Cooling arrangement for a portable air compressor
A portable air compressor assembly includes a tubular frame having side sections and an assembly longitudinal axis. A support plate between the side sections supports a power unit having a longitudinal axis arranged perpendicular to the assembly longitudinal axis. A compressor having a compressor head and longitudinal axis is mounted to the support plate with the compressor longitudinal axis parallel to the power unit longitudinal axis and perpendicular to the assembly longitudinal axis. A fan connected to the power unit generates an air flow. A ducted cover enclosing the fan includes an air passage directing the air flow from the fan to the compressor head. The ducted cover includes inner and outer covers each including a portion of the air passage. An air scoop extends into the outer cover portion of the air passage to redirect the air flow.
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This is a continuation of application Ser. No. 11/047,521, filed Jan. 31, 2005, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTIONThe present invention relates in general to air compressors and more specifically to an apparatus and method for cooling a compressor of a portable air compressor.
BACKGROUND OF THE INVENTIONAir compressors normally provide a source of pressurized air which is temporarily stored under pressure in a tank. A motor, typically an electric motor or a combustion engine, is connected to a compressor unit. The compressor unit typically includes a piston assembly having a piston slidably mounted in a cylinder, the piston compressing air from the atmosphere and forcing it into the fluid pressure tank for temporary storage. The work involved in compressing atmospheric air and the friction of the moving piston within the cylinder generate heat which must be dissipated. Cooling fins are commonly provided on the cylinder for air near the cylinder to convectively cool the piston assembly. Fans are also known which force air toward and about the piston assembly to increase convective cooling.
Several drawbacks exist for common portable air compressor cooling assemblies. One drawback is that common cooling configurations may not supply dedicated cooling air to the head area of the compressor. Another drawback is that common cooling configurations have duct portions that extend over the head area of the compressor. This can trap heat in the head area after the unit is turned off. Another drawback with some current compressor cooling designs is that only a single fan is used and the air ducting configuration(s) is/are not optimized to control the distribution of all the air flow. It is therefore desirable to provide a cooling device for a portable air compressor assembly which overcomes the drawbacks of known air compressor assemblies.
SUMMARY OF THE INVENTIONIn one preferred embodiment of the present invention, a cooling arrangement for a portable air compressor includes a portable air compressor air ducting device having a two-piece ducted fan blade cover. A first piece of the ducted cover includes a first air passage portion. A second piece of the ducted cover is adapted to connect to the first piece. The second piece has a second air passage portion adapted to align with the first air passage portion. An enclosed air passage is created between the first and second air passage portions when the first and second pieces are connected together. A grill area in the second piece of the ducted cover has a plurality of elongated apertures operable to deliver an air flow to the enclosed air passage.
In another preferred embodiment, a portable air compressor system includes a drive unit having a drive shaft. A first fan mounted to the drive shaft generates a first air flow. A compressor includes a driven shaft, a compressor head and a body. A second fan mounted to the driven shaft creates a second air flow directable toward the compressor body. A ducted fan cover at least partially encloses both the first and second fans. An air passage created in the fan cover transfers the first air flow from the first fan to the compressor head.
In yet another preferred embodiment, a portable air compressor assembly includes a tubular frame having side sections and an assembly longitudinal axis. A support plate between the side sections supports a power unit having a longitudinal axis arranged perpendicular to the assembly longitudinal axis. A compressor having a compressor head and longitudinal axis is mounted to the support plate with the compressor longitudinal axis parallel to the power unit longitudinal axis and perpendicular to the assembly longitudinal axis. A fan connected to the power unit generates an air flow. A ducted cover enclosing the fan includes an air passage directing the air flow from the fan to the compressor head. The ducted cover includes inner and outer covers each including a portion of the air passage. An air scoop extends into the outer cover portion of the air passage to redirect the air flow.
In still yet another preferred embodiment, a method for cooling a compressor of a portable air compressor assembly is provided. The air compressor assembly includes a power unit, a compressor having a body and a head area, a first fan mounted to the compressor, a second fan mounted to the power unit, and a ducted cover for protectively covering the first and second fans, the ducted cover having a ducted cavity and first and second grill areas. The method includes drawing a first air flow through the first grill area of the ducted cover using the first fan. A second air flow through the second grill area is generated using the second fan. The second air flow is directed through the ducted cavity formed within the ducted cover. The second air flow is redirected approximately 90 degrees using an opposed pair of radially curving walls of the ducted cover. The second air flow is then discharged adjacent to the head area of the compressor.
