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HK1133289B - Reciprocating compressor or pump and a portable tool powering system including a reciprocating compressor - Google Patents

Reciprocating compressor or pump and a portable tool powering system including a reciprocating compressor Download PDF

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Publication number
HK1133289B
HK1133289B HK10100545.8A HK10100545A HK1133289B HK 1133289 B HK1133289 B HK 1133289B HK 10100545 A HK10100545 A HK 10100545A HK 1133289 B HK1133289 B HK 1133289B
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HK
Hong Kong
Prior art keywords
compressor
cylinder
piston
housing
motor
Prior art date
Application number
HK10100545.8A
Other languages
Chinese (zh)
Other versions
HK1133289A1 (en
Inventor
拉里‧阿尔文‧许茨勒
L‧D‧彭纳
Original Assignee
拉里‧阿尔文‧许茨勒
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Application filed by 拉里‧阿尔文‧许茨勒 filed Critical 拉里‧阿尔文‧许茨勒
Priority claimed from PCT/CA2007/000990 external-priority patent/WO2007140596A1/en
Publication of HK1133289A1 publication Critical patent/HK1133289A1/en
Publication of HK1133289B publication Critical patent/HK1133289B/en

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Description

Reciprocating compressor or pump and system for powering portable tools including a reciprocating compressor
Technical Field
The present invention relates to compressors and pumps, and more particularly to reciprocating compressors and pumps based on cylinders and pistons.
Background
Users of pneumatic tools that require a steady source of compressed air to operate are often limited in mobility, or at least limited in mobility, by the length of the air hose connected to the fixed air compressor. Conventional air compressors are typically limited in their mobility due to large storage tanks that store compressed air, non-electric motors that drive the compressor that may emit harmful gases and require a fuel source (which adds weight and size), or electric motors that require connection to a stationary power source, such as an ac electrical outlet.
U.S. patent nos. 6,692,239 and 6,589,024 to Nishikawa et al and 5,030,065 to Baumann teach radially arranged reciprocating compression mechanisms, opposing pairs of which are each linked by a respective yoke mechanism for driving the reciprocating compression mechanism back and forth.
The reciprocating air compressor taught in japanese patent publication No. 59190486 has its cylinder block radially fastened to the polygonal peripheral wall portion of the crankcase to reduce the length of the compressor from the front to the rear. Conventional connecting rod assemblies used in such radial cylinder arrangements typically use pins to pivotally connect the primary connecting rod to the other connecting rods. Such pins may be prematurely lost when significantly reduced in size for use in compact portable devices, and may require a significant number of assembly steps to complete the connection between the main connecting rod and all of the pistons.
In an attempt to avoid the mobility limitations of the conventional compressors listed above, portable battery powered air compressors have been developed with small storage tanks or little to no storage tank. However, such battery powered type compressors typically do not provide sufficient air flow to be powered for powering pneumatic tools, which need to be supplied on a relatively continuous basis to provide a relatively large amount of air pressure for optimal operation. These compressors are generally reciprocating compressors featuring a single piston/cylinder arrangement, keeping the compressor relatively small for improved portability.
International patent publication WO 01/29421 teaches a battery powered portable compressor system featuring a dual cylinder compressor of the type described in U.S. patent No. 4,715,787 mounted on a belt and storing compressed air within a hose connecting the compressor to a pneumatic tool.
United states patent No. 3,931,554 to Spentzas teaches a double piston reciprocating motor compressor which is battery operated in the embodiment of fig. 9.
Patton et al, U.S. patent application publication No. 2002/0158102, teaches a portable pneumatic tool having a self-contained single piston compressor assembly that can be powered by a detachable battery, and a portable single piston compressor assembly that can be carried by the user to drive the pneumatic tool.
Suzuura et al, U.S. patent No. 6,089,835, teaches a portable, single piston compressor having a motor and power transmission mechanism supported in a two-piece shell, and an air tank defined by the exterior surface of a second shell and the interior surface of a third shell mounted on the second shell.
U.S. patent application publication No. 2005/0214136 to Tsai teaches a portable compressor system including a backpack divided into two chambers, wherein the chambers contain a DC motor, an air cylinder, an air storage carrying bottle, a pressure switch and a quick connector, and the other chamber contains a battery and a control box.
Us 3,961,868 teaches a compact compressor having a single cylinder with a swinging piston having an air inlet valve provided on the piston head for directing air from the crankcase into the cylinder.
A worker at a work site who is using both a portable power tool and a pneumatic tool powered by a portable compressor must typically carry two or more separate battery modules to serve as battery modules.
Us patent 5,095,259 teaches a system for operating a plurality of different dc power tools and appliances in a one-time manner. However, the use of such a system to power both an electric tool and a portable compressor for a pneumatic tool involves the arrangement of two separate power delivery lines, electrical wires from the battery module for connection to the electric tool or the compressor, and an air hose from the compressor to the pneumatic tool.
Conventional compressors and pumps typically use reed valves that use a thin, flexible strip of metal or fiberglass that is fixed at one end and can be bent in response to a pressure differential on opposite sides of the valve to open and close an orifice. These valves may break or fail to seat after repeated bending stresses experienced in operation. The metal reed also retains heat that may be considered waste energy and over time may be attacked by exposure to moisture.
Conventional pumps used, for example, for pumping water that must be prohibited from production from oil and gas wells may fail quite rapidly when operated continuously and exposed to brackish water or other fluids containing corrosive particulate materials such as sulphur or sand. More particularly, the reed in such pumps may wear or break at an accelerated rate due to such exposure.
Disclosure of Invention
According to a first aspect of the present invention there is provided a reciprocating compressor or pump comprising:
a plurality of cylinder liners, each cylinder liner having a cylindrical bore therethrough;
a plurality of pistons, each piston sealed to a respective one of the cylinder liners within the cylindrical bore of the respective one of the cylinder liners;
a drive system coupled to each piston for reciprocating each piston along the cylindrical bore of the respective cylinder casing between a fully extended position furthest from the drive system and a fully retracted position closest to the drive system;
an inlet valve and an outlet valve associated with each cylinder liner, the inlet valve configured to open when the piston is retracted toward the fully retracted position and to close when the piston is extended away from the fully retracted position, and the outlet valve configured to open when the piston is extended toward the fully extended position and to close when the piston is retracted away from the fully extended position;
a manifold having a hollow interior in fluid communication with the cylindrical bore of each cylinder liner when the drain valve associated with that cylinder liner is open;
wherein the plurality of cylinder liners and the drive system are carried by the manifold.
Preferably, the plurality of cylinder liners are arranged in a common plane and extend radially about an axis perpendicular to the common plane.
The plurality of cylinder liners may be mounted to the outer surface of the manifold, in which case each cylinder liner preferably extends along a plane in which the outer surface of the manifold lies.
Preferably, the manifold on which the cylinder liners are carried is substantially rigid.
The manifold may be sealed to an exterior surface of each cylinder liner to enclose a portion of the cylinder liner on which the exhaust valve associated with the cylinder liner is defined.
The hollow interior of the manifold may define an annular space extending about the axis to communicate with each discharge valve.
Each cylinder liner may be at least partially disposed within the hollow interior of the manifold, and each exhaust valve is disposed within the hollow interior of the manifold to control flow between the cylindrical bore of the cylinder liner and the surrounding hollow interior. In this case, each discharge valve preferably includes at least one discharge port extending through the cylinder casing and an elastic band disposed circumferentially around the cylinder casing; during movement of the piston towards the fully extended position, the elastic band can be elastically extended around the respective cylinder liner by means of fluid pressure exerted on the elastic band through the exhaust port.
The cylinder liners may project into the hollow interior of the manifold with the crank chamber in which the drive system is at least partially disposed. At this point, the crank chamber may be surrounded by an annular wall, and the hollow interior of the manifold defines an annular space extending around the annular wall that communicates with the cylindrical bore of each cylinder liner when the corresponding exhaust valve is open; wherein the cylinder liners project radially from the annular wall into the hollow interior of the manifold.
According to a second aspect of the present invention, there is provided a portable compressor or pump assembly comprising:
a carrying handle having opposite first and second ends;
a motor supported on the carrying handle and including a drive shaft extending along the carrying handle; and
a reciprocating compressor or pump supported on the carrying handle at a first end thereof and connected to a drive shaft of the motor to be driven thereby.
The portable compressor or pump assembly may also be provided with a power delivery device supported at the second end of the carrying handle, the power delivery device being connected to the motor to receive power therefrom. In this case, the power delivery device is preferably manually removable, and the portable compressor or pump assembly is preferably further provided with a conduit extending along the carrying handle in fluid communication with a receptacle into which the operation of the reciprocating compressor or pump feeds fluid; and a pressure switch is provided in fluid communication with the conduit at an end thereof closest to the second end of the carrying handle for electrical connection to the power transmission means and the motor to control operation of the motor in dependence on the pressure measured in the conduit and the receiver.
Alternatively, a second reciprocating compressor or pump may also be provided, supported on the carrying handle at the second end thereof, and connected to the drive shaft of the motor for driving thereby. In this case, it is preferable that there is further provided a power delivery device connected to the motor to receive power, the power delivery device defining a base on which the carrying handle, the motor and the reciprocating compressor or pump are mounted; and further provided with a conduit extending along said carrying handle fluidly connecting two receptacles into which fluid is delivered by operation of said reciprocating compressor or pump; and an outlet in fluid communication with the conduit and the two receivers to define a common discharge of the two reciprocating compressors or pumps.
Preferably, the duct is defined by a hollow interior of the carrying handle.
Preferably, the reciprocating compressor or pump comprises a plurality of cylinders spaced about the axis of said drive shaft in a common plane and each cylinder extending radially relative to the axis in the common plane.
According to a third aspect of the present invention there is provided a reciprocating compressor or pump comprising:
a housing defining a crank chamber;
a crank shaft including a shaft configured for driven rotation about an axis and a crank pin carried on the shaft eccentrically to the axis within a crank chamber;
a plurality of cylinders configured to extend radially outward from the crank chamber about the axis; and
piston and rod structure, it includes:
a central body pivotally secured to the crank pin for relative rotation between the central body and the crank pin about an eccentric axis defined by the crank pin, the eccentric axis being eccentric relative to an axis about which the shaft rotates;
a plurality of connection links, each connection link having a first connection portion at one end thereof connected to the central body and extending outwardly therefrom to a second connection portion, the first connection portion of each connection link allowing for substantial pivotal movement of the connection link relative to the central body; and
a plurality of pistons, each piston being connected to the second connection portion of a respective said connecting rod and being sealed against the inner wall of a respective cylinder, the second connection portion of each connecting rod allowing substantially pivotal movement of the connecting rod relative to the piston;
inlet and outlet valves associated with each cylinder, the inlet and outlet valves being configured to allow fluid to enter the cylinder and subsequently to allow fluid to be discharged from the cylinder in the event that the shaft is driven to rotate so that the piston moves along the cylinder away from the shaft thereby exerting pressure on the fluid;
wherein each connecting rod is formed integrally with at least one of the central body and the respective piston and forms a flexible connection therewith.
Preferably, the central body and the connecting rods are integral.
Preferably, the central body and the connecting rods comprise an integral plastic.
Preferably, each connecting rod is integral with a respective piston.
Preferably, each connecting rod and the respective piston comprise an integral plastic.
Preferably, a motor is further provided which is coupled to the drive shaft and is capable of driving the rotation thereof.
According to another aspect of the present invention, there is provided a reciprocating compressor or pump comprising:
a housing defining a crank chamber;
a crank shaft including a shaft configured for driven rotation about an axis and a crank pin carried on the shaft eccentrically to the axis within a crank chamber;
a plurality of cylinders configured to extend radially outward from the crank chamber about the axis; and
a connecting rod structure, comprising:
a central body pivotally secured to the crank pin for relative rotation between the central body and the crank pin about an eccentric axis defined by the crank pin, the eccentric axis being eccentric relative to an axis about which the shaft rotates; and
a plurality of connecting rods connected to the central body, each connecting rod extending outwardly from the central body into a respective cylinder to pivotally support a piston at one end of the connecting rod: the end portion is opposed to a flexible connecting portion sealed against an inner wall of the cylinder;
the body having a plurality of peripheral keyways parallel to and spaced about the eccentric axis, the keyways receiving the ends of all but one of the connection rods, the keyways and each of the connection rods being configured to prevent separation of the keyways from the corresponding connection rod in a plane perpendicular to the eccentric axis while allowing limited relative pivoting between the keyways and the corresponding connection rod in the plane perpendicular to the eccentric axis;
an inlet valve and an outlet valve associated with each cylinder, the inlet and outlet valves being configured to allow fluid to enter the cylinder and subsequently to allow fluid to be discharged from the cylinder in the event that the shaft is driven to rotate so that the piston moves along the cylinder away from the shaft thereby exerting pressure on the fluid.
Preferably, the wall of each surrounding keyway includes an arcuate portion that extends more than 180 degrees to form a mouth having a width that is less than the diameter of the arcuate portion.
Preferably, each of the all connection bars except one of the connection bars includes: a rounded end portion having a diameter greater than the width of the mouth of a corresponding one of the peripheral keyways; and a shank having a width less than the diameter of the rounded end and extending from the rounded end away from the central body of the connecting rod structure through the mouth of a corresponding one of the surrounding keyways.
Preferably, the arcuate portion of the wall of each surrounding keyway defines the entire wall.
According to a fifth aspect of the present invention, there is provided a reciprocating compressor or pump comprising:
a hollow cylinder body;
a piston mounted within the cylinder for limited reciprocation therealong;
a drive system connected to the piston and operable to drive the reciprocating movement of the piston;
inlet and outlet valves associated with the cylinder, the inlet and outlet valves being operable to admit fluid from a fluid supply outside the cylinder into the cylinder and subsequently to allow fluid to be discharged from the cylinder in the event that pressure is applied to the fluid within the cylinder during movement of the piston towards a fully extended position furthest from the drive system;
wherein the inlet valve comprises:
a valve seat comprising a protruding portion that extends into a space within the hollow cylinder between the sealed engagement of the piston and cylinder and a distal end of the cylinder opposite an open end of the cylinder through which the piston and drive system are connected;
a passageway extending through said valve seat, the passageway having an opening defined in the projecting portion to place a fluid supply outside the cylinder in fluid communication with a space within the hollow cylinder between the sealed engagement of the piston and cylinder and the distal end of the cylinder; and
an elastic band circumferentially disposed about the projection and capable of elastically elongating about the projection by means of a pressure differential between a fluid supply outside the cylinder and the space within the hollow cylinder between the sealed engagement of the piston and cylinder and the distal end of the cylinder.
Preferably, the elastic band is arranged in a circumferential recess in the protruding portion.
Preferably, the circumferential recess in the projecting portion is tapered from an outermost periphery thereof.
Preferably, the elastic band is tapered from its outer surface to its inner surface.
Preferably, the depth of the circumferential recess is sufficient to prevent the elastic band from completely exiting the circumferential recess in the event of elongation of the elastic band due to a pressure difference.
The valve seat may be formed on the piston and the passageway extends through the piston to place the piston in fluid communication with opposite sides of the sealing engagement of the cylinder.
Alternatively, the valve seat may be formed on the distal end of the cylinder with the projection extending from the distal end of the cylinder into the space within the hollow cylinder. At this point, the valve seat may be formed on a cylinder head sealed to the distal end of the cylinder block, and the passageway extends through the cylinder head for fluidly communicating opposite sides of the sealed joint of the cylinder head and the cylinder block.
According to a sixth aspect of the present invention there is provided a reciprocating compressor or pump comprising:
a cylinder liner defining a cylindrical bore;
a piston sealed to the cylinder liner within the cylindrical bore for reciprocating movement along the cylindrical bore;
a drive system connected to the piston and operable to drive reciprocation of the piston; and
inlet and outlet valves associated with the cylinder casing, the inlet and outlet valves being operable to admit fluid from a fluid supply outside the cylinder casing into the cylindrical bore and subsequently to permit fluid to be discharged from the cylindrical bore in the event that pressure is applied to the fluid within the cylinder during movement of the piston towards a fully extended position furthest from the drive system;
the discharge valve includes at least one discharge port extending through a wall of the cylinder liner and an elastomeric band disposed circumferentially around the cylinder liner; the elastic band is capable of elastically elongating around the respective cylinder liner when the piston exerts pressure on the fluid such that the fluid flows from the cylindrical hole through the discharge port; and
a receptacle sealed about the cylinder casing to enclose the elastomeric band, and elongation of the elastomeric band within the receptacle allows fluid to flow from the cylindrical bore through the at least one exhaust port into the receptacle.
Preferably, a plurality of cylinder liners is also provided, the receiver sealing around the plurality of cylinder liners for receiving fluid from the cylindrical bore of each cylinder liner.
Preferably, the elastic band is arranged in a circumferential recess in a wall portion of the cylinder liner.
Preferably, the circumferential recess in the wall portion of the cylinder liner narrows from its outermost periphery towards the cylindrical bore.
Preferably, the elastic band narrows from its outer surface to its inner surface.
Preferably, the depth of the circumferential recess is sufficient to prevent the elastic band from completely exiting from the circumferential recess in the event of elongation of the elastic band due to the compressed gas.
