Air compressor

Abstract

An air compressor having improved stability and portability. The air compressor package is positionable in an operational position, wherein the air compressor package is positioned on a base, and a transport position, wherein the air compressor package may be more readily transported. Positioning of the air compressor package into the transport position is accomplished by rotating the air compressor about a rotational axis that is generally parallel to the longitudinal axis of the air tank, which positions the air compressor in an orientation and position that is relatively comfortable, whether or not the air compressor is hand-transported. The air compressor package can employ a compact manifold that can couple the air tank to the compressor and a regulator valve and optionally to a relief valve, a drain valve and/or a pressure switch. A method for operating a compressor is also provided.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 10/805,987, filed Mar. 22, 2004, and Ser. No. 11/053,033, filed Feb. 8, 2005, which are continuation-in-part applications of U.S. patent application Ser. No. 10/630,090 filed Jul. 30, 2003, which is a continuation of U.S. patent application Ser. No. 10/154,416 filed May 23, 2002. U.S. patent application Ser. No. 10/154,416 claimed the benefit of U.S. Provisional Application No. 60/366,676, filed Mar. 22, 2002 and is a continuation-in-part of U.S. application Ser. No. 29/136,877 filed Feb. 8, 2001. U.S. application Ser. No. 29/136,877 issued as U.S. Design Pat. No. D461,196 on Aug. 6, 2002. Each of the aforementioned applications is incorporated by reference.

FIELD OF THE INVENTION

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

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. 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.

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.

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. Still, there are a range of intermediate capacity air compressors that are common tools around the construction site and which are man portable.

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.

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.

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 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.

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.

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 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

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.

In another form, the present teachings provide a method that includes: providing an air compressor apparatus having a support structure, a 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.

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.

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.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

FIG. 1 is a perspective view of a compressor package constructed in accordance with the teachings of the prior art;

FIG. 2 is a front view of a user transporting the compressor package of FIG. 1;

FIG. 3 is a perspective view of an air compressor package constructed in accordance with the teachings of the present invention;

FIG. 4 is a left side elevational view of the air compressor package of FIG. 3 as positioned in an operational position;

FIG. 5 is a rear elevational view of the air compressor package of FIG. 3;

FIG. 6 is a bottom plan view of the air compressor package of FIG. 3;

FIG. 7A is a left side elevational view of the air compressor package of FIG. 3 as it is being rotated into a transport position;

FIG. 7B is a left side elevational view of the air compressor package of FIG. 3 as positioned in the transport position;

FIG. 8 is a perspective view of an air compressor package constructed in accordance with the teachings of an alternate embodiment of the present invention;

FIG. 9 is a left side elevational view of the air compressor package of FIG. 8 as positioned in a transport position;

FIG. 10 is a perspective view of an air compressor package constructed in accordance with the teachings of another alternate embodiment of the present invention;

FIG. 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;

FIG. 12 is a front perspective view of another air compressor package constructed in accordance with the teachings of the present invention;

FIG. 13 is a rear perspective view of the air compressor package of FIG. 12;

FIG. 14 is a left side elevation view of the air compressor package of FIG. 12;

FIG. 15 is a perspective view of an air compressor package constructed in accordance with the teachings of another alternate embodiment of the present invention;

FIG. 16 is a left side elevational view of the air compressor package of FIG. 15 as positioned in an operational position;

FIG. 17 is a top plan view of the air compressor package of FIG. 15;

FIG. 18 is a bottom plan view of the air compressor package of FIG. 15;

FIG. 19 is rear elevational view of the air compressor package of FIG. 15;

FIG. 20 is an exploded perspective view of a portion of the air compressor package of FIG. 15;

FIG. 21 a left side elevational view of the air compressor package of FIG. 15 as it is being rotated into a transport position;

FIG. 22 is a left side elevational view of the air compressor package of FIG. 15 as positioned in the transport position;

FIG. 23 is a perspective view of another air compressor package constructed in accordance with the teachings of the present disclosure;

FIG. 24 is a side perspective view of the air compressor package of FIG. 22;

