Air Compressor
A compact lightweight air compressor is provided with a DC motor to provide versatile use in the field where no AC power source is available. The air compressor includes a intercooler storage vessel for cooling and storing the compressed air as well as a cooling fan arrangement that allows cooling of all the air compressor components.
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The present disclosure relates to air compressors and more particularly, to a portable air compressor having a compact and lightweight design.
BACKGROUNDThe statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Air compressors have been found to be useful for numerous tasks including inflating tires and rafts, providing compressed air to power tools such as power nailers, impact wrenches, ratchets and other uses. The availability of compressed air sources is generally limited, based upon the common necessity for an AC power source. Furthermore, the size and weight of typical air compressors can prohibit the use of air compressors in certain instances.
SUMMARYA portable air compressor is provided including a compact lightweight construction which is provided with a DC electric motor that allows the compressor to be driven by a vehicle battery or other DC power sources. The air compressor can include a crank assembly connected to a first end of the drive shaft of the electric motor. A connecting rod can be attached to the crank assembly. A piston is connected to the connecting rod. A cylinder assembly is fixedly mounted relative to a first end of the electric motor and receives the piston therein. A fan can be drivingly attached to a second end of the drive shaft and a shroud can surround the fan for directing cooling air axially along the motor housing from the second end towards the first end. An intercooler assembly is connected to the cylinder assembly for receiving compressed air from the cylinder assembly.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
With reference to the attached Figures, the air compressor 10 will now be described. The air compressor 10 can include a base 12, an electric motor and compressor assembly 14, a compressed air storage vessel 16 and an optional handle assembly 18.
With reference to
The crank case 24 includes at least one and optionally two cylinder mounting flanges 34 for mounting the cylinder assemblies 36 thereto as illustrated in
The crank assembly 48 can include a counterweight member 50 having an aperture 52 with a pair of flats 54 for receiving the drive shaft 22 of the electric motor 20. The counterweight member 50 includes a slot 56 extending from the aperture 52 to a perimeter surface of the counterweight member 50. A fastener 58 is provided in an aperture 60 that traverses the slot 56 so as to allow the counterweight member 50 to be clamped onto the driveshaft 22 by tightening the fastener 58 and drawing the slot 56 closed. An offset crank pin 64 is connected to the counterweight member 50 and is received in the connecting rods 46. A pair of spacers 65 are provided between the connecting rods 46 and a rotor clip 66 secures the connecting rods 46 on the crank pin 64.
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The compressed air storage vessel 16 can be in the form of an intercooler which provides a storage vessel combined with a plurality of cooling fins to assist in cooling the compressed air received in the storage vessel 16. The vessel body can be formed by extrusion or casting with the end walls being webbed to the finned body. The storage vessel 16 can be provided with an outlet fitting 104 which serves as a quick connect for connection to various air hose and accessories which are known in the air compressor art. The intercooler 16 can also be provided with a pressure relief valve 106 and a pressure switch as will be described in greater detail herein.
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The handle assembly 18 can be utilized for lifting and moving the compressor 10 in a convenient manner so that the components of the compressor 10 do not have to be contacted by a user. The air compressor 10 of the present disclosure has a total weight no greater than 45 lbs and has a compact package having a height no greater than 12 inches, a length of no greater than 14 inches and a width of no greater than 10 inches. Thus, the entire air compressor can fit within a 14 inch cube which is far more compact than commercially available air compressors. It is noted that in a single piston compressor arrangement, the size and weight of the air compressor can be further reduced so that the weight of the air compressor can be less than 35 lbs. As illustrated in
With the air compressor 10 of the present disclosure, the compact and lightweight arrangement of the components provide for easy portability of the air compressor 10 while the DC electric motor 20 provides greater versatility by allowing the compressor 10 to be utilized wherever there is a DC power source such as a work vehicle nearby. The air compressor 10 also provides unique cooling features including a combined storage vessel and cooling function in the intercooler storage vessel. The arrangement of the cooling fan 110 for cooling all components of the air compressor 10 also provides for greater efficiency.
Claims
1. An air compressor, comprising:
- an electric motor including a drive shaft;
- a crank assembly connected to a first end of said drive shaft;
- a connecting rod attached to said crank assembly;
- a piston connected to said connecting rod;
- a cylinder assembly fixedly mounted relative to a first end of said electric motor and receiving said piston therein;
- a fan drivingly attached to a second end of said drive shaft;
- a shroud surrounding said fan for directing cooling air axially along said motor housing from said second end toward said first end; and
- an intercooler assembly connected to said cylinder assembly for receiving compressed air from said cylinder assembly.