According to a seventh aspect of the present invention there is provided a reciprocating compressor or pump comprising:
a hollow cylinder body;
a piston disposed within an interior of the hollow cylinder and sealed thereto for reciprocating movement along the hollow cylinder;
a drive system connected to the piston and operable to drive the piston in a reciprocating motion along the hollow cylinder; and
inlet and outlet valves associated with the hollow cylinder, the inlet and outlet valves being operable to allow fluid to enter the cylinder and subsequently to allow fluid to be discharged from the cylinder upon application of pressure to the fluid during movement of the piston towards a fully extended position furthest from the drive system;
at least one of the inlet valve and the outlet valve includes:
a valve port fluidly communicating a fluid supply outside the hollow cylinder with a space within the hollow cylinder between a sealed junction of the piston and cylinder and a distal end of the cylinder opposite an open end of the cylinder through which the piston and drive system are connected; and a flapper including a fixed portion fixed to a surface surrounding one-side opening of the valve port and a movable portion connected to the fixed portion by a flexible portion, the movable portion having a rigidity greater than that of the flexible portion;
the flexible portion of the flapper between its fixed portion and its movable portion is capable of flexing in response to a pressure differential between a space within the hollow cylinder and a fluid supply outside the hollow cylinder to move the movable portion between a closed position in which the movable portion sealingly covers the orifice of the valve port and an open position in which the movable portion is at least partially lifted from the orifice of the valve port to allow fluid to flow through the orifice.
The at least one of the inlet valve and the outlet valve may comprise an inlet valve, a valve port of the inlet valve extending through the piston through a sealing engagement of the piston with the hollow cylinder, and the flapper being secured to the piston as follows: the face is located on a side of the sealing interface opposite the drive system.
A second valve port surrounded by the surface and a second movable portion and a flexible portion of the flapper may also be provided, and the second movable portion and the flexible portion of the flapper are likewise configured to sealingly close the second valve port and open the second valve port in response to a pressure differential between a space within the hollow cylinder and a fluid supply source outside the hollow cylinder. At this time, the valve port and the second valve port, the movable portion and the second movable portion of the flexible flap, and the flexible portion and the second flexible portion are preferably symmetrical with respect to the fixed portion of the flap.
Preferably, a seal is also provided which is secured to the surface to extend around the valve port and seal against the movable portion of the flapper in the closed position.
Preferably, the movable portion includes an integral extension of the flexible portion and a member made of a material more rigid than the flexible portion, which is fixed to the integral extension of the flexible portion.
Preferably, the member material comprises a metal.
Preferably, the flexible baffle comprises rubber.
According to an eighth aspect of the present invention there is provided a system for powering a portable tool, comprising:
a portable air compressor unit including an air compressor and an electric motor connected to the air compressor for driving operation of the air compressor;
a battery module including at least one battery and connectable to the electric motor to selectively supply power to the electric motor; and
a power delivery assembly comprising:
an air hose connected to the air compressor and having a pneumatic tool connector at an end of the air hose opposite the air compressor; and
a plurality of electrical conductors connected to the battery module and extending along the air hose toward an end of the air hose opposite the air compressor, the electrical conductors having a power tool connector at an end thereof opposite the battery module;
thus, the end of the power delivery assembly opposite the battery module and the portable air compressor can be connected to a pneumatic or electric tool.
Preferably, the electrical conductors are arranged in a common cover.
The battery module, the electric motor, and the electrical conductors may be wired such that power is selectively delivered to only one of the electric motor and the power tool connector at any one time.
Preferably, the battery module includes a rechargeable battery.
The pneumatic tool connector and the electric tool connector may be defined by a single quick-connect unit that is connectable to only one of the pneumatic tool and the electric tool at a time.
At this time, it is also possible to provide a pneumatic tool and an electric tool each of which is mounted with a quick-connect member having an air passage and a pair of electric contacts, the quick-connect member of the pneumatic tool enabling its air passage to be in fluid communication with an inlet of a pneumatic drive system of the pneumatic tool, and the quick-connect member of the electric tool enabling its electric contacts to be electrically connected to an electric drive system of the electric tool.
According to a ninth aspect of the present invention, there is provided a reciprocating compressor comprising:
a crank chamber;
a crank shaft supported for rotation within the crank chamber;
a motor having a drive shaft coupled to the crank shaft for driving the crank shaft to rotate within the crank chamber;
at least one cylinder projecting from the crank chamber, and an open end of each cylinder being in fluid communication with the crank chamber;
a piston disposed within each cylinder and sealed thereto, the piston being connected to the crankshaft for reciprocating movement within the cylinder, the piston moving away from the crankshaft during a compression stroke and toward the crankshaft during an intake stroke;
an intake valve associated with each cylinder in fluid communication with the crank chamber, the intake valve operable to open during an intake stroke in response to a pressure differential between the crank chamber and a space within the cylinder: a space between an end of the cylinder opposite the open end thereof and the piston, wherein the open end is in communication with the crank chamber for allowing fluid to flow into the space during an intake stroke;
a discharge valve associated with each cylinder operable to open during a compression stroke to assist in discharging fluid from the space within the cylinder during the compression stroke; and
a fan mounted between the motor and the at least one cylinder, the fan being in fluid communication with the crank chamber and operable to cause fluid to flow into the crank chamber through an inlet of the crank chamber, a first portion of the fluid flow being drawn into each cylinder during an intake stroke of the piston in the cylinder, and a second portion of the fluid flow being drawn by operation of the fan, past the fan and along a drive shaft to the motor.
Preferably, the motor and the fan are mounted in a common housing which is open at one end to the crank chamber and which has at least one opening in the housing on the side of the motor opposite the crank chamber for the second part of the fluid flow to exit after passing the motor.
Preferably, the fan is carried on the drive shaft for rotation by the motor.
Preferably, the housing is cylindrical to form an annular peripheral wall around said motor, the second part of the fluid flow passing through the motor between the motor and the peripheral wall closed around the motor.
Preferably, said at least one cylinder comprises a plurality of cylinders spaced about and disposed radially relative to the axis of rotation of the crankshaft in a common plane perpendicular to the axis of rotation.
Drawings
Exemplary embodiments of the invention are illustrated in the drawings:
fig. 1 is a perspective view showing an openable side of a portable compressor of a first embodiment.
Fig. 2 is a perspective view illustrating a driving side of the portable compressor of the first embodiment.
Fig. 3 is a perspective view of a first embodiment portable compressor having an electric motor operatively connected to the drive side of the compressor.
Fig. 4 is a perspective view of the first embodiment portable compressor with the removable cover removed.
Fig. 5 is a perspective view of the first embodiment portable compressor with the removable cover removed and the gas compressor and crank arms exploded away for illustration purposes.
Fig. 6 is a perspective view of a crank arm of the portable compressor of the first embodiment.
FIG. 7 is a fragmentary perspective view of the cylinder casing of the first embodiment portable compressor showing the valve end portion of the cylinder casing.
Fig. 8A, 8B and 8C are perspective views of the cylinder head of the portable compressor according to the first embodiment.
Fig. 9 is a perspective view of selected unassembled components of the connecting rod structure of the first embodiment portable compressor.
Fig. 10 is a perspective view of the second embodiment portable compressor with the top half of the receiver housing and the cover of the crank housing removed for illustration purposes.
Fig. 11 is a plan top view of the second embodiment portable compressor.
Fig. 11A is a sectional view of the second embodiment portable compressor taken along the line a-a of fig. 11.
FIG. 11B is a close-up view of the portion of the second embodiment portable compressor indicated by circle B of FIG. 11A.
Fig. 12 is a side view of the second embodiment portable compressor.
Fig. 13 is a perspective view of the bottom half of the receiver housing of the portable compressor of the second embodiment.
Fig. 13A is a plan top view of the bottom half of the receiver housing of the second embodiment portable compressor.
Fig. 13B is a cross-sectional view of the bottom half of the receiver housing of the second embodiment compressor taken along line B-B of fig. 13A.
Fig. 14 is a perspective view of the top half of the receiver housing of the second embodiment portable compressor.
Fig. 14A is a bottom plan view of the top half of the receiver housing of the second embodiment portable compressor.
Fig. 14B is a sectional view of the top half of the receiver housing of the second embodiment portable compressor taken along the line B-B of fig. 14A.
Fig. 15 is an exploded perspective view of a piston having a valve port and an intake valve baffle assembly of the portable compressor in accordance with the second embodiment.
Fig. 15A is an exploded side view of a piston having a valve port and an intake valve baffle assembly of the portable compressor of the second embodiment, with the piston having the valve port partially cut away.
FIG. 16 is an end view of a piston with a valve port of a second embodiment portable compressor.
FIG. 17 is a side view of a piston having a valve port of the portable compressor of the second embodiment.
Fig. 18 is a partially exploded perspective view of the cylinder liner, drive system and intake valve baffle assembly of the portable compressor of the second embodiment.
FIG. 19 is a cross-sectional view of one of the cylinder liners of the second embodiment portable compressor showing the exhaust valve port thereof.
FIG. 20 is a side view of the elastomeric band of the discharge valve of the second embodiment portable compressor for cooperation with the discharge valve port thereof.
Fig. 20A is a sectional view of the elastic band of the discharge valve of the second embodiment portable compressor, taken along the line a-a of fig. 20.
Fig. 21 is a perspective view of a portable compressor according to a third embodiment.
Fig. 22 is a side view of the third embodiment portable compressor.
Fig. 23 is an exploded perspective view of a portable compressor in accordance with a third embodiment.
Fig. 24 is a perspective view of a manifold defining base of the third embodiment portable compressor.
Fig. 24A is a bottom plan view of the base of the third embodiment portable compressor.
Fig. 24B is a sectional view of the base of the portable compressor of the third embodiment.
Fig. 25 is a perspective view of a gear and cylinder block mounting base of the portable compressor of the third embodiment.
Fig. 26 is a perspective view of a motor mount of the portable compressor of the third embodiment.
FIG. 27 is a perspective view of an alternative embodiment connecting rod and piston arrangement for use in a compressor having a plurality of cylinders spaced about and extending radially toward a drive axis.
FIG. 28 is a partial cross-sectional view of an alternative embodiment piston with a valve port and an intake valve.
FIG. 29 is a perspective view of a portable compressor assembly and a removable battery charger that may be used with the compressor assembly.
FIG. 30 is a side view of the portable compressor assembly and detachable battery charger with the detachable battery module removed.
FIG. 30A is an exploded end view of the removable battery module and control box of the portable compressor assembly.
Fig. 30B is a top plan view of a removable battery module of the portable compressor assembly.
Fig. 30C is an end view of the portable compressor assembly without the removable battery module installed.
FIG. 31 is an end view of the opposite end of the portable compressor assembly.
FIG. 31A is a partial close-up side view of a compressor and carrying handle of the portable compressor assembly.
FIG. 32 is a perspective view of an alternative embodiment portable compressor assembly.
Fig. 33A, 33B and 33C are perspective views of cut-away and partially peeled-away sections of three embodiments of hoses suitable for use in portable tool systems capable of powering pneumatic and electric tools.
FIGS. 34A and 34B are perspective views of mateable male and female connectors, respectively, for use in a portable tool system.
FIG. 35 is a side partial cross-sectional view of male and female connectors used in the portable tool system when mated together.
FIG. 35A is a close-up side view illustrating the installation of a ball bearing in a female connector that may be used in the portable tool system.
FIG. 36 is a side view of a socket body for a female connector used in the portable tool system.
Fig. 37 is a schematic diagram of a portable tool system capable of powering both pneumatic and electric tools.
Like reference symbols in the various drawings indicate corresponding parts.
Detailed Description
Figure 1 shows the openable side of a first embodiment of a portable reciprocating compressor 10 of the present invention having a housing 12 including a removable cover 14, the removable cover 14 being secured in a sealed manner to the end of an annular cylindrical outer wall 16. Fig. 2 shows the driving side of the compressor 10 of the first embodiment opposite to the openable side. Here, the circular cover 18 encloses the interior of the compressor housing 12 by: which concentrically rests on the shoulder defined by the annular cylindrical outer wall 16, within the space surrounded by the annular cylindrical outer wall 16, and mates with the inner surface of the annular cylindrical outer wall 16 and is flush with the end face 20 of the outer wall 16. The drive end 22 of the crank shaft 24 extends axially from the interior of the cylindrical housing 12 through the second cover 18 for connection to a suitable drive source, such as a portable electric motor 26 as shown in fig. 3. As seen in fig. 4 and as may be gleaned from a cylindrical housing, the reciprocating compressor of the first embodiment is of the "radial type" having a plurality of gas compressors 28, said gas compressors 28 being spaced around the crankshaft rod 24, and each gas compressor 28 extending in a radial direction with respect to the central axis of the housing 12 about which the annular outer wall 16 extends. At least in part, based on the fact that: the housing 10 not only serves to support the gas compressor 28, but also to define a receiving chamber for receiving gas compressed by the gas compressor, thus providing portability of the compressor 10. The housing may be considered a manifold when forming the receiving chamber, as it collects the compressed air from each gas compressor in its hollow interior for discharge via a single outlet during use of the portable compressor.
The housing 12 has an inner annular cylindrical wall portion 30, the wall portion 30 being concentrically disposed within the outer wall 16. The annular space between the two walls forms a receiving chamber in which the gas compressor 28 is arranged and extends radially between the two annular walls. In the first embodiment, the plurality of gas compressors includes six compressors arranged in diametrically opposed pairs and evenly spaced about the central axis of the housing 12. The space within the inner wall 30 defines a crankshaft chamber for housing components of the drive system of the compressor. The inner wall 30 has circular perforations 32 each of which receives a drive end 34 of a cylinder liner 36 of a respective gas compressor 28. A valve end 38 of the cylinder liner 36 opposite the drive end 34 is received within a bore 40 in the outer wall 16, the bore 40 being axially aligned with the corresponding bore 32 in the inner wall 30.
Fig. 5 shows one of the gas compressors 28 in an exploded state. As with conventional reciprocating compressors, each gas compressor 28 has a piston 42 disposed within the bore liner 36 and sealed within the bore liner 36 for movement along the bore liner 36 to compress the gas contained therein. The connecting link 44 has a piston end 46 with a bore provided therein, the bore cooperating with a pin extending diametrically through the piston 42 to provide a pivotal connection between the piston and the connecting link 44 for pivotal movement in a plane parallel to the housing covers 14, 18. Connecting rods and pistons of this type are well known to those skilled in the art. The drive end of the connecting rod 44 opposite the piston end 46 is adapted for pivotal action in the same plane and is connected to a crank shaft in a manner described further below. The cylinder head 48 is adapted to be mounted to a flat portion 50 of the outer surface of the outer annular cylindrical wall 16 by means of fasteners 49. The cylinder head 48 serves to retain the cylinder liner 36 in position within the opening 40 of the outer wall 16 by blocking the outward radial movement of the cylinder liner 36 from within the opening 40 of the outer wall 16. The cylinder head 48 also provides an intake valve for controlling the feed of air from outside the housing 12 into the cylinder liner 36 for compression by the piston 42. The structure and operation of such a valve is further described below.
An O-ring (not shown) is disposed radially between the opening in the housing wall and the corresponding end of the bore liner 36 to provide a seal to ensure that gas contained in the receiving chamber defined between the housing walls 16, 30 will not leak into the crankshaft rod chamber within the inner wall 30 or into the external environment surrounding the housing 12. Such O-rings are commercially available and are well known to those skilled in the art.
Fig. 5 and 9 show the main connecting rod 52 having a main body portion 54 from which a unitary rod or shaft portion 57 extends radially from the main body portion 54 to the piston end 46 having the same configuration as the piston end of the connecting rod 44 for connection to a corresponding piston. The main body portion 54 of the main connection link 52 provides an attachment point for further connection links 44, so that the connection of the main connection link 52 with the crank shaft 24 will thereby connect all connection links 44 to the crank shaft for actuating the piston 42. The driving end 56 of each connecting link 44 acts as a key to be received in a corresponding keyway in the body 54. The key and keyway are provided with smooth rounded surfaces to allow the connecting rod 44 to pivot relative to the axis of the keyway. As shown in fig. 9, the body portion 54 is provided with five keyways in the form of cylindrical bores 58 that overlap the outer periphery 60 of the cylindrical body portion 54. In this way, a set of arcuate recesses is created in the peripheral wall of the body portion 54, each recess extending over 180 degrees so that the linear distance between the ends 62 of the recesses is less than the diameter of the hole. The drive end 56 of each connection link is cylindrical and rounded and can be raised or lowered into the respective recess and fitted to be able to pivot therein, but the drive end 56 is large enough not to be pulled out of the recess or keyway through the mouth defined by the opening between the ends 62. The key slots extend parallel to a central axis of the body 54 along which a central bore 63 extends through the body 54 perpendicular to the parallel top and bottom surfaces of the body. With the rounded end 56 of each connecting rod received in the rounded keyway 58 (which is open between its ends 62), the connecting rod can pivot about its rounded end 56 in a plane perpendicular to the central axis of the body 54 and central bore 63, this pivoting being limited in either direction by the shank of the connecting rod between its ends contacting a respective one of the ends 62. By having the opening between the ends 62 smaller than the diameter of the arcuate recesses 58 and the connecting rod ends 56, the connecting rod is prevented from being withdrawn from the recess or keyway along the plane in which the connecting rod 44 pivots. The connecting rod is only allowed to withdraw from the keyway by linear movement parallel to the central axis of the body 54.