A cooling arrangement for a portable air compressor of the present invention offers several advantages. By aligning the longitudinal centerlines of both a compressor and a power unit parallel with each other and substantially perpendicular to a longitudinal axis of the air compressor, a compact arrangement of the components results. By providing two fans, a first driven by the compressor shaft and a second driven by the power unit shaft, increased cooling flow can be provided to the compressor. A ducted cover of the two fans allows for air intake through the cover and provides ducting to direct a substantially constant air flow from the power unit driven fan toward a head area of the compressor. An opposed pair of curved walls and an adapted air scoop within the ducting path smoothly transition the air approximately 90 degrees to discharge toward the compressor head area. Duct portions are provided in each of two halves of the ducted cover to provide defined duct segments which efficiently distribute the air flow and smoothly transition toward a discharge end.
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 embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
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A plurality of dividing walls 118 separate individual pairs of elongated apertures 70 of second grill area 66. Air entering each of the elongated apertures 70 is collected within an increasing radius (for example a nautilus-shaped) boundary wall 120 which is positioned to closely rotatably clear a perimeter of second fan 82 and direct substantially all of the second air flow received through elongated apertures 70 into a receiving area 122 bounded by boundary wall 120. Boundary wall 120 extends approximately perpendicular to first portion 62. From receiving area 122, second fan 82 directs the second air flow into a receiving plenum 124, similar to receiving plenum 83 of second portion 80. From receiving plenum 124, the air is directed into a transition region 126 having a substantially constant total cross-section. The total cross-section is maintained to stabilize the air flow and at least maintain its velocity. Transition region 126 is shaped similarly to transition region 90 of second portion 80. The ducting formed by receiving plenum 124 and transition region 126 is bounded by an inner duct wall 128 and an outer duct wall 130 which direct the second air flow into a discharge transition area 132.
Second portion 80 further includes one or more stiffening members 134 and an air scoop 135 having a scoop wall 136. Scoop wall 136 abuts against a flow containment wall 138 of first portion 62 when the two ducted cover halves, first and second portions 62, 80, respectively, are connected. Scoop wall 136 transitions into radially curving wall 104 to direct substantially all the second air flow within discharge transition area 132 of first portion 62 and discharge area 92 of second portion 80 through a discharge opening 139.
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A cooling arrangement for a portable air compressor of the present invention offers several advantages. By aligning the longitudinal centerlines of both a compressor and a power unit parallel with each other and substantially perpendicular to a longitudinal axis of the air compressor, a compact arrangement of the components results. By providing two fans, a first driven by the compressor shaft and a second driven by the power unit shaft, increased cooling flow can be provided to the compressor. A ducted cover of the two fans allows for air intake through the cover and provides ducting to direct and maintain a substantially constant air flow from the power unit driven fan toward a head area of the compressor. An opposed pair of curved walls and an adapted air scoop within the ducting path smoothly transition the air approximately 90 degrees to discharge toward the compressor head area. Duct portions are provided in each of two halves of the ducted cover to provide defined duct segments which smoothly transition toward a discharge end.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
Claims
1. A portable air compressor system, comprising:
- a drive unit having a drive shaft;
- a first fan rotatably mounted to the drive shaft operable to generate a first air flow;
- a compressor having a driven shaft, a compressor head and a body;
- a second fan mounted to the driven shaft operable to create a second air flow directable toward the compressor body;
- a ducted fan cover operable to at least partially enclose both the first and second fans; and
- an air passage created in the fan cover operable to transfer the first air flow from the first fan to the compressor head.
2. The system of claim 1, wherein the first fan comprises a radial flow fan.
3. The system of claim 1, wherein the air passage comprises a substantially rectangular shape.
4. The system of claim 1, wherein the air passage comprises a shape selected from one of square, circular and oval.
5. The system of claim 1, wherein the ducted fan cover comprises a polymeric material.
6. The system of claim 1, wherein the ducted fan cover comprises first and second grill areas each having a plurality of elongated apertures, the first grill area aligned with the first fan and the second grill area aligned with the second fan.
7. The system of claim 1, wherein the ducted fan cover comprises first and second members, the first member being mountable to a structure of the portable air compressor and the second member being fastenably connectable to the first member.
8. The system of claim 7, wherein the air duct further comprises:
- a first substantially U-shaped portion created in the first member; and
- a second substantially U-shaped portion created in the second member;
- wherein the first and second substantially U-shaped portions are alignable to create the air passage when the second member is connected to the first member.
9. The system of claim 1, further comprising:
- a compressor assembly longitudinal axis;
- a drive unit longitudinal axis oriented approximately perpendicular to the compressor assembly longitudinal axis; and
- a compressor longitudinal axis oriented substantially parallel to the drive unit longitudinal axis and substantially perpendicular to the compressor assembly longitudinal axis.
10. The system of claim 1, further comprising a discharge duct portion positioned adjacent to the compressor head and separated from the compressor head by a clearance dimension.
11. The system of claim 10, wherein the discharge duct portion further comprises an extension portion substantially conforming in shape to a compressor head shape.
