invention has been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example, and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims.

In addition, other areas of art may benefit from this method and adjustments to the design are anticipated. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.

Claims

1. In a gas compressor device comprising a motor having a rotatable motor shaft, a rotating disk attached to the motor shaft, and a compressor comprising a piston, the piston having a lower end, and a piston rod, and a cylinder, the improvement wherein the rotating disk has a lower section, a lower surface, and a top contour such that, as the disk turns, an object which is in moveable contact with the top contour of the disk will start at a low elevation, pass gradually to a higher elevation, reach a peak, and pass rapidly back to the low elevation.

2. The gas compressor device of claim 1, wherein there is at least one piston and at least one cylinder.

3. The gas compressor device of claim 2, wherein each piston is attached to a piston rod, which piston rod has upper and lower ends, the upper end of the piston rod being attached to the piston and the lower end of the piston rod being attached to rollers which are in contact with the top contour of the rotating disk.

4. The gas compressor device of claim 2, wherein the motor is within a motor housing having a top surface and a lower end and a frame mount is connected to the motor housing, which frame mount has a lower end and an upper end.

5. The gas compressor device of claim 4, wherein the lower end of the frame mount is attached to the motor housing, the upper end of the frame mount has a horizontal member which serves as an attachment base for the at least one cylinder of the gas compressor, and the horizontal member contains an opening for each piston rod.

6. The gas compressor device of claim 5, wherein the openings of the horizontal members contain inserts having reduced friction.

7. The gas compressor device of claim 6, wherein the cross-section of the piston rods and the openings of the horizontal members are non-circular in shape.

8. The gas compressor device of claim 5, wherein each piston rod passes through a spring containing an upper end and a lower end, the upper end being fixedly connected to the lower surface of the piston and the lower end being fixedly connected to the horizontal member of the frame mount.

9. The gas compressor device of claim 1, wherein the lower end of the motor housing has a fan attached thereto.

10. The gas compressor device of claim 3, wherein support rollers are fixedly attached to the top surface of the motor housing which rollers abut with the lower surface of the rotatable disk and support the rotatable disk.

11. The gas compressor device of claim 1, wherein the rotatable motor shaft is centrally located in and is fixedly connected to a first, central gear, the first gear meshes with a second, transfer gear, the second gear meshes with a third, disk drive gear, and the third gear is fixedly located in the lower section of the rotating disk.

12. The gas compressor device of claim 4, wherein the device has a wall having an inner surface, the rotatable disk is attached to the inner surface of the device wall, and the rotatable disk is supported by two sets of collars which contain bracelet bearings.

13. The gas compressor device of claim 1, wherein the compressor has an upper end, which upper end contains a turbine or blower fan within a housing container.

14. The gas compressor device of claim 13, wherein the turbine or blower fan forces air at the rate of at least 450 liters per minute-15. The gas compressor device of claim 13, wherein the housing container contains a filter for the gas.

15. The gas compressor device of claim 13, wherein there is a storage container for the compressed gas.