This primary connecting link 52 provides the necessary pivotal connection to each connecting link 44 in a relatively small space and without the use of small pins (e.g., similar to those used in the devices used to connect the links to the pistons) that may not provide sufficient strength at the mounting point to avoid breakage of the connecting links and separation thereof. The connection point of each connection bar is accommodated between sections of solid material of significant width or thickness to minimize the chance of failure. The construction of this main connecting rod provides simplicity by avoiding the use of pins, bushings and/or bearings for connecting to the connecting rod, while being strong and yet compact. The mating surfaces between the connection link 44 and the main connection link 52 should be smooth and hard to prevent vibration and wear. Known material processing methods, such as hardening and hammering, may be used to achieve the appropriate characteristics at these connections. It is contemplated that a similar connection structure to that between the main connection link 52 and the connection link 44 may be employed at the connection between the connection link 44 and the piston 42: an arcuate keyway extending across the piston is formed by overlapping the cylindrical bore with the face of the piston closest to the main connecting rod into which the cylindrical piston end 46 of the connecting rod can be slid prior to installation of the piston in the sleeve.
The main connecting rod 52 is journalled on a crank pin 64, which crank pin 64 extends through a central bore 63 therethrough on either side of the main connecting rod 52 for rigid connection to a respective crank arm 66, extending from the crank arm 66 to a respective crank axle journal head 67. The crank arm 66 has a receiving hole 68 for receiving the end of the crank pin 64 extending beyond the main connecting rod 52. Relative rotation between the crank arm 66 and the crank pin 64 may be prevented, for example, by a set screw 70 as shown in fig. 6, or by forming the mating crank pin 64 and receiving hole 68 to have the same straight flat side shape and size as shown in fig. 5. The crankshaft 24 is thus formed from: a crank shaft neck head 67 defining an axis of rotation and extending through each cover of the compressor housing 12 out of the compressor housing 12, a crank pin 64 offset or eccentric to the crank shaft neck head 67 and the axis of rotation, and two crank arms 66 connecting opposite ends of the crank pin 64 to the crank shaft neck head 67.
As shown in fig. 3, the crankshaft 24 is rotatable by means of the motor 26 operatively connected to the drive end 22 of the crankshaft 24 extending away from the compressor housing 12, and rotation of the crankshaft 24 causes the main connecting rod 52 to rotate about its rotational axis as the main connecting rod is connected to the crank pin 64. Movement of the main connecting rod 52 along a circular path within the crankshaft chamber translates the rotational motion of the crankshaft 24 into linear displacement of the piston 42 within the cylinder casing 26 by action of the connecting rod 44. As the primary connection link 52 approaches the particular gas compressor 28 during its rotation about the crankshaft axis of rotation, the piston 42 of that gas compressor 28 moves radially outward to a maximum displacement toward the outer wall 16 of the housing 12. As the primary connection link 52 continues to move and thus eventually passes through the gas compressor 28, the piston is pulled back radially inward toward the inner wall 30 of the housing 12. These outward and inward displacements of the piston 42 correspond to the compression stroke and the intake stroke of the compressor, respectively.
As mentioned above, the casing 12 defines internally between the outer walls 30, 16 a receiving chamber, promoting the compactness and portability of the compressor by having the function of both the casing, a support or base for carrying the cylinders, and a manifold for collecting the compressed gas of all the cylinders in a single closed space. The gas compressor 28 has a unique discharge valve to take advantage of this configuration. In conventional compressors, the gas compressors are supported on their own frame or housing, and the compressed gas from the cylinders of the gas compressors is directed to a receiving tank outside the housing through an exhaust valve in each cylinder head, and a manifold connecting the exhaust valve and the receiving tank outside the housing. In the first embodiment of the invention, the external canister is omitted and the compressed gas from the cylinder liners 36 is discharged directly to the receiving chamber of the housing 12 through this unique exhaust valve arrangement.
Rather than venting the compressed gas through an exhaust valve in the cylinder head 48 in a conventional manner, which then must be redirected back into the housing 12 to a receiving chamber having another manifold or separate plumbing of a particular type for the multiple cylinders, the exhaust valve of the first embodiment is disposed on the cylinder liner 36 within the receiving chamber. FIG. 7 shows a close-up view of the cylinder liner 36 near its valve end 38. The cylinder liner 36 has a constant outer diameter cylindrical portion 72 that flares outwardly to a larger diameter end portion 74 toward each valve and drive end 38, 34 of the cylinder block. The end portion 74 closest to the valve end 38 houses a unique vent valve. A plurality of exhaust ports 76 of the exhaust valve, which extend radially through the wall of the bore liner 36 in the end portion 74, are circumferentially spaced about the end portion 74. A belt 78 of Liquid Silicone Rubber (LSR) is circumferentially disposed around the end portion 74 to cover the exhaust port 76. The LSR band 78 has a predetermined density, elasticity, and dimensions such that the LSR band 78 may stretch to fit snugly against the bore liners 36 to seal the exhaust ports 76 when the compressor 10 is not in operation and during an intake stroke of the gas compressor 28. When the LSR band 78 experiences a relatively high pressure from inside the bore liner 36 through the exhaust ports 76 during a compression stroke of the gas compressor 28, the LSR band 78 may extend radially outward from the bore liner 36 so as to no longer cover the exhaust ports 76 and allow the compressed gas within the bore liner 36 to exit into the receiving chamber of the housing. As the pressure inside the liner 36 drops due to the compressed gas entering the receiving chamber, the LSR band 78 then returns to its original position covering the exhaust port 76. The exhaust port 76 and the LSR band 78 thus cooperate to form an exhaust valve that operates by means of the pressure difference between the interior of the liner and the receiving chamber: during the compression stroke, the LSR band 78 expands around the liner to an open position; while at all other times the LSR band 78 resiliently returns to the closed position to provide a seal between the interior of the liner and the receiving chamber. It has been found that the characteristics of LSRs enable them to be used conveniently, to be durable and at the same time to withstand the heat normally associated with compression, while in such applications. However, it should be understood that other resilient materials having similar properties and characteristics may be used to form the LSR band 78 of the vent valve.
An advantage of an extendable, flexible strip over conventional metal reed valves is that the strip does not retain heat in the same way due to the significantly different material properties. These unique valves thus improve the efficiency of the compressor, since less energy used to open the valves is effectively dissipated through the generation of waste heat. In other words, more energy applied to the valve actually contributes to its physical movement than conventional reed valve configurations, so that less energy from the compressed air is wasted, i.e., less heat is generated, when using the unique compressor valve of the present invention than when using conventional reed valves with the same cracking pressure.
The elastic, extensible, flexible band also has other advantages over conventional reed valves: they do not corrode when exposed to moisture and do not experience bending fatigue that could cause the reed valve to fail and fail to properly seat on the opening of the exhaust port or to disconnect the reed. Thus, the use of LSR or similar materials may improve the service life of the compressor and reduce the need or frequency of maintenance, repairs and overhaul. This unique compressor valve structure not only reduces the waste heat generated, but the liquid silicone rubber also has a relatively high thermal stability, which means that its material properties are relatively stable throughout the temperature range experienced during typical use and storage of the compressor.
In the first embodiment, two precautions are taken to ensure that the exhaust valve band 78 does not displace axially along the cylinder liner 36 during the compression stroke as it stretches around the liner to open the exhaust port 76. First, the exterior surface of the wall of the cylinder liner 36 has a recess 80 that extends circumferentially around the end portion 74 closest to the valve end 38, and effectively creates a flange 82 on both sides of the recess 80. The exhaust ports 76 extending through the wall of the cylinder liner 36 are spaced along this recess, and the exhaust valve band 78 is thus positioned in the recess to cover the exhaust ports 76. The flange 82 serves to retain the vent valve band 78 in the recess 80, while the depth of the recess 80 is such that the vent valve band does not completely withdraw from the recess during the rising pressure experienced by the piston during its compression stroke. Second, the opening 40 in the outer wall 16 of the housing 12 (with the valve end 38 and the corresponding end portion 74 of the cylinder liner 36 received in the opening 40) is sized to have a diameter slightly larger than the end portion 74 to create an annular space between the cylinder liner 36 and the outer wall 16. The exhaust valve band 78 may expand into this annular space during the compression stroke, but this expansion is limited by contact with the outer wall 16 at the periphery of the opening 40. This prevents the exhaust valve band 78 from expanding too far to slide over the flange 82 of the end portion 74 and risk displacing it along the cylinder liner 36 from its axial position covering the valve ports.
In the first embodiment, the same unique valve structure is used to form the intake valve in the cylinder head 48. As shown in fig. 8A to 8C, the cylinder head 48 has a cover portion 84 in the form of a flat plate, the cover portion 84 being intended to be mounted flush against the corresponding flat portion 50 of the outer surface of the outer housing wall 16. Fastener holes 86 are provided in the corners of the cover portion 84 for receiving fasteners 49 that are threadably engaged with the outer wall 16. Inlet 88 is recessed into cover portion 84 from an exterior face 90 of cover portion 84 and then continues through an interior face 92 of the cover portion to form a cylindrical portion 94, which cylindrical portion 94 protrudes into the bore liner when cylinder head 48 is mounted on the compressor housing 12. The outside of the inlet port 88 (i.e. the side which can be viewed from the outside of the compressor housing when the cylinder head is mounted on the compressor housing) is shaped like the air intake of a jet engine, with a curved outer edge 88A and an inlet conical or conical center portion 88B, the outer edge 88A forming a trumpet-like flare expanding in the direction outwards from the housing 12, like a flare with velocity summation, and the inlet conical or conical center portion 88B being surrounded by, concentric with, and tapering in the direction outwards from the housing 12 towards its end. The inlet of this profile serves to accelerate the air flowing therethrough to increase the volume of air fed into the cylinder. These surfaces of the inlet are polished to provide an extremely smooth surface finish. A cylindrical portion 94 extending perpendicularly from the inner face 92 of the cover portion 84 has gas inlets 96, the gas inlets 96 extending radially through the wall of the cylindrical portion 94 and being spaced circumferentially around the wall thereof; these intake ports 96 create a passage between the inlet port 88 and the interior of the cylinder liner 36 when the cylinder head 48 is installed. At the end of the cylindrical portion 94 opposite the cover portion 84, a flange 98 extends radially outwardly along the circumference of the cylindrical portion 94, creating a recess 100 between the flange 98 and the inner face 92 for restraining the further elastic band 78. The elastomeric band 78 functions similarly to the band of the exhaust valve, except that the elastomeric band 78 functions to allow uncompressed gases to enter the cylinder liner 36 for compression therein by the piston 42.
During the intake stroke, the piston 42 is retracted radially inwardly toward the inner wall 30 of the housing 12 (and also toward the fully retracted position nearest the crankshaft chamber and drive system components disposed therein) by the respective connecting rod 44, and the pressure within the cylinder liner 36 is reduced. Since the pressure outside of the housing 12 exceeds this reduced pressure within the cylinder liner 36, the pressure outside of the housing 12 causes the elastic band 78 around the cylindrical portion 94 of the cylinder head 48 to expand, thereby uncovering the intake ports 96 and allowing gas to flow from outside the compressor housing 12 into the cylinder liner 36 for compression by the piston 42 during the compression stroke. As gas enters the cylinder liner 36, the pressure differential between the ambient environment and the interior of the cylinder liner is reduced, causing the elastomeric band 78 to resiliently return from its expanded, open position to its closed position sealing the gas inlet ports 96. During the compression stroke, as the piston moves toward the fully extended position furthest from the crankshaft chamber, the progressively increasing pressure within the cylinder liner 36 not only acts to stretch the elastomeric band of the exhaust valve to open the exhaust port, but also to maintain the elastomeric band of the intake valve sealed against the intake port. In other words, the increased pressure within the cylinder liner of each gas compressor promotes expansion of the discharge band, but interferes with expansion of the intake band. Likewise, the characteristics of the elastic band may be carefully selected to provide the desired function at the desired pressure level of the compressor.
As shown in fig. 4 and 5, a gas passage 102 is provided, the gas passage 102 extending from within the receiving chamber between the inner and outer walls 30, 16 of the housing 12 through the circular cover 18 for communication with components supported on the exterior of the housing. As can be seen in fig. 2, these components may include male and female connection fittings 104, 105 for connecting a discharge line or air delivery hose having male or female connectors thereon, a pressure gauge 106 for monitoring the pressure within the receiving chamber or manifold, and a pressure relief valve 108 for manually venting the receiving chamber of compressed air. It should be understood that the compressor of the present invention may be equipped with other components for use with conventional compressors. For example, a pressure switch may be mounted and connected between the battery and the motor in a known manner to activate and deactivate the motor in response to the pressure measured within the receiving chamber or manifold: activated when additional compressed air is required and deactivated when the pressure reaches a certain value. The pressure switch may be adjustable to allow adjustment of this value to control the pressure of the discharge air for a particular application. The removable circular covers 14, 18 may have cooling fins 110 to help dissipate heat generated during compression. Fig. 3 shows the compressor coupled to the DC motor 26 at the drive end 22 of the crank shaft 24, the DC motor being powered by a schematically shown battery module 112, which battery module 112 may be rechargeable. In the first embodiment, the motor 26 is tilted at about 30 degrees to reduce the height at which the motor extends from the circular cover 18, thus requiring a transmission 114 to transfer power from the motor to the crank shaft. It should be understood that the motor may be mounted in alternative orientations. In a first embodiment, a crank shaft extends outwardly from the housing through each cover so that a drive source may be connected to one end and a second compressor may be coupled to the other end so that two or more compressors may be operated by one drive source. It should be appreciated that the compressor may still operate with only one end of the crank shaft extending outwardly from the housing to couple with the drive source.
The crank shaft 24, driven by the motor 26, drives the primary connecting rod 52 about its rotational axis by action of the crank pin 64. This rotational action is converted to linear displacement of the piston 42 within the cylinder liner 36 by the action of the connecting rod 44 (including the rod portion extending from the main connecting rod, or the main connecting rod). As a result, the plurality of gas compressors 28 will begin their respective compression strokes in a sequential manner about the axis of rotation and then sequentially discharge the compressed gas into the receiving chamber, effectively providing a nearly continuous supply of compressed gas discharged from the compressor 10. In the same sequential manner, the intake stroke of the gas compressor 28 will begin sequentially in a sequential manner around the compressor, effectively providing a near continuous intake of gas from outside the compressor housing to prevent the receiving chamber from being evacuated. The compressor of the first embodiment is of the "single-stage" type, i.e.: the air compressed within each bore liner is discharged directly to the receiving chamber rather than to an additional bore liner for further compression.
With six radially arranged gas compressors spaced about the drive shaft rod axis, when the piston of one gas compressor reaches the fully extended position to complete its compression stroke, the diametrically opposed piston of the gas compressor reaches the fully retracted position to complete the intake stroke. At this point, two of the remaining four gas compressors are in their compression stroke with their pistons moving toward their fully extended position, while the other two gas compressors are in their intake stroke with their pistons moving toward their fully retracted position. The uniform spacing of the gas compressors about the drive shaft axis ensures that the time between completion of one compression stroke and the next is consistent with a fixed rotational speed of the drive shaft.
As can be seen in fig. 4 to 6, each crank arm 66 extends through the crank shaft neck 67 to form an integral, semi-circular convex shaped counterweight 116 disposed diametrically opposite the main connecting rod 52 about the crank shaft axis of rotation. The counterweight helps to minimize vibration of the compressor 10 during operation caused by eccentric rotation and reciprocation. The weight may have a closable container 118 provided thereon, the container 118 being used to store weight-increasing material, whereby the overall weight of the weight is adjusted by adding or removing such material to provide dynamic balancing. Access to such containers is provided by means of a removable lid 14.
The compressor is not lubricated by oil, but comprisesTeflonTMOr other suitable low friction material, ring 120 extends around the outer periphery of each piston 42 to reduce friction between the cylinder liners 36 and the pistons. Piston rings are used in a conventional manner to provide a seal between the piston and the cylinder liner to prevent air from the gas compressor from leaking into the crankshaft rod chamber.
A practical prototype of the first embodiment has been manufactured and coupled with a custom 1: 1 drive line and housing to a 28 volt cordless hand round saw (kill-saw) motor powered by a 28 volt lithium ion battery. The components that were joined together weighed 12 pounds or less depending on the material used, and the prototype compressor had a diameter of 7 inches and a thickness of 2.5 inches. Together with the attached motor, the overall size of the prototype compressor can fit within a 4 x 7 x 14 inch space. The 28 volt DC motor of the prototype produced 465 inch pounds of torque at 4200rpm, and the six pistons were 1 inch in diameter with a stroke of 1-1/4 inches. The first embodiment prototype compressor was designed to have a flow rate of 7 cubic feet per minute at 70PSIG discharge. Another configuration is to locate the motor directly on top of the compressor, creating a direct drive, rather than an angled line transmission.
The compressor of the first embodiment can be used as part of a compact system that can be easily carried by a user to power any number of pneumatic tools without any movement restrictions caused by power lines or air hoses. Such a system may include:
backpack, which is a lightweight load-bearing enclosure, is adapted to be worn on the back of an operator. The backpack may have an adjustable strap with padding, a handle for carrying, a pouch for the fitment, clasps and loops for carrying and attaching tools, and an air inlet and cooling air outlet.
The chassis, which is a lightweight mounting mechanism, on which the compressor motor and the instruments are mounted, and the entire chassis is placed in the backpack.
Compressor housing-which is an integral unit containing a crank housing (crank shaft chamber), a crank shaft, connecting rods, a piston, cylinder liners, cylinder heads, and an exhaust head cover (circular cover having at least one passage or valve port therethrough, each equipped with a connecting fitting) for exhausting air. The compressor is a single stage air cooled radial design having opposed cylinders in a balanced opposed configuration. The two compressor frames may be bolted together back-to-back and driven via flexible couplings to accommodate applications requiring increased air volumes.