12. The system of claim 1, further comprising a discharge duct portion extending at least partially over the compressor head.
13. A portable air compressor system, comprising:
- a generally tubular frame having a pair of approximately parallel side sections each parallel to an assembly longitudinal axis;
- a support plate disposed between the side sections;
- a power unit having a longitudinal axis, the power unit mounted to the support plate such that the power unit longitudinal axis is substantially perpendicular to the assembly longitudinal axis;
- a compressor having a compressor head and a compressor longitudinal axis, the compressor mounted to the support plate having the compressor longitudinal axis substantially parallel to the power unit longitudinal axis and substantially perpendicular to the assembly longitudinal axis;
- a first fan connected to a drive shaft of the power unit operable to generate an air flow;
- a ducted cover operable to at least partially enclose the first fan, the ducted cover including an air passage operable to transfer the air flow from the first fan to the compressor head, the ducted cover divisible into an inner cover connectable to an outer cover, each of the inner and outer covers including a portion of the ducted air passage;
- an air scoop extending into the portion of the air passage of the outer cover operable to redirect the air flow; and
- a second fan connected to a driven shaft of the compressor and operating to direct a second air flow perpendicular to a direction of air flow in the air passage and independently of the air flow in the air passage toward a body of the compressor.
14. The system of claim 13, wherein each portion of the ducted air passage is substantially U-shaped such that the ducted air passage defines a substantially rectangular-shape when the inner and outer covers are connected.
15. The system of claim 14, wherein the outer cover further comprises an increasing radius boundary wall at least partially encircling the first fan.
16. The system of claim 13, wherein the air scoop is integrally connected to the inner cover.
17. The system of claim 16, wherein the air scoop further comprises an opposed pair of radially curving walls operable to redirect the air flow.
18. The system of claim 13, wherein the outer section of the cover further comprises:
- a first grill area having a first plurality of elongated apertures aligned with the first fan; and
- a second grill area having a second plurality of elongated apertures aligned with the second fan.
19. The system of claim 13, wherein the support plate is substantially horizontally positioned in a normal operating position of the air compressor assembly.
20. A portable air compressor system, comprising:
- a compressor assembly having an assembly longitudinal axis, a power unit and a compressor rotatably driven by the power unit;
- a power unit longitudinal axis;
- a compressor longitudinal axis, the compressor longitudinal axis being oriented substantially parallel to the power unit longitudinal axis and both the compressor longitudinal axis and the power unit longitudinal axis oriented substantially perpendicular to the assembly longitudinal axis;
- each of the power unit and the compressor having a rotatable shaft, each rotatable shaft having a separate fan coupled thereto; and
- a fan cover at least partially enclosing the fan of each the power unit and the compressor, the fan cover including an enclosed duct for directing a portion of an air flow discharged by the fan of the power unit toward the compressor, to assist in operably cooling the compressor.
21. The system of claim 20, wherein the compressor further comprises a head area, the enclosed duct of the fan operable to direct the portion of the air flow substantially toward the head area.
22. The system of claim 20, further comprising a drive belt operable to rotatably connect the power unit to the compressor, wherein the fan cover is also operable to substantially enclose the drive belt.
23. A method for cooling a compressor of a portable air compressor assembly, the air compressor assembly including a power unit, a compressor having a body and a head area, a first fan mounted to the compressor, a second fan mounted to the power unit, and a ducted cover for protectively covering the first and second fans, the ducted cover having a ducted air passage and first and second grill areas, the method comprising the steps of:
- drawing a first air flow through the first grill area of the ducted cover using the first fan;
- directing the first air flow toward the compressor body;
- generating a second air flow through the second grill area using the second fan;
- directing the second air flow through the ducted air passage;
- redirecting the second air flow approximately 90 degrees using an opposed pair of radially curving walls of the ducted cover; and
- discharging the second air flow adjacent to the head area of the compressor.
24. The method of claim 23, further comprising maintaining a cross-sectional area of the ducted passage to maintain a velocity of the second air flow in a transition region of the ducted air passage.
25. The method of claim 23, further comprising creating the ducted cover as opposed first and second portions.
26. The method of claim 25, further comprising forming the ducted air passage as air passage segments each disposed in one of the first and second portions.
27. The method of claim 26, further comprising extending an air scoop from one of the first and second portions into the air passage segment of the other one of the first and second portions to scoop the second air flow from the ducted cavity.
Type: Application
Filed: Apr 9, 2009
Publication Date: Aug 13, 2009
Applicant: Black & Decker Inc. (Newark, DE)
Inventors: Michael P. Baron (Phoenix, MD), David E. Chreene (New Freedom, PA), William Spencer (Ellicott City, MD), Erik A. Ekstrom (Woodstock, MD)
Application Number: 12/384,867
International Classification: F04D 29/58 (20060101);