Cooling arrangement for a portable air compressor

Abstract

A portable air compressor assembly includes a tubular frame having side sections and an assembly longitudinal axis. A support plate between the side sections supports a power unit having a longitudinal axis arranged perpendicular to the assembly longitudinal axis. A compressor having a compressor head and longitudinal axis is mounted to the support plate with the compressor longitudinal axis parallel to the power unit longitudinal axis and perpendicular to the assembly longitudinal axis. A fan connected to the power unit generates an air flow. A ducted cover enclosing the fan includes an air passage directing the air flow from the fan to the compressor head. The ducted cover includes inner and outer covers each including a portion of the air passage. An air scoop extends into the outer cover portion of the air passage to redirect the air flow.

1 . A portable air compressor system, comprising:
 a drive unit having a drive shaft;   a first fan rotatably mounted to the drive shaft operable to generate a first air flow;   a compressor having a driven shaft, a compressor head and a body;   a second fan mounted to the driven shaft operable to create a second air flow directable toward the compressor body;   a ducted fan cover operable to at least partially enclose both the first and second fans; and   an air passage created in the fan cover operable to transfer the first air flow from the first fan to the compressor head.   
   
   
       2 . The system of  claim 1 , wherein the first fan comprises a radial flow fan. 
   
   
       3 . The system of  claim 1 , wherein the air passage comprises a substantially rectangular shape. 
   
   
       4 . The system of  claim 1 , wherein the air passage comprises a shape selected from one of square, circular and oval. 
   
   
       5 . The system of  claim 1 , wherein the ducted fan cover comprises a polymeric material. 
   
   
       6 . The system of  claim 1 , wherein the ducted fan cover comprises first and second grill areas each having a plurality of elongated apertures, the first grill area aligned with the first fan and the second grill area aligned with the second fan. 
   
   
       7 . The system of  claim 1 , wherein the ducted fan cover comprises first and second members, the first member being mountable to a structure of the portable air compressor and the second member being fastenably connectable to the first member. 
   
   
       8 . The system of  claim 7 , wherein the air duct further comprises:
 a first substantially U-shaped portion created in the first member; and   a second substantially U-shaped portion created in the second member;   wherein the first and second substantially U-shaped portions are alignable to create the air passage when the second member is connected to the first member.   
   
   
       9 . The system of  claim 1 , further comprising:
 a compressor assembly longitudinal axis;   a drive unit longitudinal axis oriented approximately perpendicular to the compressor assembly longitudinal axis; and   a compressor longitudinal axis oriented substantially parallel to the drive unit longitudinal axis and substantially perpendicular to the compressor assembly longitudinal axis.   
   
   
       10 . The system of  claim 1 , further comprising a discharge duct portion positioned adjacent to the compressor head and separated from the compressor head by a clearance dimension. 
   
   
       11 . The system of  claim 10 , wherein the discharge duct portion further comprises an extension portion substantially conforming in shape to a compressor head shape. 
   
   
       12 . The system of  claim 1 , further comprising a discharge duct portion extending at least partially over the compressor head. 
   
   
       13 . A portable air compressor system, comprising:
 a generally tubular frame having a pair of approximately parallel side sections each parallel to an assembly longitudinal axis;   a support plate disposed between the side sections;   a power unit having a longitudinal axis, the power unit mounted to the support plate such that the power unit longitudinal axis is substantially perpendicular to the assembly longitudinal axis;   a compressor having a compressor head and a compressor longitudinal axis, the compressor mounted to the support plate having the compressor longitudinal axis substantially parallel to the power unit longitudinal axis and substantially perpendicular to the assembly longitudinal axis;   a first fan connected to a drive shaft of the power unit operable to generate an air flow;   a ducted cover operable to at least partially enclose the first fan, the ducted cover including an air passage operable to transfer the air flow from the first fan to the compressor head, the ducted cover divisible into an inner cover connectable to an outer cover, each of the inner and outer covers including a portion of the ducted air passage;   an air scoop extending into the portion of the air passage of the outer cover operable to redirect the air flow; and   a second fan connected to a driven shaft of the compressor and operating to direct a second air flow perpendicular to a direction of air flow in the air passage and independently of the air flow in the air passage toward a body of the compressor.   
   
   
       14 . The system of  claim 13 , wherein each portion of the ducted air passage is substantially U-shaped such that the ducted air passage defines a substantially rectangular-shape when the inner and outer covers are connected. 
   
   
       15 . The system of  claim 14 , wherein the outer cover further comprises an increasing radius boundary wall at least partially encircling the first fan. 
   
   
       16 . The system of  claim 13 , wherein the air scoop is integrally connected to the inner cover. 
   
   
       17 . The system of  claim 16 , wherein the air scoop further comprises an opposed pair of radially curving walls operable to redirect the air flow. 
   
   
       18 . The system of  claim 13 , wherein the outer section of the cover further comprises:
 a first grill area having a first plurality of elongated apertures aligned with the first fan; and   a second grill area having a second plurality of elongated apertures aligned with the second fan.   
   
   
       19 . The system of  claim 13 , wherein the support plate is substantially horizontally positioned in a normal operating position of the air compressor assembly. 
   
   
       20 . A portable air compressor system, comprising:
 a compressor assembly having an assembly longitudinal axis, a power unit and a compressor rotatably driven by the power unit;   a power unit longitudinal axis;   a compressor longitudinal axis, the compressor longitudinal axis being oriented substantially parallel to the power unit longitudinal axis and both the compressor longitudinal axis and the power unit longitudinal axis oriented substantially perpendicular to the assembly longitudinal axis;   each of the power unit and the compressor having a rotatable shaft, each rotatable shaft having a separate fan coupled thereto; and   a fan cover at least partially enclosing the fan of each the power unit and the compressor, the fan cover including an enclosed duct for directing a portion of an air flow discharged by the fan of the power unit toward the compressor, to assist in operably cooling the compressor.   
   
   
       21 . The system of  claim 20 , wherein the compressor further comprises a head area, the enclosed duct of the fan operable to direct the portion of the air flow substantially toward the head area. 
   
   
       22 . The system of  claim 20 , further comprising a drive belt operable to rotatably connect the power unit to the compressor, wherein the fan cover is also operable to substantially enclose the drive belt. 
   
   
       23 . A method for cooling a compressor of a portable air compressor assembly, the air compressor assembly including a power unit, a compressor having a body and a head area, a first fan mounted to the compressor, a second fan mounted to the power unit, and a ducted cover for protectively covering the first and second fans, the ducted cover having a ducted air passage and first and second grill areas, the method comprising the steps of:
 drawing a first air flow through the first grill area of the ducted cover using the first fan;   directing the first air flow toward the compressor body;   generating a second air flow through the second grill area using the second fan;   directing the second air flow through the ducted air passage;   redirecting the second air flow approximately 90 degrees using an opposed pair of radially curving walls of the ducted cover; and   discharging the second air flow adjacent to the head area of the compressor.   
   
   
       24 . The method of  claim 23 , further comprising maintaining a cross-sectional area of the ducted passage to maintain a velocity of the second air flow in a transition region of the ducted air passage. 
   
   
       25 . The method of  claim 23 , further comprising creating the ducted cover as opposed first and second portions. 
   
   
       26 . The method of  claim 25 , further comprising forming the ducted air passage as air passage segments each disposed in one of the first and second portions. 
   
   
       27 . The method of  claim 26 , further comprising extending an air scoop from one of the first and second portions into the air passage segment of the other one of the first and second portions to scoop the second air flow from the ducted cavity.