Motor-the DC drive motor directly drives the compressor or indirectly through a gearbox and is mounted on the undercarriage by means of a vibration isolator.
Battery module-DC batteries are placed in an adapter mounted on the chassis. The battery is removable for external charging.
Pressure switch-air/electric pressure switch, which is installed on the chassis to control the pressure of the discharged air according to the application and is adjustable.
A power switch, which is an electrical switch, is located on the exterior of the backpack to isolate the battery from the motor and accidental operation. When the power switch is on, the pressure switch will activate the motor as needed to maintain the discharged air pressure.
A pressure relief valve, which is a manual valve, is located on the outside of the backpack to relieve the compressor for maintenance or travel.
The pressure gauge, which is a pressure indicator, is installed on the discharge head cover of the compressor to indicate the actual working pressure and to calibrate the pressure switch.
Quick disconnect device-it is a standard pneumatic tool quick disconnect device that is mounted on the outside of the backpack for connection to the air tool hose.
The efficiency of the first embodiment compressor enables a sufficient amount of compressed air to be rapidly produced, thereby eliminating the need for a separate large-capacity container (tank). Sufficient compressed air can be made on demand to operate most typical hand-held air-actuated tools. Since the compressor has sufficient efficiency, it is possible to drive the compressor with a battery-driven motor and obtain the same output as can be expected from a compressor with electric wires. In this case, it is also possible to combine the battery, motor and compressor together, placing them together in a wearable bag, so that the individual can move freely, while having a sufficient compressed air to operate any air tool that can normally only be driven by a stationary compressor via a long hose.
Fig. 10 to 12 show a second embodiment portable compressor 200 which is similar to the first embodiment portable compressor in that it has six radially arranged cylinder jackets 36 and a similar drive system with a motor 26 driving the rotation of the main connecting rod 52 by means of a crank for effecting successive compression strokes of the piston 42 within said cylinder jackets to discharge compressed gas into a common receiver. However, the second embodiment compressor 200 is different from the first embodiment compressor in many respects.
As shown in fig. 10 and 11, the compressor 200 of the second embodiment does not have a single type of housing but includes two separate housings. The receiver housing 202 defines a manifold into which compressed gas is discharged from the cylinder liners 36, and is formed by a bottom half 203 and a top half 204 that mate together with the cylinder liners 36 disposed therebetween. With its two halves mated together, the receiver housing 202 is annular in shape to define a central opening 206. The crank housing 208 is positioned within the central opening 206 of the receiver housing 202 and likewise has an annular shape defining a central opening within which the main body of the main connection link 52 and the crank pin are disposed. The cylinder liners 36 are received in openings 210 extending radially through the crank housing 208 from a central opening of the annular crank housing 208 toward the surrounding receiver housing 202. The cylinder liners 36 are sealed to the crank housing 208 at these openings and project radially outward from the crank housing 208 into the surrounding receiver housing 202.
Unlike those of the first embodiment, the cylinder liners 36 of the second embodiment compressor 200 do not flare outwardly to an increased diameter at opposite ends of the cylindrical portion 72. Instead, each cylinder liner 36 has a threaded portion 212 extending from its driving end 34 closest to the central opening of the crank housing 208 to mate in a sealing manner with corresponding threads provided on a corresponding opening 210 through the crank housing 208. As shown in fig. 18 and 19, the cylinder liner 36 also does not flare outwardly toward the valve end 38 opposite the actuation end 34, but rather has a recess 80 in its outer surface and a pair of flanges 82 disposed on opposite sides of the recess 80. The one of the flanges 82 that is farthest from the drive end 34 of the liner defines the valve end 38 thereof, which valve end 38 is closed in the second embodiment compressor. A plurality of exhaust ports 76, spaced about the central longitudinal axis of the cylinder block, extend radially through the liner 36 at recesses 80 defined between the flanges 82 to communicate the hollow interior or cylindrical bore of the liner with the exterior of the liner. An elastic band 78 of flexible material is stretched around the cylinder liner 36 within a circumferential recess 80 to define the exhaust valve in cooperation with the exhaust port 76 in the same manner as the first embodiment.
In the second embodiment compressor 200, the recess 80 of the exhaust valve has a tapered V-like shape that narrows inwardly from the radially outermost portion of the flange 82 toward the hollow interior of the bore casing 36, as best shown in fig. 19. As shown in fig. 20A, the flexible elastic band 78 also changes from a maximum width at its outermost surface 78a to a minimum width at its innermost surface 78 b. The grooves 80 and the resilient flexible strip 78 taper at the same angle to fit and seal tightly in an optimal condition when the flexible strip is extended radially outwardly without the influence of the force of compressed air acting on it from the interior of the bore liner 36 through the exhaust port 76.
Fig. 10 shows a second embodiment compressor 200 with the top half 204 of the receiver housing 202 removed to show the mating side or face 214 of the receiver housing bottom half 203 (shown separately in fig. 13). A set of fastener holes 216 extend into the bottom half 203 from the mating face 214 and are spaced around the bottom half near its periphery 218. Spaced radially inward from the outer periphery 218 and adjacent to the fastener hole 216, an outer seal groove 220 is formed that extends completely around the central opening 206 of the receiver housing 202, and an O-ring like seal is disposed in this outer seal groove 220 to seal against the mating face of the top half 204 when the two halves of the receiver housing are mated together.
A point radially inward from the outer seal groove 220 is a groove 222 recessed into the receiver housing bottom half 203 from the mating face of the receiver housing bottom half 203, the groove 222 also extending completely around the central opening 206. Unlike the circular central opening 206 around which the groove 222 extends, the groove 222 has a longitudinal path extending around the central opening 206, and the outer edge 222a of the groove forms the outline of a hexagonal shape defining the rounded corners 222b of the groove and six straight sections 222c, each of which extends perpendicular to the longitudinal axis of a respective one of the cylinder liners. A concave portion 224 of the groove 222 is formed at a midpoint of the six straight sections 223; the recessed portion 224 is recessed further down into the bottom half 203 from the mating face 214 of the bottom half 203 than the rest of the groove 222. The groove 222 is of sufficient width at each recessed portion 224 to accommodate between the two sides of the two flanges 82 at the valve end 38 of each cylinder jacket 36 that form the valve seat groove 80 that receives the exhaust valve elastomeric band. The width of the groove 222 between the recesses 224 is small so that the flange 82 will only be properly positioned within the recesses 224. Each recessed portion 224 of the groove 222 is arcuate in a vertical plane along the longitudinal path of the groove around the central opening 206, forming a circular cradle or seat in which the flange 82 of the liner 36 projecting radially outward from the liner cylindrical portion 72 may rest. An inner portion 226 of the bottom half mating face 214 radially inward of the recess 222 at each recessed portion 224 thereof is similarly recessed in an arcuate manner in a vertical plane, but at a smaller diameter, to receive or cradle the cylindrical portion 72 of the respective cylinder liner 36 projecting from its flanged valve end 38 into the central opening 206 of the receiver housing 202. One such seat or bracket for supporting the cylindrical portion of a respective cylinder liner is shown at 227 in FIG. 13.
Radially inward from the groove 222, concentric with the central opening 206, the groove 222, the outer seal groove 220, and the outer periphery 218, is disposed an inner seal groove 228 extending completely around the central opening 206 in an inner portion 226 of the mating face 214. Between the cylinder liners 36, the inner seal groove 228 is configured radially outward relative to its location at the arcuate recess in the inner portion 226 of the mating face 214 (where the groove 228 is located below the cylinder to form a seat or cradle 227). At the more outwardly disposed portions 230 of the inner seal groove 228, a second set of fastener holes 232 are formed spaced around the central opening 206, positioned between the outwardly portions 230 and an inner periphery 234 of the receiver housing bottom half 203, and extending from the inner portion 226 of the mating face 214 into the bottom half.
Fig. 14 shows the top half 204 of the receiver housing 202 separately, prior to assembly with the bottom half 203. The top half 204 of the receptacle has substantially the same structure as the bottom half, except primarily for the seal groove. The top half 204 has a mating face 214 ' divided into inner and outer portions 226 ' and 236 ' by a groove 222 ', the groove 222 ' extending concentrically around the central opening 206 in a generally hexagonal shape with rounded corners. The groove 222 'has an arcuate recess 224' centrally disposed along a straight section of the groove disposed between its rounded corners for alignment with the recess 224 of the bottom half 203. When the two halves of the receiver housing 202 are placed face-to-face with each other, the outer portions 236, 236 ' of the mating faces 214, 214 ' are sealed together by seals disposed in place within the outer seal groove 220, and the inner portions 226, 226 ' between the bore liners 26 are sealed together by seals disposed in place in the inner seal groove 228 at the outwardly disposed portion 230 of the inner seal groove 228. The seals disposed in the internal seal grooves 228 of the bottom half 203 of the receiver housing 202 also serve to seal the bottom half 203 to each cylinder liner 36 by virtue of the engagement of the seals along each bracket or seat 227 with the bottom half of the cylindrical portion 72 of the respective cylinder liner 36.
Because the sealing action between the two halves of the receiver housing, and between the bottom half 203 and the bore liner 36, is at the seal groove of the bottom half 203, the top half 204 need only provide a sealing action between itself and the bore liner 36. Six cylinder seal grooves 238 are provided in the top half 204 of the receiver housing 202, each cylinder seal groove 238 extending along a respective one of the brackets 227 ', with the brackets 227' being formed by vertically disposed arcuate recesses in the inner portion 226 'of the mating face 214'. Each end of each cylinder seal groove 238 extends slightly beyond an edge 240 defined between the arcuate seat or cradle 227 'and the adjacent flat section of the inner portion 226' of the mating face 214 'to ensure that when the halves are assembled with the cylinder liner 36 therebetween, there is no clearance between the receiver housing 202 and the cylinder at the cylinder seats or cradles 217, 217'. A seal is provided in place at each cylinder seal groove 238.
To assemble the second embodiment compressor 200, the cylinder liners 36 are threadably engaged with threaded openings provided in the outer periphery of the crank housing 208, as shown in FIG. 10. The pistons are mounted within the cylinder jackets with respective connecting rods attached thereto, and the slave connecting rods 44 are connected to the master connecting rods 52. The secondary connecting links are those that are not integral with the main body 54 of the primary connecting link, but are pivotally connected thereto as disclosed in the first embodiment compressor, and the stem or shaft 57 integral with the main body 54 is part of the only remaining connecting link. A disc-like cap 242 having an outer diameter approximately equal to the outer diameter of the body 54 of the main connection link 52 is disposed on the top of the body and is held in place by the head of a crank pin 64 extending downwardly through the cap, with the main connection link 52 journaled on the crank pin 64. Below the main connecting rod body 54, a crank pin passing through the body is secured to the crank arm 66 and an integral weight 116, the crank neck 67 of the crank arm 66 in turn being coupled to the drive shaft of the motor 26, which in the second embodiment is a disc-shaped pancake or torque motor fixed to the bottom of the crank housing 208, to minimize the size of the compressor 200.
After the crank housing 208, gas compressor, and drive system are assembled, the crank housing 208 and attached motor 26 are lowered into the central opening 206 such that the cylindrical portion 72 of the cylinder liner 36 is placed into the cradle 227 defined by the arcuate recess in the inner portion 226 of the mating surface 214 and the flange 82 of the cylinder liner 36 is placed into the recessed portion 224 of the groove 222. This partial assembly is best shown in fig. 10, where the top half 204 of the receiver housing has not yet been installed. To complete the assembly, the top half 204 is lowered onto the bottom half 203, and the generally hexagonal shape of the peripheral wall portions 218, 218 'of the two halves 203, 204 allows for easy visibility of their alignment to provide the cylinder brackets 227, 227' of the opposite halves in alignment above and below the cylinder liners 36. The fastener holes 216 ', 232' of the top half 204 of the receiver housing 202 are through holes, while the fastener holes 216, 232 of the bottom half 203 are blind holes with threads. The fastener holes 216 ', 232' of the top half are aligned with the fastener holes 216, 232 of the bottom half so that threaded fasteners 244 may be passed through and into the bottom half 203 and fastened to the bottom half 203 to clamp the two halves of the receiver housing together with the cylinder liner 36 therebetween.
As shown in fig. 11A and 11B, since the two halves 203, 204 of the receiver housing 202 have substantially identical structures, the recesses 222, 222' of the two halves are mirror-symmetrical about the mating faces of the halves, thereby forming a closed channel 246 that extends completely around the central opening 206, in which channel the valve end 38 of each cylinder liner 36 is disposed. The seal disposed in the outer seal groove 220 of the bottom half 203 provides an air tight seal between the outer portions 236, 236 'of the mating faces 214, 214' around the entire passage 246, along the outside of the passage. The seal disposed in the inner seal groove 228 of the bottom half 203 provides a seal between the two halves along the outwardly disposed portion 230 of the inner seal groove between the cylinder liners 36, and provides a seal between the bottom half and each cylinder liner 36 along the arcuate recess forming the cylinder bracket 227 in the inner portion 226 of the mating surface. The seals disposed in the cylinder seal grooves 238 of the top half 204 accomplish the sealing off of the passage 246 by providing an air tight seal between the top half 204 and each cylinder liner 36.
The passages 246 thus form a receiver, or collector, or manifold, which extends around each and all of the cylinder liners 36 and sealingly encloses the cylinder liner valve ends 38, including the exhaust valves on each cylinder block formed by the exhaust ports 76 extending radially through the cylinder liners 36 between the liner flanges 82, and the elastomeric bands 78 extending around the cylinder liners 36 between the flanges 82, as well as the elastomeric bands 78. At three of the rounded corners 222b of the groove 222 in the bottom half 203, gas channels 102 are provided which extend through the bottom half 203 parallel to the axis about which the annular receiver housing 102 extends. The holes defining these passages pass through the exterior face 248 of the bottom half 203 opposite its mating surface 214. As with the compressor of the first embodiment, these passages are threaded to provide a sealed coupling to a connection fitting, pressure gauge, pressure relief valve or pressure switch.
The receiver housing 102 provides a significantly smaller manifold or receiver for collecting compressed air from each cylinder to be discharged via a common outlet, such as a male or female connection fitting coupled to a respective gas passage 102 for connection to an air carrying hose suitable for connection to a pneumatic tool, as compared to the first embodiment compressor. By defining a channel of relatively small cross-section that surrounds the exhaust valve on each cylinder liner, but does not surround too many other portions of the cylinder liner, the volume of space for containing the compressed gas can be reduced. Keeping the volume of the receiver to a minimum is desirable because the "on demand air" situation is more common for the compressor to further operate on the actual demand or need for compressed air, and less common for the purpose of filling the storage tank with compressed air. The six cylinders are arranged spaced in a radial arrangement around the axis of the drive shaft so that the pistons can successively reach their maximum displacement to successively complete their compression strokes around the compressor, which can provide sufficient compressed air to operate conventional pneumatic tools continuously without the need for an external air tank and with minimal fluctuations.
As shown in fig. 15 to 18, the second embodiment compressor 200 has a different air intake configuration from the first embodiment compressor. The second embodiment does not provide the intake valve in the cylinder head sealingly mounted to the end of the cylinder liner, and the intake valve of the second embodiment is formed on the piston 42. Two inlet ports 250 extend axially through the piston 42 on opposite sides of a central bridge 252, the central bridge 252 extending diametrically across a cylindrical annular wall 253 defining the outer periphery of the piston 42. Each inlet port is generally semi-circular in cross-sectional shape with a diameter slightly smaller than the diameter of the piston, thereby occupying a large portion of the cross-section of the piston, while leaving the central span between the two inlet ports intact. A face 254 of the piston opposite its end (the face 254 being defined by the annular wall 253 and the respective end of the central bridge 252) surrounds each inlet 250: from which end the connecting link 44 projects to connect to the main connecting link 52. An O-ring groove 256 in the face 254 of the piston 42 extends around both intake ports 250 to accommodate a conventional O-ring to provide a proper seal for the intake ports 250 when they are closed. A flapper 258 made of a flexible resilient material such as LSR is shaped to define a disk 260, the disk 260 having three cylindrical projections 262 of equal length, the cylindrical projections 262 being spaced apart along a linear strip 263 formed on and extending diametrically across the surface of the disk and projecting perpendicularly therefrom away from the surface of the disk. On opposite sides of the rectilinear strip 263, two thin metal sheet elements 264 are bonded to the surface of the shutter disk 260 on which said strip is formed. Each plate member 264 is shaped similarly to the corresponding portion of the baffle disc 260 with which it is associated such that the arcuate edge of the plate member is substantially flush with the outer periphery of the baffle disc 260. The projecting portions 262 are of sufficient length to project from the rectilinear strips 263 to engage three corresponding blind holes 266 extending from the face 254 of the central bridge 252 of the piston 42 into the central bridge 252 at spaced locations and sizes along the central bridge 252 corresponding to the projecting portions.
