Abstract:
The present invention discloses an apparatus and method for protecting a condensate removal device from damage that may be caused when the condensate removal device comes into contact with foreign objects. The present invention discloses placing a shield around the condensate removal device to help prevent the condensate removal device from coming into contact with any foreign object. The present invention also discloses placing a removable cap around the condensate removal device and a condensate removal device that may recess within a mounting assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims benefit of 35 U.S.C. § 119(e) of U.S. Provisional Application Ser. No. 60/187,724 filed Mar. 8, 2000. Said U.S. Provisional Application Ser. No. 60/187,724 is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to condensate removal devices and more typically to condensate removal protection. 
     BACKGROUND OF THE INVENTION 
     Known to the art is the placement of a condensate removal device in proximity to a low point of a compressed air tank for the removal of condensate that may form within a compressed air tank. During the utilization of a compressed air tank, it is common for water and other liquids to condense from the air inside of the air tank as a consequence of the pressure and temperature differences inside the tank and outside the tank. Water and other liquids that may accumulate inside the air tank may be removed through the installation of a condensate removal device placed near a low point of the air tank. Typically, condensate removal devices known to the art are valves that may be opened and closed easily yet are capable of maintaining a constant pressure inside the air tank. 
     Since compressed air tanks tend to be large and heavy, they may not be easily transported. As a result, typical mobile compressed air tanks may be fitted to a frame comprising wheels and handlebars. This allows a person or persons to lift the compressed air tank and pull or push it to a desired location. While traveling on a smooth surface, the design works well. However, in many construction sites, movement to a remote location over an uneven and unpaved surface may be necessary. A frequent problem that occurs while moving the compressed air tank to a remote location is that the drain valve for removing condensate from an air tank may be damaged during transport to a remote location. Foreign objects tend to come into contact with the valve during transport causing damage to the valve. Another problem is that compressed air tanks may be moved during the day and typically are placed upon the bed of a pickup truck in order to transport the compressed air tank to another worksite. Since typical compressed air tanks are heavy, it is not easy for persons to use care and caution when placing the compressed air tanks onto the bed of a pickup truck. Thus, the compressed air tank may be lifted and pushed onto the bed in a quick manner. Often, other items located on the bed of the truck may come into contact with the drain valve damaging the valve when the compressed air tank is placed upon the bed of a pickup truck. Upon damage to the drain valve, the compressed air tank becomes non-functional. 
     Consequently, it would be advantageous to provide an apparatus to act as a shield to prevent the condensate removal device from coming into contact with foreign objects. Further, it would be advantageous if the condensate removal device could recess into a mounting device allowing the mounting device to shield the condensate removal device. Another advantageous aspect would be to cover the condensate removal device with a removable cap to protect the condensate removal device. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention is directed to a novel apparatus for protecting the condensate removal device from damage caused by contact with foreign objects. The present invention is directed towards a shield that prevents objects from coming into contact with the condensate removal device. The present invention is further directed to a recessed condensate removal device where the condensate removal device may be recessed within a mounting device that to prevent damage to the condensate removal device by shielding contact from foreign objects. Further, the present invention is directed to a removable cap that may be placed around and cover the condensate removal device. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The numerous objects and advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which: 
     FIG. 1A depicts a compressed air tank known to the art; 
     FIG. 1B is a side view of a compressed air tank known to the art as shown in FIG.  1 A. 
     FIG. 1C is a detailed view of a mounting assembly known to the art; 
     FIG. 2A depicts a view of an exemplary condensate removal protection apparatus of the present invention; 
     FIG. 2B is a side view of the exemplary condensate removal protection apparatus as shown in FIG. 2A; 
     FIG. 3A depicts an alternative exemplary condensate removal protection apparatus of the present invention; 
     FIG. 3B is a side view of the alternative exemplary condensate removal protection apparatus as shown in FIG. 3A; 
     FIG. 4A depicts an exemplary condensate removal protection apparatus with full enclosure of the present invention; 
     FIG. 4B is a side view of the exemplary condensate removal protection apparatus with full enclosure as shown in FIG. 4A; 
     FIG. 5A depicts an exemplary recessed condensate removal device of the present invention; 
     FIG. 5B is a side view of the exemplary recessed condensate removal device as shown in FIG.  5 A. 
