Abstract:
A compressor system having a first compartment for housing relatively quietly operating equipment, and a second compartment for housing relatively noisy operating equipment. The second compartment is substantially closed off from the surrounding atmosphere to reduce the amount of noise that can be heard outside the compressor system on account of the noisy equipment operating within the compressor system housing. The second compartment includes a small air inlet opening and a small air outlet opening to allow enough air to flow through the second compartment to cool the equipment housed therein. The small openings reduce the amount of air-born noise which is released to the outside environment. The compressor system also has an air intake directing device for directing an appropriate amount of air into the second compartment to cool the noise generating machinery located within the second compartment, and for directing an appropriate amount of air to an air inlet opening of a compressor, thereby more efficiently using the air drawn into the compressor system housing.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to compressor systems and, more particularly, to air compressor systems.  
         BACKGROUND OF THE INVENTION  
         [0002]    Conventional air compressors typically include a compressor, a motor to drive the compressor and an air and oil cooling system to cool the compressed air and lubricating oil. Conventional air compressors are usually enclosed within a housing. A blower, fan or the like draws air into or pushes air through an opening in the housing. Some of the air which enters the housing is drawn into the compressor for ultimate use and the remaining portion of the air passes through the housing to cool the compressor, the motor, the air and oil cooling system, and other components before being discharged from the housing.  
           [0003]    [0003]FIG. 1 schematically illustrates a conventional compressor system  10 . The compressor system  10  includes a housing  14  having an air intake opening  18  and an air outlet opening  22 . A compressor (i.e., airend) and a motor or drive train operatively connected to the compressor are housed within the housing  14 . A fan  26  is positioned downstream from the airend of the compressor and motor to draw air in through the air intake opening  18 . Some of the air drawn into the housing is compressed in the airend of the compressor and some of the air flows over the compressor and motor to cool the compressor and motor. The fan  26  also pushes the air through a plenum box  30  which is used to distribute the air over an air and oil cooler  34  before pushing the air out of the air outlet opening  22 .  
         SUMMARY OF THE INVENTION  
         [0004]    A problem with the known compressor system described above is the large amount of noise that emanates from the openings in the housing. The air flowing through the housing to cool the compressor and motor flows, for the most part, in a linear path from the air intake opening in the housing through the air outlet opening in the housing. Noise generated by the compressor and motor is freely emitted through the openings in the housing because there is no significant obstruction or other sound reducing means within the housing to reduce the amount of noise which can be carried out of the housing. Thus, there is a need for a new compressor system that significantly reduces the amount of noise which emanates from air inlet and outlet openings provided in the compressor system housing.  
           [0005]    A feature of the present invention is to provide a compressor system having a housing which includes separate compartments. A first compartment houses an air and oil cooling system for the compressed air and lubricating oil. A second compartment houses a compressor and motor which generate most of the operating noise of the compressor system. A large portion of air drawn in through an air intake opening of the housing is directed to cool the air and oil cooling system positioned in the first compartment. A smaller portion of air drawn in through the air intake opening of the housing is directed into the second compartment to cool the compressor and motor. According to the principles of the present invention and contrary to conventional wisdom, it has been determined that only a small portion of the air drawn into the housing is actually needed to sufficiently cool the compressor and motor. Thus, the second compartment is substantially closed, except for a first limited opening to allow the required amount of cooling air in and a second limited opening to allow the cooling air to exit. The compressor and motor are substantially isolated from the air intake opening and air outlet opening in the housing, thereby reducing the amount of noise generated by the compressor and motor that would normally emanate out such openings. Limiting the amount of cooling air which flows over the noise generating compressor and motor also reduces the amount of air-born noise which can exit out of the openings of the housing.  
           [0006]    Another feature of the present invention is to provide a compressor system which regulates the amount of air fed to the compression chamber of a compressor, the amount of air used to cool an air and oil cooling system for the compressed air and lubricating oil, and the amount of air which cools the compressor and motor, all for the purpose of reducing the amount of noise emitted from an air intake opening and an air outlet opening in the housing of the compressor system. Thus, the present invention provides in one aspect thereof, an air directing device which receives a stream of air flowing through an air intake opening in the compressor system housing. A portion of air drawn in through the air intake opening of the housing is caused to cool the air and oil cooling system for the compressed air and lubricating oil. Another portion of air drawn in through the air intake opening of the housing is separated into two streams of air by the air directing device. The first separated stream of air is fed to a compression chamber of the compressor. The second separated stream of air is directed through a non-linear path to flow over the compressor and motor to cool the compressor and motor, and then out of the air outlet opening in the housing. Because only a small portion of the air entering the compressor system housing is actually used to cool the compressor and motor, and because the air used to cool the compressor and motor travels in a non-linear path through the compressor housing, the amount of noise generated by the compressor and motor that emanates from the openings in the compressor housing is greatly reduced, as compared to conventional compressor systems.  