The linear strip 263 and the diametrically extending portion of the disc 260 of the flexible baffle 258 along which the strip 263 extends define a fixed portion 268 of the baffle 258 that is restrained in a substantially fixed position relative to the piston face 254 by engagement of the protruding portion 262 with the blind bore 266. The other portions of the disk 260 on each side of this fixed portion define a movable portion 270 of the disk 260, the movable portion 270 extending laterally from the fixed portion, and the movable portion 270 is able to move in a pivoting-like action relative to the fixed portion as the flexible disk 260 bends along the boundary between the fixed portion and the movable portion, i.e., along the edge 272 between the linear strip 263 and the disk face on which the linear strip is formed. With the projecting portion 262 received in the blind hole 266, the movable portion 270 is movable relative to the fixed portion 268 from a closed position, in which the movable portion 270 and the fixed portion 268 are coplanar, to an open position, in other words, the movable portion 270 forms, together with the fixed portion 268, a flat disc 260; and in the open position, each movable portion 270 extends out of the plane of the fixed portion 263 and away from the piston face 254. In the closed position, the plate 264 secured to each movable portion 270 of the disk is flush against the O-ring seal 256a disposed in the O-ring seal groove 256 (along the arcuate portion of the respective generally semi-circular inlet 250) for covering or closing the inlet. In the open position, the plate 264 is at least partially lifted from flush contact with the seal 256a to open or uncover the air inlet to allow air to flow through the air inlet.
As best shown in fig. 15a, the rectilinear strips 263 form a step at each end from a central portion 263a from which said projecting portion 262 extends out to a shorter end portion 263b having a smaller thickness equal to the thickness of each sheet metal element 264. When the flapper is in place for use, this central portion 263a will be positioned flush against the face of the central bridge 252 of the piston over its entire length from the location of the inside perimeter of the annular O-ring seal groove 256 at one end of the central bridge 252 to the diametrically opposite point on the inside perimeter of the O-ring seal groove 256. The difference in thickness between the central portion 263a and the end portion 263b of the band 263 is equal to the distance that the O-ring seal 256a received in the O-ring seal groove 256 protrudes from the piston face 254 in a direction perpendicular to the piston face 254. The end portion 263b of the strip is flush with the face of the O-ring seal 256a that projects slightly beyond the piston face 254 from the O-ring seal groove 256, as is exhibited by the sheet metal piece 264 when the flapper is closed over the intake port. The end of the central portion 263a of the band 263 spans the entire length of the central bridge 252 and abuts the inner periphery of the O-ring seal 256 a. Thus, when the movable portion of the flapper is in the closed position to seal against both intake ports 250, the stepped end of the strip 263 seals the O-ring seal 256a between the two plates from the interior of the annular O-ring seal groove 256 and against the O-ring seal 256a to complete an annular seal around the piston face. In the open position, these stepped ends of the strap 263 continue to remain engaged with the O-ring seal due to the fixed engagement between the integral projecting portion 262 and the piston, but the metal plate 264 will be lifted off the O-ring to allow air to pass through the intake port.
In the illustrated embodiment, the disc 260, the band 263 and the projection 262 are an integral unit that may be molded in place on the piston. For example, two temporarily elongated linear obstructions may be placed on opposite sides of the central bridge 252 along the central bridge 252 of the piston, each obstruction having a height equal to the O-ring seal 256a disposed in the O-ring seal groove 256, thereby forming parallel chords of a circle defined by the O-ring seal. Each sheet metal piece 264 may thus be positioned on top of the barrier and the arcuate portion of the O-ring seal on the corresponding side of the central bridge. After arranging the piston and the plate equipped with O-rings in the mould in this way, the LSR may be poured or injected into the mould, covering the piston and the plate. The LSR entering the area between the obstacles along the central bridge 252 forms a strip 263, and the obstacles prevent the LSR from flowing past the obstacle under the panel and into the air intake. The LSRs that flow further down from the area between the obstacles into the blind holes 266 in the central bridge 525 form protruding portions, each of which is provided with a thread, so that when the LSR is dry, the interference between the periphery of each protruding portion and the thread of the respective blind hole 266 prevents the protruding portion from being drawn straight out, thus fastening the flapper to the piston. In other words, the threads within each hole or blind bore 266 act like barbs that project into the outer periphery of the respective projecting portion 262 of the baffle. By using multiple projections and mating threaded holes, the projections are prevented from being rotatably withdrawn from their respective threaded holes. Once the area between the obstacles is filled, the body of sheet formed on the strip defines the disc 260. Forming separate seal grooves around the two intake ports, rather than a single O-ring seal groove 256 extending around the two intake ports, can increase the ease of molding the flapper onto the piston, as some temporary measures to prevent LSR leakage into the intake ports need not be taken during molding.
Alternatively, the flapper 258 may be formed and mounted on the piston in a two-stage forming process, in which the disc 260 and the band 263 are formed on two metal plates 264 which are held positioned opposite one another in the mold as in their closed position in use (coplanar with their straight sides spaced from one another by a distance corresponding to the band 263 to be formed); the mold, which is shaped so that the LSR flows between the plates, will form the strip 263 and the LSR flowing onto the face of the plate will form a disc that is integral with the strip at the top. The die has three projections that are spaced along the portion of the die that forms the strip to create three perforations that are spaced along the strip and pass through the strip and the disk that is integral with the strip. The disc and the strap are formed in the sheet metal piece in such a way that the second stage involves fixing these components in place on the piston so that the three holes in the disc and the strap configuration can be aligned with the blind hole 266 in the central portion 252 of the piston and the sheet metal piece 264 set flush with the O-ring seal already installed on the piston. The LSR is then poured or injected into the blind hole 266 in the piston via the strip and corresponding hole in the disc formed during the first stage, the LSR dries to form the same connection as the piston described above and is also bonded to the previously formed LSR disc and strip.
Rather than using the extensions 262 to secure the flapper to the piston, threaded fasteners may be engaged with threaded holes in the piston through the disc 260. A metal strip material may be applied to the side of the disc opposite the piston to pass the fastener through the metal strip and flexible flapper to better distribute the pressure applied by the fastener head to the disc along the stationary portion to hold the disc stationary.
By virtue of the intake valve formed on the piston 42, air is not drawn into the cylinder liner 36 through the cylinder head disposed on the outer periphery of the compressor as in the first embodiment, but is instead drawn into the cylinder liner 36 through the hollow space surrounded by the annular crank housing 208. Because the hollow space or crank chamber at the center of the annular crank housing 208 is closed at the bottom by the motor 26, the top end of this space must be at least partially open to allow intake air to enter the cylinder liners 36 through the openings 210 in the annular crank housing wall. Thus, the cover 274, which is engageable to the crank housing 208 proximate the top surface 276 of the crank housing 208, has an opening 278 therethrough to allow air to flow into the hollow space or crank chamber defined by the annular crank housing 208 containing the drive system components. The lid is in the shape of a circular disc and has four lugs 280, such lugs 280 projecting radially outwardly from the disc at evenly spaced points around the disc. Four corresponding notches 282 extend radially into the inner periphery of the crank housing 208, each having a respective slot extending from one side thereof below the top surface 276 and parallel to the top surface 276, such that when the cover is lowered slightly into the crank chamber to rest the tab 280 within the open notch 282 at the top surface 276, the cover 274 can be rotated about its axis to slide and snap the tab 280 into the slots. This prevents cap 274 from being pulled straight upward from crank housing 208 without the need to manually unlock the rotation of the cap so that tab 280 can return to notch 282, which is open at top surface 276 of crank housing 208.
The pressure of the air outside the compressor 200 will eventually exceed the pressure in the cylinder liner 36 between the piston 42 and the valve end 38 of the cylinder liner as the pressure decreases during the intake stroke of the piston 42 back toward the crank housing 208. Because the intake port 50 is in fluid communication with the outside air surrounding the compressor 200 via the cylinder liner 36, the port 210, the crank chamber, and the crank chamber inlet defined by the port 278 in the cover 274, this increase in pressure forces the movable portion 270 of the flexible flap and the sheet metal member 264 coupled thereto into an open position, thereby uncovering the intake port 250 and allowing air to flow into the cylinder liner 36 between the valve end 38 of the cylinder liner 36 and the piston 42 for later compression by the piston 42 during a compression stroke. As air enters the end of the liner 36 through the air inlet 250, the pressure differential between the ambient environment and the interior of the liner is reduced, causing the movable portion 270 of the resilient flap to resiliently return from the flexed open position to a closed position coplanar with the fixed portion 268 to block the air inlet 50.
The relatively large total cross-sectional area of the air intake 50 of the second embodiment compressor increases the volume of air drawn in compared to the first embodiment. When the pressure is relatively low when a typical pneumatic tool is in use, the large air intake and LSR baffle allow a large volume of compressed air to be generated relatively quickly by multiple cylinders, with relatively little heat retained, thereby generating sufficient pressure to rapidly and repeatedly power the pneumatic tool. It is also contemplated that these unique valves can overcome the limitations of the size of the inlet port of conventional reed valves relative to the compression effect that can be achieved, and thus can have the potential to be used in higher pressure applications. The use of a flexible resilient flap having a movable portion extending from a fixed portion to carry a separate sheet metal piece attached to the flap for covering a corresponding intake port reduces the likelihood of premature failure as compared to metal or fiberglass reed valves that may be fatigued and unable to properly position or snap off, because all flexing or bending is done by LSR or other suitable flexible material rather than by the sheet metal piece. The sheet metal pieces, because they are significantly more rigid than the flexible flapper, each provide a consistently flat surface for sealing with the O-ring and limit the flexing or bending of the flapper to the boundary between the stationary and movable portions, allowing only a pivoting-like action about that boundary. As with the flexible, resilient LSR band of the exhaust valve of the second embodiment and the two sets of valves of the first embodiment, the LSR flapper of the intake valve of the second embodiment reduces wasted energy and is less prone to failure due to stress than conventional reed valves that retain heat.
It will be appreciated that a flap having a fixed portion secured to a surface surrounding a single vent on one side of the fixed portion and only a single corresponding moveable portion will operate in the same manner and that this type of valve is not limited to use specifically as an air inlet valve nor to the type of valve in which the piston is mounted. It should also be understood that flexible materials other than LSR may be used to provide similar advantages, and that the plate may be made of materials other than metal and still provide the greater rigidity needed at the moveable portion of the valve flap. In the second embodiment compressor, as shown in fig. 17, the central bridge 252 bridges the entire inner diameter of the annular piston wall portion 253 from the face 254 only along part of the length of the piston to provide a space within the annular piston wall portion 253 to connect with the connecting rod 44. Seal ring grooves 290 and nesting band grooves 292 are provided in the outer surface of the annular piston wall 253 near the face 254 closest to the valve end 38 of the cylinder liner 36 and near the opposite connecting rod end 294 of the piston, respectively, extending circumferentially around the annular piston wall 253 and spaced along the piston length to support seal rings and nesting bands, such as friction reducing Teflon piston rings.
As with the compressor of the first embodiment, the compressor 200 of the second embodiment may be mounted in a backpack adapted to be carried on the back of a user, along with rechargeable battery modules. It should be understood that the compressor 200 may be adapted to utilize circuitry for the power supply, motor, and pressure switch as is well known to those skilled in the art to releasably mount the battery unit directly thereto. With a compressor including a motor and a battery module provided in such a compact unit, particularly for use with a relatively thin and flat oblate or torque motor, a full size backpack may no longer be required, which would be convenient for the user to carry. For example, the compressor may be equipped with a belt that may be tightened to fit around the waist or legs of the user. The use of a mesh or perforated material, when carried in a bag or some other substantially closed container, will reduce any interruption in the steady supply of intake air to the compressor. The battery module may be connected to the compressor through an opening in such a mesh bag or container to allow easy and quick replacement of the rechargeable battery without first removing the entire assembly from the container it carries.
Fig. 21 to 23 show a third embodiment of a portable compressor 300, as with the first and second embodiments, having a plurality of reciprocating back and forth type gas compressors disposed radially about a central axis perpendicular to a common plane and carried by a receiver or manifold receiving compressed air from the cylinders of each gas compressor to be discharged through a common outlet. The third embodiment compressor differs significantly in its structure with only three cylinders. However, it will be understood by those skilled in the art that the number of cylinders in each embodiment may vary.
The base 302 of the third embodiment compressor 300 supports three gas compressors 28 evenly spaced about the central axis of the base 302 and extending radially. The base 302 is a solid piece of material having two identical, flat, parallel opposing faces 304, 306, and has an outer perimeter defining a base body of fixed thickness perpendicular to the opposing faces 304, 306 that is significantly less than the span of the opposing faces 304, 306. The periphery of the body 302 is contoured such that the appearance of the body is formed by an irregular hexagonal body having three equal length long sides and three equal length short sides alternating along the hexagonal body periphery with each long side being recessed along the opposing faces 304, 306 in the same manner toward the center of the body. Referring to the plan view of fig. 24A, each concave longer side 308 of the body 302 is made up of three straight sections: a longest central section 308a and two shorter end sections 308b at opposite ends of the central section. The central section 308a of each longer side 308 is parallel to a virtual straight line extending between adjacent ends 310a of two shorter sides 310 adjacent to the longer side 308. End sections 308b of the same longer side 308 extend obliquely outward from the central section 308a to connect at right angles to the same end 310a adjacent the shorter side 310.
As shown in fig. 21 and 22, each cylinder liner 36 is mounted to the top surface 304 of the main body 302 and projects outwardly from a respective shorter side 310 of the main body 302 radially away from the center of the main body. In the third embodiment compressor, the bore liners 36 are of the standard conventional type having a hollow cylindrical body, each open at its opposite ends and extending for its entire length about its longitudinal axis. As shown in fig. 23 and 25, the cylinder block mount 312 for each cylinder liner 36 has a right angle bracket structure including a rectangular base portion 314 like a plate member for mounting flush with the top of the top surface 304 of the main body 302, and an annular portion 316 projecting perpendicularly from one end of the base portion 314. A cylindrical protrusion 318 protrudes perpendicularly from the base portion 314 between a predetermined end portion of the base portion, from which the annular portion 316 protrudes, and the other end portion in the direction opposite to the protrusion of the annular portion 316. The protrusions 318 fit into corresponding blind holes 319, the blind holes 319 extending perpendicularly from the body top face 304 into the body 302 at a predetermined distance radially inward from the respective shorter side 310, the distance being such that the base portion 314 of the cylinder mount 312 extends from the protrusions 318 towards the shorter side 310 to support the ring portion 316 thereat. The protrusion 318 is hollow and has a hole 320 extending through the base portion 314 such that the protrusion 318 is open at both ends thereof. On each side of the protrusion 318, a fastener slot hole 322 is formed in the base portion 314, which extends toward the following end of the base portion 314: from which end a ring-shaped portion 316 protrudes away from the opposite end. The slot 322 passes through the base portion 314 to the bottom surface of the base portion 314, but at a depth below the top surface 324 of the base portion 314, the slot 322 narrows and shortens by a continuous flange 325 of fixed width projecting therethrough. In other words, the slot changes from a first set of larger size steps to a second set of smaller sizes when viewed moving from the top surface 324 of the base portion 314 toward the opposite bottom surface. A pair of spaced threaded fastener blind holes 326 on each side of the blind hole 319 extend perpendicularly from the top surface 304 of the slot into the body 302 to align with the respective fastener slots 322 when the protrusion is lowered into the blind hole 319. Two threaded fasteners 328 pass through each slot 322 and threadingly engage in a respective pair of fastener holes 326 to clamp the cylinder mount 312 to the top surface 304 of the body 302 by engagement of the fastener heads with the flanges 235 of the base portion 314 protruding into the slots 322.
The annular portion 316 of the cylinder mount 312 has a circular central opening 330 that extends through the annular portion 316 about an axis perpendicular to the annular portion 316. Similar to the slot 322 in the base portion 314, the central opening 330 of the ring portion 316 is stepped from a larger diameter at an outer face 332 of the ring portion 316 to a smaller diameter at an inner face 334 of the ring portion 316, where the outer face 332 is opposite the inner face 334 and the base portion 314 extends from the inner face 334. This creates an annular flange that projects into the opening 330 when viewed from the outer face side of the cylinder mount 312, against which one of the annular end faces 336 of the cylinder liner 36 abuts when the cylinder liner 36 is pushed into the opening 330 from the outer face side of the cylinder mount 312. The piston 42 is sealingly mounted within a bore or hollow interior of the cylinder liner 36, and the piston end 46 of the connecting rod 44 is connected to the piston to project out of the cylinder liner 36 through the annular portion 316 of the cylinder block mount 12.
A cylinder cap 338 is mounted to the end of the cylinder liner 36 opposite the cylinder block mount 12 to close that end. The cylinder head 338 has three fastener holes 350 extending through the cylinder head parallel to its cylinder receiving opening 352 and evenly spaced about the opening, while three corresponding fastener receiving holes 354 extend through the annular portion 316 of the cylinder mount 312 parallel to the central opening 330 and evenly spaced about the central opening 330. Three fasteners 356 pass through holes 350 in cylinder head 338 and extend into holes 354 in cylinder block mount 312 to engage holes 354 to clamp cylinder liner 336 in place between the cylinder head and the mount. The intake valve 338a and the exhaust valve 338b of the cylinder head 338 are conventional ball check valves known to those skilled in the art that are configured to open and close in response to a pressure differential between the air in the portion of the cylinder liner between the cylinder head and the piston and the ambient air outside of this space, as in conventional air compressors.