FIG. 25 is a perspective view of a portion of the air compressor package of FIG. 23 with the cowling removed;

FIG. 26 is an enlarged perspective view of a portion of the air compressor package of FIG. 23 illustrating the coupling of the manifold to the air tank in greater detail;

FIG. 27 is a perspective view of the manifold;

FIG. 28 is a longitudinal section view of the manifold taken through the inlet and outlet ports;

FIG. 29 is a section view perpendicular to the longitudinal axis of the manifold through the outlet port, the pressure port and the relief port;

FIG. 30 is a longitudinal section view of the manifold taken through the drain port;

FIG. 31 is a section view similar to FIG. 30 but taken through the air tank and the manifold; and

FIG. 32 is an enlarged view of a portion of FIG. 32.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIGS. 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 5 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.

With additional reference to FIG. 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 maintained in a state of flexion, which tends to be uncomfortable for the user and fatiguing.

In FIGS. 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.

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.

The support structure 16 is illustrated to be configured in a “roll-cage” manner that extends around both the compressor mechanism 12 and the 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 platform 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.

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 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 FIGS. 3 and 4, as opposed to the substantially vertical orientation that is illustrated in the prior art air compressor package 1 of FIG. 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.

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 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 FIG. 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.

With renewed reference to FIG. 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, CG_AT and CG_AC, respectively, are positioned relatively close to the base 66 when the air compressor package 10 is oriented in its operational position (FIGS. 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 CG_ACP. As those skilled in the art will understand, the center of gravity CG_ACP 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.

With reference to FIGS. 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 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 CG_ACP of the air compressor package 10.

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 FIG. 4 to a transport position that is illustrated in FIG. 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 FIG. 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 CG_ACP 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.

Furthermore, since the center of gravity CG_ACP 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 CG_AT and CG_AC 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.

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 FIGS. 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 extending sides 32a. Like the handle 18 of the air compressor package 10 that is illustrated in FIG. 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 CG_ACP of the air compressor package 10a when the air compressor package 10a is positioned in the transport position.

In the arrangement of FIG. 10, the handle 18a is similar to that of the embodiment of FIG. 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 CG_ACP. 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 CG_ACP. 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.

The arrangement of FIG. 11 is generally similar to that of FIG. 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 FIGS. 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 FIG. 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.

With reference to FIGS. 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 FIG. 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 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.

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.

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 FIG. 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 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., CG_AT) 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).

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.

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 user 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.

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.

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 FIG. 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.

With specific reference to FIG. 14, the air tank 14 and the compressor mechanism 12 may be coupled to the support structure 16 such that their centers of gravity, CG_AT and CG_AC, 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 CG_ACP that is located relatively close to a surface onto which the air compressor package 10d has been placed, thereby rendering the air compressor package 10d relatively resistant to tipping.

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 CG_ACP of the air compressor package 10d.

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 FIG. 14 to a transport position that is similar to that which is illustrated for the air compressor package 10 in FIG. 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 CG_ACP of the air compressor package 10d is relatively closer to the base member 310 as compared to the embodiments of FIGS. 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 FIG. 3, since this configuration permits the air compressor package 10d to be transported relatively closer to the lateral side of a user.

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.

An alternative arrangement for an air compressor package 120 constructed in accordance with the teaching of the present invention is depicted in FIGS. 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.

As described above, the air compressor mechanism 122 further comprises a compressor 132 operable to intake and compress ambient air and a 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.

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.

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.

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 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 CG_ACP 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 FIG. 21 prior to reaching a transport position as shown in FIG. 22.

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 FIG. 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.

When positioned in the transport position, the plane 160 that includes the centerline 162 of the handle 150 and a center of gravity CG_ACP 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. Furthermore, since the center of gravity CG_ACP 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.

With reference to FIGS. 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 FIGS. 12 and 13. In this regard, the compressor mechanism 512 includes an oil-less compressor that is driven by an electric motor.

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 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.

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.

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 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.

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.

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 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 FIG. 23, as opposed to the substantially vertical orientation that is illustrated in the prior art air compressor package 1 of FIG. 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.