2. The air compressor according to claim 1, wherein said intercooler assembly includes a storage vessel and a plurality of cooling fins disposed on a surface of said storage vessel.
3. The air compressor according to claim 1, wherein said intercooler assembly is disposed above said electric motor.
4. The air compressor according to claim 1, wherein said intercooler assembly is connected to said cylinder assembly by a pipe attached to said cylinder assembly and extending a length of said intercooler assembly and attached to an end of said intercooler assembly furthest from said cylinder assembly.
5. The air compressor according to claim 4, further comprising a cover plate covering said pipe.
6. The air compressor according to claim 1, further comprising a base including a base wall and a plurality of sidewalls receiving said electric motor therein.
7. The air compressor according to claim 6, further comprising a handle assembly mounted to said base.
8. The air compressor according to claim 6, wherein said handle assembly includes a pair of end support members mounted to opposite ends of said base and a handle extending between said end support members.
9. The air compressor according to claim 6, wherein said base includes a plurality of vent openings therein.
10. The air compressor according to claim 1, wherein said motor is a DC electric motor.
11. The air compressor according to claim 1, further comprising a crankcase attached to said first end of said electric motor, said cylinder assembly being mounted to said crankcase and said intercooler assembly being mounted to said crankcase.
12. The air compressor according to claim 1, wherein said compressor has a height of no greater than 12 inches, a length of no greater than 14 inches and a width of no greater than 10 inches.
13. The air compressor according to claim 1, wherein said compressor has a weight of no greater than 45 pounds.
14. An air compressor, comprising:
- an electric motor including a drive shaft;
- a crank assembly connected to a first end of said drive shaft;
- a connecting rod attached to said crank assembly;
- a piston connected to said connecting rod;
- a cylinder assembly fixedly mounted relative to a first end of said electric motor and receiving said piston therein; and
- an intercooler assembly connected to said cylinder assembly for receiving compressed air from said cylinder assembly, said intercooler assembly including a storage vessel and a plurality of cooling fins disposed on a surface of said storage vessel.
15. The air compressor according to claim 14, wherein said intercooler assembly is disposed above said electric motor.
16. The air compressor according to claim 14, wherein said intercooler assembly is connected to said cylinder assembly by a pipe attached to said cylinder assembly and extending a length of said intercooler assembly and attached to an end of said intercooler assembly furthest from said cylinder assembly.
17. The air compressor according to claim 16, further comprising a cover plate covering said pipe.
18. An air compressor, comprising:
- an electric motor including a drive shaft;
- a crank assembly connected to a first end of said drive shaft;
- a connecting rod attached to said crank assembly;
- a piston connected to said connecting rod;
- a cylinder assembly fixedly mounted relative to a first end of said electric motor and receiving said piston therein;
- a storage vessel connected to said cylinder assembly for receiving compressed air from said cylinder assembly; and
- a base including a base wall and a plurality of sidewalls receiving said electric motor therein.
19. The air compressor according to claim 18, further comprising a handle assembly mounted to said base.
20. The air compressor according to claim 19, wherein said handle assembly includes a pair of end support members mounted to opposite ends of said base and a handle extending between said end support members.
21. The air compressor according to claim 18, wherein said base includes a plurality of vent openings therein.
22. An air compressor, comprising:
- an electric motor including a drive shaft;
- a crank assembly connected to a first end of said drive shaft;
- a connecting rod attached to said crank assembly;
- a piston connected to said connecting rod;
- a cylinder assembly fixedly mounted relative to a first end of said electric motor and receiving said piston therein;
- a vessel connected to said cylinder assembly for receiving compressed air from said cylinder assembly, wherein said compressor has a height of no greater than 12 inches, a length of no greater than 14 inches and a width of no greater than 10 inches.
23. The air compressor according to claim 22, wherein said compressor has a weight of no greater than 45 pounds.
24. The air compressor according to claim 22, wherein said electric motor is a DC electric motor.
25. The air compressor according to claim 23, further comprising a base for receiving said electric motor and a handle mounted to said base.
Type: Application
Filed: Oct 29, 2007
Publication Date: Apr 30, 2009
Applicant: WARN INDUSTRIES, INC. (Milwaukie, OR)
Inventors: Bryan M. Averill (Portland, OR), Steven M. Schile (Portland, OR), Darren G. Fretz (Canby, OR), Eric J. Webb (Vancouver, WA)
Application Number: 11/926,681
International Classification: F04B 17/03 (20060101); F04B 35/04 (20060101);