As shown in fig. 23, the driven gear 358 has a cylindrical projecting portion 360 projecting vertically upwardly from a top surface 362 thereof for mounting into a bore 364 extending through the driving end 56 of the connection link 44 perpendicular to the length of the connection link 44 to provide a pivotable connection of the connection link 44 with the driven gear 358. A pin 368 projects from below driven gear 358 into a circular central bore 370 of driven gear 358, which pin 368 is also concentrically received in bore 320 through base portion 314 and protrusion 318 of cylinder mount 312 for rotatably mounting driven gear 358 to cylinder mount 312. To accommodate the driven gear 358, the central section of the inner face 334 of the annular portion 316 at the top surface 324 of the base portion 314 has an arcuate recess 372 concentric with the axis of the bore 320.
As shown in fig. 23 and 26, the motor mount 374 of the third embodiment compressor 300 includes an annular plate 376 having a circular central opening 378 therein along with four fastener holes 380 evenly disposed about the opening 378 and extending through the plate 376. The motor 26 includes a cylindrical housing 382 having two end faces through each of which a drive shaft passes for rotation. The motor 26 is lowered to place its bottom end 384 on the annular plate 376 so that the bottom end 386 on the drive shaft may project downwardly through the central opening 378 in the annular plate 376. Four fasteners 387 pass through the fastener holes 380 from below the ring plate 376 to engage the bottom end 386 of the motor 26. Three legs 388 are fastened to the annular plate member 376 at positions equally spaced apart on the outer periphery of the annular plate member 376, each leg 388 having a projecting portion 389 projecting downward parallel to the central opening axis of the annular plate member and a plate-like base portion 390 fixed at the bottom end of the projecting portion and extending laterally perpendicularly to the projecting portion 389. The base portion 390 of each leg 388 is disposed flush with the top of the top surface 304 of the base 302 along and adjacent to the central section 308a of the respective longer side 308 such that a pair of perforations 392 spaced apart along the laterally extending base portion 390 may be aligned with corresponding blind holes 394 extending perpendicularly into the base 302 from the top surface 304 of the base 302. A fastener 396 passes through a hole 392 in the base portion of each leg 388 for engagement with the blind hole 394 in the base 302. The motor mount 374, and thus the motor 26 secured to its annular plate 376, is thus secured to the base 302. The fan blade unit 395 is coupled to the top end of the drive shaft projecting upwardly from the motor housing 382 to enhance air circulation for cooling during operation of the motor 26.
A drive gear 396 is secured to the bottom end 386 of the drive shaft of the motor 26 and is positioned between the three driven gears 358 at the center of the body 302 above the top surface 304 of the body 302 and in meshing engagement with the driven gears 358. When the motor is energized by connection to a power supply, such as a rechargeable battery, the drive gears 396 are rotated by driven rotation of the drive shaft of the motor 26 undergoing rotation, and the driven gears 358 are rotated about the axis of their pins 368. Operation of the projections 360 on each driven gear about the respective pin 368 axis drives the reciprocating back and forth motion of the piston 42 in the respective cylinder liner 36 for intake and compression strokes by means of the connecting link 44 pivotally connected at the ends to the projections 360 and the piston 42. The driven gears 358 may be relatively positioned about their respective axes prior to meshing with the drive gear 396 to ensure consistent timing between one piston completing a compression stroke and the next piston completing a compression stroke, so that compression is so completed during operation of the motor 26 to effect rotation of the drive gear.
As shown in fig. 24B, the base 302 carries not only the gas compressor defined by the cylinder liners, cylinder head and piston, but also the drive system for operation of the compressor, but also has a hollow interior defined by a set of intersecting holes to provide a manifold for collecting the compressed air in all of the cylinder liners and discharging it through a common outlet. Extending parallel to and between the top and bottom surfaces 304, 306 of the body into each shorter side 310 of the body 302 is a respective receiving hole 400. The open end 402 of each receiving bore at the respective shorter side 310 of the body periphery is threaded for engagement with a correspondingly threaded end 404a of a ninety degree fitting 404. The barbed end 404b of the ninety-degree fitting 404 has a rubber tube 406 sealingly mounted on the fitting. Straight barbed fittings 407 are sealingly engaged to opposite ends of the tube 406 and are sealingly coupled to a cylinder head 338 of a cylinder projecting out from the same short side 310 of the base 302 in communication with the valve port of an exhaust valve 338 b. Each discharge valve of the compressor will thus compress the gas within the cylinder liner to discharge into the respective receiving bore 400.
As shown in fig. 24B, the receiving holes 400 do not intersect with each other. Rather, a set of three additional holes 408 are provided, each extending from the central section 308a of the base 302 at a respective one of the longer sides 308, parallel to and between the body top and bottom surfaces 304, 306, and intersecting at the center of the body 302. Each of the receptacle and the further aperture is perpendicular to the respective side or side section from which it extends. To avoid the blind hole 319 from the top surface 304 of the base 302, each receiving hole 400 extends into a respective shorter side 310 proximate an end 310a of the respective shorter side 310 and intersects with a further hole 408 extending centrally between the same adjacent long side and the center of the body 302 from the adjacent long side 308. With each receiving bore 400 opening into a respective additional bore 408, which intersect at the center of the main body 302, these fluidly communicating bores thus define a common hollow interior of the main body.
The open end 410 of each further hole 408 at the central section 308a of the respective longer side 308 of the body periphery is threaded for connection with a respective one of: a connection fitting 105 for coupling to a drain carrying hose, a pressure switch 412 for operating the motor 26 on the basis of the pressure measured within the hollow interior of the body 302, and a plug 414 for closing the open end 410 of the further bore 408 therein. The use of plugs 414 may provide the option of connecting additional components when desired. After removal of the plug, the base may be equipped with a pressure gauge to provide additional connection fittings. For example, if the connection fitting 105 shown in fig. 21 and 23 is a female connection fitting, it may be necessary to remove the plug 414 to attach a male connection fitting, thereby allowing a user to select between the two connection fittings depending on the type of hose to be connected to the compressor 300.
The hollow interior of the main body 302 formed by the intersecting bores 400, 408 defines a manifold for collecting compressed air from each cylinder liner 36 through a hose 406 attached to the open end 402 of the receiving bore 400 and for directing the compressed air to the open end 410 thereof of the other bore 408 for discharge via a common outlet to a compressed air carrying hose suitable for connection to a pneumatic device. The manifold also serves to carry or support a plurality of cylinders, as in the first and second embodiments. The illustrated three cylinder embodiment may be used in configurations requiring more cylinders, such as the six cylinder configuration shown in the first and second embodiments, and in less demanding pneumatic applications. Alternatively, a larger manifold defining a base may be provided to accommodate more gas compressors.
With three gas compressors spaced about the axis of the drive shaft, when the piston of a gas compressor completes its compression stroke by reaching the fully extended position, one of the remaining two gas compressors is in its compression stroke with its piston moving toward the fully extended position and the other gas compressor is in its intake stroke with its piston moving toward the fully retracted position.
Each of the three embodiments described above provides a compressor with more than two gas compressors radially arranged around the drive shaft in a common plane for reducing the height or thickness of the unit. By having the rigid base or housing supporting the cylinders simultaneously double as a manifold for collecting the compressed gas of each cylinder into the same common receiving space, the compactness of each portable unit can be improved over conventional portable compressors. Those skilled in the art will appreciate suitable materials for the compressor embodiments described above, including metals as well as plastics, with plastics or lighter weight metals such as aluminum, which help to increase the portability of the compressor by reducing the overall weight of the compressor. As shown, by comparing the first, second and third embodiments of the compressor, it can be seen that this portability does not rely entirely on the cylinder liners being partially disposed within the manifold itself, or entirely on the use of the advantageous and unique compressor valves disclosed herein, yet these features do contribute to a substantially compact and protected substantially enclosed unit.
As will be appreciated by those skilled in the art, any of the compressor embodiments described above may additionally include an embedded regulator valve installed in the discharge or outlet of the compressor to control the pressure of gas carried by an air hose coupled to the compressor.
Fig. 27 shows an alternative connecting rod and piston arrangement 500 that can replace the primary connecting rod 52, the secondary connecting rod 44 and the piston 42 of the first or second embodiment compressors 10, 200. The structure 500 is a single, integral unit having a solid central body 502, the central body 502 having a disk-like shape with identical top and bottom circular surfaces 504, 506 and a surrounding wall 508 defining a constant height or thickness of the body 502. A central bore 510 extends completely through the center of the body 502 perpendicular to the top and bottom faces 504, 506 of the body so that the structure 500 can be journaled on a crank pin of a drive system of a compressor that runs about the axis of rotation of the crank shaft about which the crank pin runs. Six connecting rods 512 project radially outwardly from the peripheral wall portion 508 of the solid body 502 at evenly spaced points around the body, each supporting a respective piston 514 at an end opposite the periphery of the central body. Each connection rod 512 has flexible portions 518 at opposite ends of a central rigid portion 519 for connection to the surrounding wall portion 508 of the body 502 and a face 520 of the piston 514 closest to the body 502. The flexible portion allows the required pivoting action between the connecting rod 512 and each body 502 and piston 514 to convert the orbital action of the central body 502 about the axis of the drive shaft into a reciprocating back and forth linear action of the piston within the cylinder housing. In other words, the connecting rod 512 (which is along a plane perpendicular to the axis through the bore 510 of the body 502, i.e., along a plane perpendicular to the drive shaft axis of the body) may undergo a pivot-like action relative to the body 502 and a pivot-like action relative to the piston 514. As with the single integral component formed by molding plastic, the connecting rod and piston structure 500 significantly reduces the number of components relative to the corresponding structure of the first and second embodiments of the compressor. This reduces the total number of parts of the total number of parts that must be manufactured and the assembly time required to manufacture the compressor.
It should be understood that the connecting link and the piston 514 of the piston structure 500 may be of a type having no valve port, as in the first embodiment in which the face of the piston opposite the connecting portion to the connecting link is solid, or of a type having a valve port including an intake valve formed thereon, as in the second embodiment. It should also be appreciated that by having each connecting rod 512 integral with only one of the piston 514 and the body 502, components used in the drive system may be similarly reduced. For example, molding the central body 502 and the connection rods 512 along with the connection rods 512 as a single integral plastic unit with the ends of the body 502 adapted for connection to separate pistons, such as in the first or second embodiment, still reduces the number of drive system components to be assembled. As another example, each connecting rod is integrally molded with its respective piston, and the ends of the connecting rods opposite the pistons may be pivotally connected to separate central bodies using pins or keyways.
Fig. 28 shows an alternative valved piston arrangement 600 which may replace the piston and inlet valve of the second embodiment compressor 200. As can be seen from a comparison of fig. 28 and 8C, the intake valve of the piston structure 600 is similar to the intake valve formed on each cylinder head of the first embodiment compressor. The piston 600 has a one-piece piston body 602 defining a cylindrical base 604, the cylindrical base 604 having an actuating end face 606 and a valve end face 610 opposite the actuating end face, a connecting link 608 extending through the actuating end face 606, an annular wall portion 612 projecting from the valve end face 610 in a direction opposite the actuating end face 606 flush with an outer periphery 614 of the base 604, and a cylindrical projecting portion 616 projecting centrally from the valve end face 610 within a hollow space 618, wherein the hollow space 618 is surrounded by and coaxial with the annular wall portion 612. A plurality of air inlets 620 extend radially from a centrally located radially outward recess of the driving end surface 606 through the cylindrical projection 616 and communicate with a channel 622 that is obliquely bored into the base 604 from the driving end surface 606 of the base 604 that receives the piston 600 and the pin connection portion of the connection link 608. The passage 622 converges toward the radial center of the protruding portion 616 and extends therein to communicate with the intake port 620. With the sealing ring portion 624 disposed within a groove in the outer surface of the annular wall portion 612, and the annular wall portion 612 partially defining the circumference of the piston to provide sealing engagement between the piston 600 and the cylinder liner in which the piston is disposed, the fluid communicating channel 624 and the inlet port 620 thus define a passageway that fluidly communicates the opposite sides of the sealing engagement between the piston and the cylinder liner.
A flexible, resilient band 78, similar to that used in the intake valve of the first embodiment and the exhaust valves of the first and second embodiments, is disposed around the protruding portion 616 to tightly seal against the intake ports 620 until, during the intake stroke of the piston, the pressure of the ambient air outside the cylinder jacket exceeds the pressure sufficient to stretch the resilient band around the protruding portion 616, to uncover the intake ports 620 and allow the ambient air to flow from outside the cylinder jacket into a passage 624, which passage 624 passes from the drive end surface 606 through the intake ports 620 into the enclosed area between the piston and the end of the cylinder jacket closed by the exhaust valves. As the pressure in this region increases under the influence of the ingress of ambient air, the elastic band eventually tends to re-tighten around the protruding portion 616 to re-close the air inlet 620. The increased pressure within the cylinder liner during the compression stroke serves only to further retain the elastomeric band 78 of the intake valve in this closed sealing position over the intake port 620.
A flange 626 disposed at the end of the projecting portion 616 opposite the valve end face 610 of the cylinder body base 604 projects radially outwardly from the projecting portion 616 around its entire periphery to define a seat or groove defined around the projecting portion 616 extending between the flange 626 and the valve end face 610 to hold the elastomeric band 78 in place adjacent the projecting portion 616 having the valve port. The flange 626 blocks the elastic band 78 from moving axially along the protruding portion 616 to ensure that when the elastic band is resiliently tightened again around the protruding portion, the elastic band will be in position to cover the air inlet 620 again.
It should be understood that the first embodiment compressor 10 may be modified to remove the cylinder head 48 and allow the outer periphery of the compressor as defined by the housing outer wall 16 to be enclosed around the cylinder liner 36, and instead use a piston mounted on the intake valve of the second embodiment compressor 200 or an alternative piston structure 600. This of course requires the provision of at least one opening to communicate the environment surrounding the compressor with the crank chamber surrounded by the inner wall 30 of the housing 12, for example by means of the lid or cover 14 extending through the lid or cover 16 mounted relative to the motor 26.
Pump and method of operating the same
While the embodiments described above are each presented in terms of an air compressor, it should be understood that the unique and advantageous features of the present invention may be used not only in the context of a gas compressor, but also in a reciprocating back and forth pump that is used to move fluid from a lower pressure region to a higher pressure region with little or no compression of the fluid. For example, a more compact piston-based multi-cylinder reciprocating pump can be manufactured using the following concept: so that the base or frame not only carries the cylinder but also defines the manifold, or even partially disposes the cylinder within the manifold. The unique valve configuration of the compressor described above will provide some advantages within the pump. The compressor disclosed above may be used as a soak-resistant pump, where the compressor is fed with air from the ambient air similar to the suction of fluid by the pump from the surrounding fluid in which the pump is submerged. Alternatively, the unit may be connected to a fluid source fluidly sealed to the unit for communication with the inlet port.
For example, a pump similar in construction to the compressors of the first and second embodiments may be used to pump water out of a gas well or to pump gas into the ground in an underground storage tank. The components of such a pump may be fabricated using an inert epoxy resin instead of aluminum or another metal to prevent the possibility of reaction when in contact with a fluid or solvent, and LSR based valves have enhanced resistance when exposed to fluids containing abrasive substances. A high efficiency pump allows its power to be provided by batteries or photocells, allowing it to be used in areas where power supplies may not be present. For example, the pump may be used at remote well sites where drive lines have not been constructed, thereby avoiding or delaying the high costs and environmental impacts associated with installing such long distance electric drive systems. As with embodiments requiring more suction power than a single unit provides in order to remove water from the well, a set of pumps having a housing like the compressors of the first or second embodiments may be mounted on a single drive shaft extending through each housing with the discharge conduit of the pump connected to the intake of the lower pump. The pump is lowered into a well on the drive shaft to ground draw fluid up through the row of pumps and finally to the surface. The sealing rings of the pistons used in such pumps can be based on the known relatively high chemical resistance of polyetherketones to use polyetherketones to increase the service life of the pump.
The portable compressor assembly 700 shown in fig. 29 has a compressor 702 similar to the second embodiment compressor described above. The compressor 702 is mounted at one end of a circular cross-section hollow cylindrical tube 704, the hollow cylindrical tube 704 defining a carrying handle with a rechargeable battery module 706, the rechargeable battery module 706 being mounted at the opposite end. The motor is housed within a circular cross-section cylindrical housing 712 that extends below and parallel to the carrying handle 704, and is operatively connected at its opposite ends to the battery module 706 and to the compressor 702. A power adapter or battery charger 714 is releasably mounted to the battery module 706 and electrically coupled with the battery module 706 as needed to charge batteries or run a motor from a conventional AC electrical outlet. Due to the relative positioning of the components, the assembly 700 is compact, easy to carry by hand, and well balanced.
As shown in fig. 29 and 30, the compressor 702 is different from the compressor of the second embodiment in that it has only three cylinder liners 36 and has a different outer peripheral shape. The receiver housing 716 can be viewed as having two portions divided by an imaginary line 722 in fig. 31: a main bottom portion 718, and a top protruding portion 720 (the terms "top" and "bottom" as used herein relate to positioning and orientation as shown in the particular drawings to which reference is made). This three cylinder arrangement results in the main portion of the receiver housing 716 having a six-sided shape, unlike the generally, e.g., regular hexagonal shape of the receiver housing 202 of the second embodiment compressor, which has equal length sides but with the sides somewhat curved and the corners rounded, and is more like the perimeter shape of the third embodiment compressor 300 defining the manifold base 302, but without the longer sides being recessed inwardly from the shorter sides where the cylinders are arranged. The main portion 718 of the receiver housing 716 of the compressor 702 thus has a six-sided peripheral shape, with three equal-length longer sides disposed alternately about the periphery, and three equal-length shorter sides as if formed by a triangle with each corner cut along a line between the two sides that previously intersected to define the corner. The three cylinder liners 36 are evenly spaced around the crank housing 724 disposed within the central opening of the receiver housing defined by the inner peripheral wall portion 726 of the main portion 716 to project from the crank housing 724 into the receiver housing 716 toward each of the shorter outer peripheral sides of the housing main portion 716. As in the second embodiment, a manifold like passage extends around the central opening in the receiver housing 716 and seals around all of the cylinder liners 36 at the valve ends thereof to define a receiver space into which compressed air is discharged from each cylinder liner during a compression stroke of the piston sealed therein.