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.

With reference to FIGS. 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.

With reference to FIGS. 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.

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.

With reference to FIGS. 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.

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) can be a normally closed valve that opens when the air pressure that is acting on it is greater than a predetermined air pressure.

With reference to FIGS. 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.

With reference to FIGS. 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 FIG. 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 single location, which is relatively less expensive to manufacture than an air tank that employs multiple mounting locations for the various ports.

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.

Claims

1. An air compressor comprising:

a support structure, a compressor and an air tank in fluid connection with the compressor, the air tank having a capacity of at least 0.5 gallons, the support structure including a frame that defines a side member and a handle that extends from the side member, the side member including a first leg, an arm and a second leg, the first leg being disposed under a first side of the compressor and being secured to the air tank at a first location, the second leg having 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 having a generally cylindrical shape, the air tank abutting the first leg and the second portion of the second leg;

wherein 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.

2. The air compressor of claim 1, wherein the compressor comprises a substantially oil-less pump.

3. The air compressor of claim 1, wherein air compressor further includes a shroud member and the support structure further includes one or more tab members that are coupled to the frame, the shroud member being coupled to the tab members.

4. The air compressor of claim 3, further comprising:

a manifold assembly having a regulator, which is coupled in fluid connection to the air tank;

a coupling;

a first gauge, which is adapted to sense a pressure of air in the air tank; and

a second gauge, which is adapted to sense a pressure in a portion of the manifold assembly between the regulator and the coupling.

5. The air compressor of claim 4, wherein the manifold assembly is removably coupled to the shroud.

6. The air compressor of claim 1, wherein the support structure further includes a pair of struts that are fixedly coupled to the first leg.

7. The air compressor of claim 6, wherein the compressor is mounted to the strut members.

8. The air compressor of claim 1, wherein the support structure further includes a pair of feet and wherein the axis about which the air compressor can be rotated is defined by the feet.

9. A method comprising:

providing an air compressor having a support structure, a 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.

10. The method of claim 9, wherein the air tank is disposed between the handle and the compressor.

11. The method of claim 10, wherein the support structure includes a tubular frame that defines a pair side members and the handle, the handle being disposed between and connecting the side members, each side member including a first leg, an arm and a second leg, the first leg being disposed under a first side of the compressor and being secured to the tank at a first location, the second leg having 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.

12. The method of claim 10, wherein the handle is mounted to the air tank.

13. An air compressor comprising:

a compressor;

an air tank having a tank wall that defines a tank cavity;

a pressure regulator; and

a manifold with a manifold body that includes an inlet port and an outlet port, the manifold body being coupled to the air tank, the inlet port being coupled in fluid connection to tank cavity and the compressor, the outlet port being separate from the inlet port, the outlet port being in fluid connection with the tank cavity and the pressure regulator.

14. The air compressor of claim 13, wherein the manifold body further includes a relief port that is separate from the inlet port and the outlet port, and wherein a relief valve is coupled to the relief port.

15. The air compressor of claim 13, wherein the manifold body further includes a pressure port that is coupled in fluid connection to a pressure switch.

16. The air compressor of claim 13, wherein the manifold body further includes a drain port that is fluidly isolated from the inlet port and the outlet port, wherein the drain port is in fluid communication with the tank cavity.

17. The air compressor of claim 16, wherein the drain port includes a drain port inlet that is disposed in the tank cavity at a position that is relatively lower than an end of the manifold body through which the inlet port and the outlet port are in fluid communication with the air tank.

18. The air compressor of claim 16, wherein the manifold body further includes a manifold wall that defines a manifold cavity and wherein the inlet port and the outlet port intersect the manifold cavity and wherein the drain port inlet is an aperture that is formed partially through the manifold wall member.

19. The air compressor of claim 13, wherein the manifold body further includes a manifold wall that defines a manifold cavity and wherein the inlet port and the outlet port intersect the manifold cavity.

20. The air compressor of claim 13, further comprising a drain valve coupled to the drain port.