     FIG. 6 depicts exemplary positions the condensate removal device may be placed on an air tank; 
     FIG. 7A depicts an additional exemplary embodiment of the condensate removal protection apparatus of the present invention; and 
     FIG. 7B depicts an another additional exemplary embodiment of the condensate removal protection apparatus placed on a side of an air tank. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. 
     Referring now to FIGS. 1A 1 B, an exemplary compressed air tank  100  known to the art is shown. Compressed air tanks  100  typically comprise an air tank  110  and a tank drain valve  115 . A tank drain valve  115  may be connected to an air tank  110  via a mounting assembly  120 . The mounting assembly may include a weld flange  170  (FIG. 1C) and a plug  160  (FIG. 1C) that is capable of being threaded within the weld flange  170  (FIG.  1 C). The tank drain valve  115  may be threaded to allow the valve  115  mounted within the mounting assembly  120 . 
     Referring specifically to FIG. 1C, a detailed view of a mounting assembly for a valve is shown. The weld flange  170  is welded to the air tank  150 . A mounting device  160  may be threaded and placed within the weld flange  170 . This type of mounting assembly allows for a greater opening in the tank  150  as required per ASME standards for some types of compressed air tanks  100 . By removing the valve  140 , an inspection of the inside of air tank  150  may be more easily accomplished. Drain valves known to the art project a great distance away from the air tank. This leaves the drain valves exposed to possible damage as a result of contact with foreign objects. 
     Referring to FIGS. 2A and 2B, an exemplary embodiment  200  of a condensate removal protection apparatus of the present invention is shown. A condensate removal device may be mounted to an air tank (not shown) at a low point of the air tank in order to remove condensate from the air tank. As shown in FIGS. 2-7, the condensate removal device is a valve  210 , however, the present invention is not limited to valves. Any condensate removal device that allows ease in opening and closing a removable closure and may maintain a constant pressure inside the tank when the removable closure is closed may be utilized without departing from the scope and spirit of the present invention. Further, different types of mounting assemblies may be incorporated with the present invention to a person of ordinary skill in the art and thus various types of mounting assemblies may be incorporated with the present invention without departing from the scope and spirit of the present invention. An example of a condensate removal device is a plug. A plug may be utilized yet is not recommended because it does provide the necessary ease in removing and replacing the plug when draining is necessary. Typically, manufacturers recommend that a compressed air assembly be drained at least once a day to prevent against corrosion on the inside of the air tank. Thus, ease in opening and closing the removal device is paramount. Further, different types of mounting assemblies may be incorporated with the present invention to a person of ordinary skill in the art and thus various types of mounting assemblies may be incorporated with the present invention without departing from the scope and spirit of the present invention. 
     Referring specifically to FIGS. 2A and 2B, in an exemplary embodiment two l-shaped support pieces  220  may be placed on opposite sides of the valve  210  to prevent the valve  210  from coming into contact with any foreign objects. The valve  210  may be connected to a mounting assembly  215  that connects the valve  210  to an air tank. The exemplary support pieces as shown in FIGS. 2-4 may be manufactured from any strong and durable material including metal, plastic, fiberglass, and wood. For ease in manufacturing, a preferred material for the support may be metal as it may be easily welded to an air tank. Foreign objects may include but are not limited to mud, dirt, rocks, tools, equipment, concrete, wood, and hose. Along with providing a shield against contact with foreign objects, the condensate removal protection apparatus  200  provides room to allow access by tools or hands in order to open and close the valve  210 . 
     Alternate embodiments may be utilized in order to protect a condensate removal device from coming into contact with foreign objects. Referring now to FIGS. 3A and 3B, an alternative exemplary embodiment  300  of the condensate removal protection apparatus of the present invention is shown. Surrounding the valve  310  and the mounting assembly  315 , a cylindrical support  320  may be mounted to an air tank. This may allow coverage on all sides of the drain valve  310  and the mounting assembly  315 , however, an opening is present to allow access to the valve  310  for draining of condensate from an air tank. It should be noted that a shape that is not cylindrical that surrounds the valve including but not limited to square, rectangular, trapezoidal may be recognized and utilized by a person with ordinary skill in the art without departing from the scope and spirit of the present invention. 