The protruding portion 720 of the receiver housing 716 is rectangular in shape, protruding vertically upward from the flat top of the main portion 718 at a virtual straight line 722 in fig. 31. The two halves 728, 730 of the receiver housing 716 are each unitary, meaning that the main and projecting portions of each half are defined by a single piece of material, wherein such halves mate face-to-face in a sealing arrangement as shown by line 732 in fig. 29, in a manner similar to those of the second embodiment. As shown in fig. 31A, a hollow straight cylindrical channel 733 extends vertically upward into the protruding portion 718, along its central axis, from an annular manifold defining the channel in the main portion 718, in a direction perpendicular to the virtual boundary 722 between the two portions. As with the channels defining the annular manifold of the second embodiment, the linear and annular channels of the compressor 702 are each formed by grooves or recesses that fit into the two halves 728, 730 of the receiver housing 716. Due to the intersection of the annular and linear cylindrical channels, the external seal disposed around the annular channel does not form a closed circle, but rather forms an arc around the annular channel that extends upward from adjacent sides of the linear cylindrical channel to the other and along both sides of the linear cylindrical channel toward the top surface 734 of the receiver housing 716 to close near the upper limit of the linear cylindrical channel 733.
As shown in fig. 31A, a cylindrical bore 735 extends vertically through the cylindrical passage 733 at the projecting portion 720, from just the exterior non-mating face of the receiver housing half 728 through the receiver housing to the exterior non-mating face of the other half 730, i.e., from the handle side of the compressor to the side opposite the handle 704. A cylindrical passage 733 extending from an annularly-defined manifold channel in the main portion 718 of the receiver housing 716 terminates at its intersection with the cylindrical bore 735, forming a T-shaped connecting portion 737 between the top surface 734 of the receiver housing extension and the parallel imaginary top end 722 of the main portion 718. The bore 735 corresponds most closely to the gas passages of the first and second embodiment compressors for forming an outlet from the manifold or receiver defined within the hollow interior of the receiver housing, but differs in that the bore extends through both halves of the housing. The outer face 736 of the outer half 728 of the compressor receiver housing 716, opposite the handle 704 and the motor housing 712, the aperture 735 is threaded to receive and sealingly engage the conventional female quick connect fitting 105 to allow connection of an air hose equipped with a corresponding male half at one end. At the inner face 738 of the inner half 730 of the receiver housing 716, proximate the handle 704, and the motor housing 712, the bore 735 is threaded to receive and sealingly engage a correspondingly threaded end of the hollow cylindrical carrying handle 704. With this arrangement, the hollow interior of the cylindrical carrying handle 704 is in fluid communication via the intersecting cylindrical passage 733 and bore 735 with a manifold or receiver that receives compressed gas from the cylinder liners 36 during operation of the compressor 702.
The end of the hollow carrying handle 704 opposite the compressor 702 is passed through an appropriately sized bore in the support plate 741 and threadably engages a threaded bore 739, which bore 739 communicates with the otherwise closed control box 740 hollow interior. The hollow interior of the control box 740 is thus in fluid communication with the hollow interior of the handle 704 in the protruding portion 720 of the receiver housing 716, the bore 735, and the cylindrical passage 733, as well as the annular passage within the main portion 718 of the receiver housing 716. These interconnected regions thus define a single enclosure for receiving compressed air during operation of the compressor 702, and have a single outlet or vent at the female air hose quick connect assembly 105. A pressure switch (not shown) is mounted within the hollow interior of control box 740 and is wired to a diverter switch 742 mounted on its top surface 744.
The support plate 741 has a similar but slightly smaller peripheral shape than the receiver housing 716 of the compressor 702, and the aperture in the plate 741 through which the handle 704 passes is located in the portion of the plate corresponding to the projection 720 of the receiver housing 716 of the compressor. A threaded fastener 741a passes through the plate 741 from the side thereof into a threaded receiver 740a in the control box at the face through which the handle extends for engagement with the receiver 740 a. A portion of the plate 741 corresponding to the main portion of the compressor receiver housing protrudes downward from the attachment portion of the plate to the control box 740 for supporting the motor housing 712. Below the control box 740 is a rechargeable battery module 706 that is releasably coupled to the control box 740 and the motor housing 712 for establishing electrical connections with the motor within the motor housing 712 via a diverter switch 742 and a pressure switch of the control box 740 via circuit means known to those skilled in the art.
By setting the switch 742 in operation, the battery module 706 is electrically connected to the motor within the motor housing 712 when the pressure measured by the pressure switch in the control box 740 is below a predetermined limit. The drive shaft of the motor, which extends parallel to the handle 704 along a cylindrical housing 712 surrounding the shaft, projects concentrically into a central opening in the crank housing 724 and is connected to the crank shaft of the compressor 702 so that the crank shaft is driven in rotation by the starter motor to operate the compressor. The pneumatically driven device may be fluidly connected to the outlet defined by the second cylindrical passage 735 of the outer face 736 at the compressor 702 via an air hose coupled to the female quick connect assembly 105 for operation with compressed air provided from the portable compressor assembly 700.
In the embodiment of the portable compressor assembly 700 shown in fig. 29-31, the control box 740 has the same size and shape as the protruding portion 720 of the compressor 702, and the battery module 706 has the same size and shape as the main portion 718 of the compressor 702. When assembled, the control box sits on top of battery module 708 and on its flat top surface 746 defined by the shorter of the six-sided battery module. With the battery module 706 engaged to the motor housing 712 and the control box 740 having corresponding externally threaded ends that are threadably coupled to the hollow cylindrical handle 704, the combined battery module 706 and control box are in the same orientation as the compressor 702 of the same size and shape, providing a balanced, somewhat symmetrical appearance. Making the combined weight of battery module 706 and control box 740 similar to the weight of compressor 702 may also contribute to a more balanced weight distribution across the cylinder center plane, depending on the weight distribution within motor housing 712.
Fig. 30 shows the portable compressor assembly 700 with the detachable battery module 706 removed. Removably mounting battery modules allows for the replacement of depleted battery modules with fully charged battery modules, the easy replacement of old, damaged or defective battery modules, and the recharging of battery modules remotely from the remaining assembly. As shown in fig. 30 and 30A, battery module 706 has a pair of spaced apart electrical contacts 748 projecting perpendicularly from its planar top surface 746 for contacting a corresponding pair of electrical contacts within a pair of recesses 750 projecting perpendicularly upwardly from the otherwise planar bottom surface 752 of control box 740 into its hollow interior. Battery module electrical contacts 748 and control box recess 750 are sized and spaced such that when control box 740 is lowered onto battery module 706 to bring top surface 746 of the battery module and bottom surface 752 of the control box into flush, surface-to-surface contact, battery module electrical contacts 748 may protrude into recess 750 and contact electrical contacts in the control box.
To lock the battery module and control box together, a pair of resiliently biased latches 754 project inwardly and downwardly from the bottom surface 752 of the control box 740 at opposite ends thereof when the two components are brought together in this manner. The latches 754 are deflected into a parallel vertical position shown in fig. 30a, in which each latch extends perpendicular to the bottom surface 752 of the control box, but may be forced to converge toward each other away from the control box. When the control box 740 is lowered onto the battery module, the latches hang in openings or recesses in the upper surface 746 of the battery module, and the sloped surfaces 756 within these openings force the latches 754 together slightly out of the biased position as they move further downward into the openings. Once the latches pass the bottom ends of these surfaces 756, they will deflect away from each other back to their parallel position to catch the ledge that defines the end of each latch on the bottom edge of the respective angled surface, preventing inadvertent withdrawal of the latches from the opening and separation of the control box and battery module. To separate these components, the user simultaneously depresses two buttons 758 that are disposed at opposite ends of the control box 740, i.e., the ends thereof on opposite sides of the longitudinal axis of the handle 704, to again force the latches away from their biased position toward each other and away from near the bottom edge of the ramped surface 756 so that they may be withdrawn from the opening. Releasable latch arrangements of this type are known for connecting rechargeable battery modules to portable power tools such as handheld cordless drills.
An additional pair of electrical connectors 760 in the form of parallel elongate tracks extending along the interior face 762 of the battery module are sized and shaped to slide upwardly into a corresponding pair of recesses 763 provided in the respective end faces 764 of the motor housing 712. As shown in fig. 29 and 30c, a flange 761 projects radially outwardly from the motor housing 712 around an end face 764 thereof to allow the fastener 761a to be engaged by this flange 761 with the support plate 741 at circumferentially spaced apart points near the motor housing 712. The plate 741 thus supporting the motor housing is of sufficient thickness with recesses 741b in a face 741c of the plate opposite the motor housing 712 so that heads of the fasteners 761a may be recessed from this face 741c, which thus continues to remain flat and smooth for sliding the battery module 706 in and out of engagement with the control box 740 along the face. A slot 741d extends upwardly from the bottom of the plate 741 to expose a parallel recess 763 in the end face 764 of the motor housing 712 that extends upwardly from the bottom of the motor housing to receive a rail-like electrical connector 760 of the battery module 706 that extends far enough from the end face 762 of the battery module 706 to extend through the slot 741d of the plate into the recess 763 of the motor housing 712 when the battery module 706 is lifted upwardly along the outer face 741c of the plate 741 into engagement with the control box 740. The flange 761 of the motor housing 712 does not completely surround its end face 764, but instead stops on each side of the pair of grooves 763 without protruding below the grooves and impeding the sliding access of the battery module contacts 760 thereto.
As with recess 750 in control box 740, recess 763 in motor housing 712 contains electrical contacts positioned for physical contact with rail-like electrical contacts 760 of battery module 706, which are wired to the motor for powering the motor once the electrical contacts are completed to slide upward into full latching engagement with control box 740. Electrical connections 748 and 760 on the top face 746 and the interior face 762 of the battery module 706 are wired into the battery module for electrical connection to the motor in the motor housing 712 via the at least one rechargeable battery in the battery module via the diverter switch and pressure switch in the control box 740.
The motor housing 712 is fastened to the compressor 702 by a threaded fastener 765 which is fed through an additional flange 766 which projects radially outwardly from the circumference of the circular cylindrical motor housing 712 at its end opposite the battery module 706 for engagement with a threaded blind bore 767 which extends from the receiver housing interior face 738 into the receiver housing 716 interior half. As shown in fig. 31, the motor housing fastening fasteners 761a, 765 of the illustrated embodiment are provided in pairs at each end of the motor housing 712, each fastener being spaced along a respective longer side thereof of the six-sided main portion 718 of the receiver housing 716.
A fan, shown generally at 768 in fig. 30, is mounted inside the motor housing 712 near its flanged compressor end, the housing being at least partially open on the left side for fluidly communicating the hollow interior of the motor housing 712 with the crank chamber of the compressor defined by its crank housing 724. The fan 768 is mounted on the drive shaft of the motor, generally indicated at 711, so that when the motor is powered, the rotation of its drive shaft not only runs the compressor via its crank shaft, but also rotates the fan to promote the flow of air from the surrounding environment into the crank chamber through the opening or inlet 769 in the crank housing cover. While the openings 769 are shown shaped like those shown for the second embodiment compressor, the openings or inlets may have a characteristic shape such as those on the cylinder head of the first embodiment, having a flared peripheral shape with velocity superimposed inlets to promote velocity increase to bring increased volumes of air into the crank chamber.
A portion of the air drawn into the crank chamber enters the cylinder liner 36 via the valve in which the piston is mounted, for compression therein, as described for the second embodiment compressor, while the remainder of the air continues to flow into the motor housing and through the fan 768. Air flows around the motor between the motor and the surrounding housing 712, continuing along the housing 712 to a circumferentially spaced exhaust or opening 770 in the housing wall proximate to the end face 764 of the motor housing 712 where the support plate 741 is disposed. The inlet fan 768 thus facilitates the intake of the compressor by facilitating air flow therein, while also providing an air flow through the motor to assist in heat dissipation from the motor and exhausting air out of the motor housing 712. The motor, which is mounted concentrically within the housing 712, has a cylindrical shell that may have heat fins projecting outwardly therefrom toward the cylindrical housing 712, which is closed about the motor, to enhance the transfer of heat from the motor to the fan that induces the flow of air therethrough.
Fig. 29 and 30 show a battery charger 714 that can be releasably connected to a rechargeable battery module 706, with or without attachment to a control box 740, to charge the battery module. The charger has a housing having substantially the same shape and dimensions as the battery module 706 and the main portion 718 of the compressor receiver housing 716 to provide a consistent appearance between the components of the portable compressor assembly 700. A pair of protruding electrical contacts 772 are provided on the end surface 774 of the charger housing to cooperate with corresponding electrical contacts mounted in the recess 775 of the end surface 776 as the electrical contacts cooperate between the battery module 706 and the control box 740 when the end surface 776 of the battery module 706 relative to the motor support plate 741 becomes flush together along a line perpendicular to their axes. Two resilient latches or clips 778 project from the charger housing along parallel axes of the vertical end 774 in the deflected position. The width of each clip extends obliquely downward away from the top center surface 779, 780 of the charger housing along a respective inclined side surface extending downward from the housing. The latches or clips 778 are forced out of their parallel deflected position to separate from the end 774 of the charger housing and the charger is urged into flush facing surface contact with the battery module 706 for connection to the electrical terminals of the two components. With the charger 714 so positioned relative to the battery module 706, the latches or clips 778 return to their deflected position with the latch ends configured to pass just past the end surface 762 of the battery module 706 where the motor housing 712 is configured. A ledge or shoulder formed at the latching end engages around an edge defined between a motor side 762 of the battery module 706 and an angled side surface 782 of the battery module 706, the angled side surface 782 extending downward and away from a top surface 746 of the battery module. This engagement prevents the battery module from being extracted along an axis perpendicular to the mating surfaces of the battery module and the charger. The non-vertical edges engaged by the latch or clip 778 also serve to resist the charger 714 from sliding down off of the battery module 706. Contact by the charger's electrical terminals 772 at the bottom end of the shelf defined by the closed bottom end of the corresponding recess 775 in the battery module exterior end face 776 also prevents the charger from falling off the battery module.
The electrical cord 777 coupled to the charger 714 includes a conventional plug 778 for connecting to a conventional AC outlet, and the charger 714 and battery module 706 are configured to allow either: the battery module is charged or powered when depleted, or the DC motor is powered via power and pressure switches when the electrical cable 777 is connected to an appropriate external power source.
Fig. 32 illustrates an alternative portable compressor assembly 784 embodiment having an appearance similar to the portable compressor assembly 700 of fig. 29-31. However, the portable compressor assembly 784 of this alternative embodiment is characterized by two reciprocating compressors 702, 702', with a compressor at each end of the hollow carrying handle 704. The two compressors 702, 702 'are almost identical except for a slight difference in the protruding portions 702, 702'. The compressor 702 is identical to the other portable compressor assemblies described in detail above. However, the compressor 702 ' differs in that the cylindrical bore in fluid communication with the hollow cylindrical carrying handle 706 is not provided with the female quick connect fitting 105, but is powered at, or does not extend completely through, the exterior non-mating face of the exterior half 728 ' of the receiver housing 716 '. The annular manifold-defining passages of the two compressors 702, 702' are in fluid communication with each other via the cylindrical bores and cylindrical passages of the two compressors by defining a conduit hollow carrying handle 704 for discharge through a single outlet defined at the female quick connect fitting 105. The diverter switch 742 is mounted at the top surface 734 'of the second compressor 702' in the same location as the other embodiments and is wired to a pressure switch (not shown) that communicates with the common enclosed space fed by the cylinders of the two compressors.
As described for the single compressor of the other embodiments, the motor housing 712 'is connected to each compressor 702, 702' at each end by a flange and fastener, and each end is in open fluid communication with the crank chamber of the respective compressor. A motor housed within the motor housing 712' is centrally mounted adjacent the motor housing and has a drive shaft extending from both ends thereof, each end of the drive shaft being connected to a crank shaft of a respective one of the two compressors. Two fans are mounted on the drive shaft for being driven in rotation, each fan being interposed between the motor and a respective compressor. An opening 782 ' in the peripheral wall portion of the motor housing 712 ' and spaced thereabout is centrally located along the housing 712 ', i.e., spaced about the motor. Each fan operates in the same manner to draw inlet air through the cap defined in the crank housing by the opening into the crank chamber of the respective compressor so that a portion of the air flow can be drawn into the cylinder for compression and the remainder of the air flow continues into the motor housing 712' through the fan to the motor. The air flows from the two fans meet at the longitudinal center of the motor housing 712 'in the space between the motor and the surrounding walls of the housing, and are spread outwardly through vents or openings 782'. Convective heat transfer occurs from the motor to these air flows so that heat is carried through the opening 782' out of the housing to cool the motor and housing.