     Additionally, a cap may be placed on the bottom of the cylindrical support  320  to protect the valve from contact from any direction. Referring to FIGS. 4A and 4B, in an exemplary embodiment  400  a cylindrical support  420  surrounding a valve  410  and a mounting assembly  415  may be threaded to allow a cap  430  to be connected to the cylindrical support  420 . The advantage of this embodiment is that the valve  410  may be completely enclosed within a protective apparatus, however, a cap  430  must be removed when draining is to take place. The cap  430  may be fitted with an extension  440  on the outer end of the cap to allow easier access to opening the cap  430 . Once again, a shape that is not cylindrical and a cap formed to fit over the shape of the support may be utilized without departing from the scope and spirit of the present invention. 
     Turning to an alternative way of protecting a valve from contact from foreign objects, in an exemplary embodiment  500  of the present invention a valve may be recessed within the mounting assembly as shown in FIGS. 5A and 5B. Referring specifically to FIG. 5A, an air tank  510  is shown comprising a valve  520  connected to a threaded plug  530 . The plug  530  may the secured to the tank via a weld flange  525  that may be welded to an air tank  510 . In this embodiment, the plug  530  may be thought of as a reducer as it covers a larger hole in the air tank  510  and reduces the hole to one that may fit the valve  520 . The plug  530  provides a number of advantages. First, it provides a good seal to ensure pressurization within the air tank  510 . Also, it allows for an easier inspection as dictated per ASME standards for some compressed air tanks. Further, by recessing the valve  520  within the plug  530 , the valve  520  may be protected from contact with foreign objects. Yet there is enough space to allow access to the valve  520  by a user to open and close the valve  520 . The plug  530  may be threaded to allow easy installation and removal from the tank via a threaded weld flange  525 . As shown in FIG. 5B, the outer end of the valve  520  may protrude outside of the mounting  530 . It should also be noted that protective supports as shown in FIGS. 2-4 may also be incorporated with the recessed valve embodiment to ensure greater protection from contact from foreign objects. Thus, for example, a recessed valve may be utilized in conjunction with two 1-shaped supports in proximity of the valve to further protect the valve from contact with foreign objects. Also, it should be recognized that the plug  530  as shown in FIGS. 5A and 5B are exemplary only and various modifications may be made to the mounting device to allow recessing of the valve  520  within the mounting device  530  by one of ordinary skill in the art without departing from the scope and spirit of the present invention. 
     Referring now to FIG. 6, the placement of the condensate removal device need not be in the center of the air tank. For example, in exemplary embodiments  600  the condensate removal device may be placed near the bracket  620 , in the middle  630 , and near the wheels  640  along with areas in between the front and end of the air tank  650 . Also, it should be noted that the present invention is not limited to a single style of air tank as the condensate removal protection apparatus may be utilized in all types of air tanks. An exemplary middle location  630  may be preferred as inspections made on the air tank may be made easier with a hole located in the center of the air tank on the bottom side and a hole in the center of the air tank on the top side. Typically, a check valve may be placed in the center of the air tank on the top side. With these two locations, an thorough inspection of the inside of air tank is possible to check for wear and corrosion. In all of the locations regarding placement of the condensate removal device, exemplary supports as shown in FIGS. 2-4 may be incorporated with the condensate removal device. 
     Further, in another exemplary embodiment  700  the condensate removal device  710  may be attached to a tube  720  that is connected to an air tank  730  as shown in FIG.  7 A. This may reduce the distance that the condensate removal device  710  protrudes outwardly from the air tank  730 . In another exemplary embodiment  750 , the condensate removal device  760  may be placed on a side of an air tank  770 . As shown in FIG. 7A, the condensate removal device may be placed on a side close to the wheels  780 . In order to remove condensate from an air tank  770 , lifting of the front of the air tank  770  may be required. Different embodiments may be available to a person with ordinary skill in the art in order to protect a condensate removal device from contact from foreign objects that do not depart from the scope and spirit of the present invention. 
     It is believed that the present invention and many of its attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction, and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely an explanatory embodiment thereof, it is the intention of the following claims to encompass and include such changes.