As shown in FIG. 32, the alternative embodiment portable compressor assembly 784 has a rectangular power unit 786 that not only carries power to the motor disposed within the motor housing 712, but also serves to define the base of the assembly. The two compressors are located at the top of a rectangular power plant 786 carrying the motor housing 712' between them. The power plant is wired to the motor via a diverter switch 742 and a pressure switch that can be mounted to the compressor 702' proximate to the diverter switch. The power unit includes a conventional removable electrical cord 777', along with a male plug 778 for connecting to a conventional AC electrical outlet and a female end portion 788 for manually releasably connecting to a male prong provided within a recess 790 in the outer housing of the power unit 786. The power device may be an adapter for converting electrical power from an AC external power supply for use by the DC motor. Alternatively, the power plant may include at least one rechargeable battery along with an embedded charger that is connected to an external power supply using a removable cable 777', or the power plant may be a unit that is capable of charging its internal rechargeable battery or that operates a motor when connected to an external power supply. The power unit is manually separable for releasable connection to the compressor or motor housing to allow quick and easy replacement of the power unit by known releasable fastening methods, for example, by using flexible spring clips similar to those used to connect battery chargers and battery modules of other portable compressor assembly embodiments for engagement between the compressor 702, 702' and the power unit 786, in which case mating male (protruding) and female (recessed) electrical connectors are also similar to those taught above to provide disconnectable electrical connectors between the detachable assemblies.
The assembly of fig. 29 to 32 is readily carried and provides a fairly compact arrangement, particularly when used with a compressor of the type described above, in which case the cylinder block extends radially to the drive shaft rod axis at a location spaced about that axis in a common plane perpendicular to that axis. The relatively high efficiency of the first and second embodiment compressors means that the handle assembly can be used to provide a portable unit that can be carried comfortably with one hand and can be easily transported from yard to yard, which can be used in higher demand applications than previously available portable units. Other portable compressors may similarly be equipped with a handle carrying a battery module or another compressor at opposite ends and adapted such that its motor is carried between the ends carried by the handle.
Fig. 37 diagrammatically illustrates a portable tool system 800 that can provide a significant degree of portability and flexibility, particularly when using any of the three compact compressor embodiments described above, and which can be carried in a backpack, bag, mesh bag or container with perforations, or on a leg strap or belt, also as described above. The system 800 has a compressor 802 driven by a compressor motor 804, the compressor motor 804 being wired to a rechargeable battery module 806 via a pressure switch 808 in a conventional manner for operating the motor 804 in response to a demand for compressed air. The pneumatic tool 809 is connected to the compressor via an air hose for selective operation. A selector switch 810 is wired between the battery module 806 and a pressure switch 808, which is also wired to the electrical connections for coupling with the power tool 812 in a selected manner. The switch 810 has an off position, a pneumatic tool in-process position, and an electric tool in-process position in which the battery modules are electrically isolated, connected to the pressure switch and the motor, and connected to the electric tool, respectively. The system 800 is configured to be switched off when not in use, or configured to power one of a pneumatic tool or an electric tool.
Fig. 33A-33C illustrate three hose configurations, each suitable for use in the portable tool system 800 to carry air to the pneumatic tool 809 and electrical to the power tool 812 so as to define a single power delivery unit that can be connected to both the pneumatic and power tools.
Fig. 33A shows a first hose 820 having a flexible tube 822 of electrically insulating material, the flexible tube 822 defining an air passage through which compressed air is delivered from the compressor to the pneumatic tool. The first flexible conductive layer 824 is formed by a mesh-like conductive material wrapped around the flexible tube 822 to extend along the length of the flexible tube 822 from one end of the hose to the other end. An intermediate layer 826 of electrically insulating material extends around the first conductive layer 824 to separate and electrically isolate the first conductive layer 824 from a second conductive layer body 828 of flexible conductive mesh closed around the intermediate insulating layer 826. Finally, an outer cover 830 of electrically insulating material covers the second conductive layer 828 to form the outer perimeter of the hose 820. Alternating layers of insulating and conductive material maintain the desired electrical isolation of the conductor layers to prevent shorting across the conductor layers, while also covering the conductors inside and outside of the hose 820.
Fig. 33B shows a second hose 840 also having a hollow flexible tube 842 through which air is carried but having, instead of alternating conductive layers and insulating layers, a first conductive wire or strip 844 and a second conductive wire or strip 846 helically wound around the flexible tube 842 in a parallel spaced apart manner between opposite ends of the hose 840. This parallel spiral configuration provides the appearance of a strip having a repeating pattern: a first conductor, a space, a second conductor, a space; extending along the flexible tube 842, wherein each "space" stripe is an uncovered portion of the flexible tube 842. The spacing between the spiral conductors electrically isolates the conductors while allowing a greater degree of flexibility in the resulting hose structure. In order to ensure that the conductors do not come into contact and cause short circuits during flexing of the hose, each conductor has its own outer insulation. Like the first tube 820, the outer insulating layer 848 covers the conductive layers and flexible tubing to define the outer circumference of the tube 840, protect the underlying layers, and prevent any contact of the conductors with the outside of the tube. The flexible tube 842 prevents any contact of the conductors with the inside of the hose.
Fig. 33C shows a third hose 860 in which a hollow flexible tube 862 has a first conductor 864 and a second conductor 866 adhered to the first conductor for extending along the flexible tube 862 in diametrically opposite positions. Each conductor is in the form of a strip having a substantial width spanning exactly half of the circumference of the flexible tube to leave an uncovered diametrically opposed space 866 of the tube between the two conductors, each space defining an insulation space or a spaced strip extending along a respective side of the flexible tube. It is understood that the two conductors can be formed by a metal foil, a conductive tape or a conductive coating adhered to the flexible tube. The width of the formed fitting conductors adhered to the flexible tube can be varied to vary the width extension of the insulating strip or space extending along the tube, for example, to increase the width of the space to better prevent inadvertent shorting between the two conductors. Again, the outer insulative layer 868 covers the conductive layer and flexible tube to define the outer circumference of the hose 860, protect the underlying layer, and prevent any contact of the conductors with the outside of the hose.
Fig. 34A and 34B show male and female halves of electrical and pneumatic couplers, respectively, each having an overall shape similar to the corresponding half of a quick-connect pneumatic coupler of a conventional air hose. Fig. 35 shows the two halves joined together.
The male connector 900 has a plug end 902, a plug body 904, and a threaded end 906 opposite the plug end 902. As with conventional air hose quick connects, the hollow cylindrical plug end 902 is in fluid communication with a central bore extending longitudinally through the entire male connector 900 to allow air to flow through the bore, and the plug body 904 is contoured or shaped to define a ball groove or recess 908 between two protrusions 910, 911. The male connector 900 differs from conventional quick connectors for air hoses in that the plug body 904 includes a first tubular conductive portion 912 concentrically disposed within a second tubular conductive portion 914 with an insulating layer 916 extending completely around the first conductive portion between the two conductive portions to electrically isolate the conductive portions. A first conductive portion 912 protrudes through one end of the first conductive portion to support the plug end 902. When assembled on the end of the hose 820, 840, 860 therein, each conductor of the hose is electrically connected to a respective one of the plug body conductive portions 912, 914.
The male connector 900 on one end of the hose can mate with a female connector 920 of the type shown in FIG. 34B that engages the compressor outlet. Like conventional air hose quick connectors, the female connector 920 has a socket body 922 with a central bore therethrough that extends the full length of the female connector from an end 924 having threads on the interior of the female connector. On the end of the receptacle body 922 opposite the threaded end 924 is a hollow cylindrical sleeve 926 that extends concentrically around the receptacle body 922 and is configured for limited sliding movement along the body. The sleeve 926 is biased toward the end of the receptacle body 922 opposite the threaded end 924 by a spring 928, which spring 928 is mounted between shoulders 930, 932 on the exterior of the receptacle body 922 and on the interior of the sleeve 926, respectively, defining an annular spring receiving space therebetween. As in conventional air hose quick connectors, the ball bearings 934 are spaced from the socket body within openings 936 through the socket body wall that taper toward the interior of the socket body. A groove or recess 938 extends in the sleeve interior surface relative to the sleeve at a height directly above ball bearing 934. Ball bearings 934 project into the interior of the socket body 922 far enough to stop the protrusions 910 of the male connector 900 nearest the plug end 902, past the action of ball bearings 934 further into the bore of the female connector 920 until the sleeve 926 is pulled down toward the threaded end 924 to align the sleeve's recesses 938 with the ball bearings 934 to allow them to move radially outward as the protrusions 910 of the male connector 900 move through the recesses 938 and the ball bearings 934. The plug end 902 of the male connector enters the receiving space in the bore of the female connector and the sleeve 926 is released to return to its spring-biased position against a flange or shoulder 940 formed at the end of the receptacle body 922 opposite the threaded end 924. When ball bearing 934 leaves recess 938 in sleeve 926, release of the spring bias to sleeve 926 forces ball bearing 934 radially inward to protrude into ball groove 908 of male connector 900, locking it in engagement with the female connector by impeding protrusion 910 from being withdrawn past ball bearing 934.
The female connector 920 differs from conventional female connectors in that the second set of ball bearings 950 are disposed in a second set of tapered openings 952 that are spaced about the circumference of the socket body above the first set of ball bearings 934, i.e., on the side of the first set of ball bearings opposite the threaded end 924. A second recess 954 is provided in the inner wall of the sleeve, similarly spaced above the first recess 938, directly above the second set of ball bearings 950, and the sleeve is in the biased position shown in fig. 35. The slightly narrowed portion of the second conductive portion 914 of the male connector 900 is indicated by reference numeral 956. Projections 910, 911 defining the recess 908 of the male connector are formed at the ends of their first and second conductive portions 912, 914, respectively, nearest the plug end 902. A narrowing 956 of the second conductive portion 914 occurs between the protrusion 911 and the threaded end 906 of the male connector 900. The second set of ball bearings 950 in the female connector 920 cooperates with the second recesses in the sleeve 954 and the narrowed portion 956 of the second conductive portion 914 of the male connector 900 in the same manner as the first set of ball bearings 934 cooperate with the first recesses 938 in the sleeve 926 and the ball grooves 908 of the male connector 900. When in its radially innermost position, i.e., the sleeve 926 is in its spring biased position away from the threaded end 924, each set of ball bearings is in contact with a respective conductive portion of the female connector 920.
Each set of metallic ball bearings 934, 950 is in contact with a respective conductive portion of the female connector 920 when biased into their radially innermost position to protrude into the interior of the socket body to contact the respective conductive portion of the male connector 900. This can be achieved, for example, by: a socket body 922 of electrically insulating material is formed and a continuous strip of conductive material is applied to the socket body 922 about the outer periphery of the socket body 922 at each set of apertures bounding the ball bearings, as shown in fig. 36. The conductive strips are electrically isolated from each other by their separation along the insulating receptacle body 922, and the conductive strips are electrically coupled to the selector switch 810 and the battery module 806. Grooves 960, 962 extending along receptacle body 922 in its outer wall allow cables or other conductive materials or coatings of the receptacle body to be placed within the grooves along the exterior of the receptacle body without interfering with the mating pieces of male connector 900 within female connector 920 or sliding sleeve 926 along receptacle body 922. Each conductive coating strip may be slightly recessed into the outer circumference of the receptacle body 922, as shown for strip 966 in fig. 35A, so as not to protrude outward from the rest of the receptacle body 922 and interfere with the sliding movement of the ferrule 926 along the receptacle body. This figure also shows how the connection between the conductive ball bearing 950 and the coating strip 966 is established by having the coating material cover the sloped surrounding wall portion of the aperture so that the ball bearing is held against the coating by the sleeve in a biased position.
The grooves 960, 962 extend from the conductive strips 964, 966, respectively, toward the internally threaded end 924 of the receptacle body 922 for connection to the selector switch 810 by electronic means near the mounting end of the female connector. For example, the conductor-filled grooves 960, 962 are opposite the bands 964, 966 and connection ends 960a, 962a closest to the threaded connection end 924 but spaced from the threaded connection end 924 along the socket body 922 may be used to exit the solder connection location points of the leads of the battery and switch to establish selective electrical connections to the bands 964, 966 and the sets of ball bearings 934, 950 while electrical isolation from the compressor housing coupled to the socket body 922 at the threaded end may be ensured by a suitable threaded fitting because the housing or fitting may be made of a conductive material. The circuit breakers 968 in the conductive strips 964 connecting the first set of ball bearings 934 allow conductors to pass through the strips to the strips of the second set of ball bearings 950.
When the male connector 900 is engaged with the female connector 920, contact between the conductive ball bearing sets 934, 950 of the female connector 920 and the respective conductive portions 912, 914 of the male connector 900 connects the conductors of the hoses 820, 840 or 860 to the switches. At the opposite end of the hose is a further female connector 920 which may be wired to a conductor of the hose and may be engaged to a power tool equipped with a further male connector 900, the further male connector 900 having its conductive portion wired to the power drive system of the tool. By setting the switch 810 into operation of the power tool, and the tool being activated by its switch or trigger, the circuit is closed from the battery 806, through the switch 810, through the male/female coupling at the compressor, through the hose, and through the male/female coupling at the power tool for operation of the tool.
Alternatively, the female connector on the tool end of the hose may be connected to a pneumatic tool equipped with a male connector in which the conductive portions 912, 914 are not wired to anything and are therefore electrically isolated to define an open electrical circuit through which power will not flow even if the switch 810 is set to an operating state of the electrical tool. Alternatively, the male connector on the tool may be made entirely of a non-conductive material to ensure that the circuit is not closed. If the switch is set to a state where the pneumatic tool is in operation, the battery is connected to a pressure switch 808, which pressure switch 808 will activate the motor 804 if the pressure detected in the compressor manifold is below a predetermined value, and the motor will thereby operate the compressor and feed compressed air into the pneumatic tool for its operation through the male/female coupling at the compressor, through the air hose, through the male/female coupling at the hose tool end.
It will also be appreciated that the system may be adapted to be able to provide both air flow and electrical power to the tool end of an electrically/pneumatically powered delivery hose, for example for use with rotary and pneumatically powered hammer drills adapted to use electrical power for pounding. As with the portable compressor assembly embodiment, the system may include a battery charger that also functions as an adapter for use with an external power source when desired.
Since various modifications may be made in the present invention as described above, and many apparently widely different embodiments of the present invention are within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.

Claims (9)

1. A reciprocating compressor comprising:
an electric motor having a drive shaft arranged for driving rotation about an axis;
a plurality of cylinder liners, each cylinder liner having a cylindrical bore therein and each cylinder liner extending radially away from the axis, the plurality of cylinder liners including at least three cylinder liners spaced apart about the axis;
a drive system, comprising: a central body eccentrically carried on the drive shaft; and a plurality of connecting rods, each connecting rod connected at one end thereof to the central body;
a plurality of pistons, each piston being connected to a respective connecting rod at a second end of the respective connecting rod opposite the central body, and each piston being sealed against an inner wall of a respective cylinder liner;
the drive system is configured to effect movement of the central body under rotation of the drive shaft to move the piston along the cylinder casing outwardly away from the axis of the drive shaft to a fully extended position furthest from the drive system and then to pull the piston radially inwardly toward the axis to a fully retracted position closest to the drive system;
an inlet valve associated with each cylinder liner, the inlet valve configured to open when the piston is retracted toward the fully retracted position and to close when the piston is extended away from the fully retracted position;
a drain valve associated with each cylinder liner, the drain valve including at least one drain port extending through the cylinder liner and an elastomeric band disposed circumferentially around the cylinder liner; during movement of the piston towards the fully extended position, the elastic band can be elastically extended around the respective cylinder liner by means of the fluid pressure exerted on the elastic band through the discharge opening;
and
an annular manifold having a hollow interior passage extending about said axis and into which the cylinder liners extend partially to position an exhaust valve within said hollow interior passage such that when the exhaust valve associated with each cylinder liner is open, said hollow interior passage of the manifold communicates with the cylindrical bore of each cylinder liner;
wherein the manifold defines a rigid support on which the electric motor, the cylinder liners, and the drive system are carried.
2. The reciprocating compressor of claim 1, further comprising a crank chamber in which the drive system is at least partially disposed, the cylinder liners projecting from the crank chamber into the hollow interior of the manifold.
3. The reciprocating compressor of claim 1 or 2, wherein the electric motor is supplied with electric power by a battery.
4. The reciprocating compressor of claim 1 or 2, wherein the drive system comprises a rechargeable battery operatively connected with an electric motor.
5. The reciprocating compressor of claim 3, wherein the drive system includes a rechargeable battery operatively connected with an electric motor.
6. The reciprocating compressor of claim 1 or 2, wherein the elastic band comprises a liquid silicone rubber.
7. The reciprocating compressor of claim 3, wherein the elastic band comprises a liquid silicone rubber.
8. The reciprocating compressor of claim 4, wherein the elastic band comprises a liquid silicone rubber.
9. The reciprocating compressor of claim 5, wherein the elastic band comprises a liquid silicone rubber.
HK10100545.8A 2006-06-08 2007-06-08 Reciprocating compressor or pump and a portable tool powering system including a reciprocating compressor HK1133289B (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US80421606P 2006-06-08 2006-06-08
US60/804,216 2006-06-08
PCT/CA2007/000990 WO2007140596A1 (en) 2006-06-08 2007-06-08 Reciprocating compressor or pump and a portable tool powering system including a reciprocating compressor

Publications (2)

Publication Number Publication Date
HK1133289A1 HK1133289A1 (en) 2010-03-19
HK1133289B true HK1133289B (en) 2013-08-09

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