           [0007]    Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    [0008]FIG. 1 is a schematic illustration of a conventional compressor system.  
         [0009]    [0009]FIG. 2 is a schematic illustration of a compressor system embodying the present invention.  
         [0010]    [0010]FIG. 3 is a schematic illustration of an air directing device according to one aspect of the present invention.  
         [0011]    [0011]FIG. 4 is a perspective view showing the top, back and right side panels of the compressor system housing according to the present invention.  
         [0012]    [0012]FIG. 5 is a perspective view showing the top, front and right side panels of the compressor system housing according to the present invention.  
         [0013]    [0013]FIG. 6 is a perspective view of the compressor system according to the present invention with the top, back and right side panels shown in FIG. 4 removed.  
         [0014]    [0014]FIG. 7 is a perspective view of the compressor system according to the present invention with the top, front and right side panels shown in FIG. 5 removed.  
         [0015]    [0015]FIG. 8 is a right side plan view of the compressor system of FIGS.  6 - 7  with the right side panel shown in FIGS.  4 - 5  removed.  
         [0016]    [0016]FIG. 9 is a front side plan view of the compressor system of FIGS.  6 - 7  with the front side panel shown in FIG. 5 removed. 
     
    
       [0017]    Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0018]    [0018]FIG. 2 schematically illustrates a compressor system  100  embodying the present invention. As explained above, a feature of the present invention is to provide a compressor system having reduced noise emission during operation. Another feature of the present invention, is to provide a compressor system which better utilizes the air drawn into the compressor system for actual use and for cooling purposes.  
         [0019]    The compressor system  100  includes a housing  104  having an air intake opening  108 , an air outlet opening  112 , a first compartment  116 , and a second compartment  120 . A blower  124  positioned within the first compartment  116  draws air through the air intake opening  108  (shown by arrow  128 ), through the first compartment  116 , and discharges the air out of the air outlet opening  112  (shown by arrows  132 ). A compressor  136  having an airend, and a motor or drive train  140  operatively connected to the compressor are positioned within the second compartment  120 . The second compartment  120  is substantially closed from the atmosphere outside the compressor system  100 , except for a restricted first air inlet opening  144  which communicates with the air intake opening  108  of the housing  104 , and a restricted second air outlet opening  148  which communicates with the blower  124 . The blower  124  draws air through the air inlet opening  144 , through the second compartment  120 , through the air outlet opening  148  (shown by arrow  152 ), and discharges the air out of the air outlet opening  112  of the housing  104 . The air flowing through the second compartment  120  cools the compressor  136  and motor  140 . The compressor  136  and motor  140  are isolated from the main air flow which flows through the first compartment  116  of the compressor system  100 , such that the noise generated by the compressor  136  and motor  140  is substantially contained within the second compartment  120 . In addition, the air flows in a non-linear or curved path through the air inlet opening  144 , through the second compartment  120 , and out of the air outlet opening  148  to further reduce the amount of air-born noise that escapes out of the second compartment  120 . In other words, unlike conventional compressor systems which do not provide sound obstructing material between an air intake opening and an air outlet opening in the housing to reduce the amount of noise which emanates from the openings, the boundaries of the second compartment  120  and the non-linear path of the air flow into and out of the second compartment  120 , provide a sound barrier for the noise generated by the compressor  136  and motor  140  located within the second compartment  120 .  
         [0020]    It is contemplated that the compressor system  100  schematically illustrated in FIG. 2 could have other configurations, so long as the compressor  136  and motor  140  are isolated or spaced away from the air intake opening  108  and the air outlet opening  112 , and so long as the cooling air which flows over the compressor  136  and motor  140  does not flow in a substantially linear path from the air intake opening  108  through the air outlet opening  112 . It is also contemplated that the compressor  136  may be any suitable compressor, however, for the purposes of the preferred embodiment, the compressor  136  is an oil-flooded air compressor. As generally known, the oil fed into the compressor  136  must be removed from the stream of compressed air before the compressed air may be used downstream for pneumatic equipment and/or other tools. Normally, it is desirable to cool the compressed air before it is sent on for ultimate use, and to also cool the oil separated from the compressed air before it is fed back to the compressor  136 . Accordingly, as shown in FIG. 2, an air and oil cooler or heat exchanger  156  for the compressed air and lubricating oil is provided. According to one embodiment of the present invention, the heat exchanger  156  is positioned within the first compartment  116  adjacent to the air intake opening  108 . The blower  124  draws air through the heat exchanger  156  to cool the compressed air and lubricating oil traveling therethrough.  
         [0021]    According to another embodiment of the present invention, an air plenum box  160  is positioned within the first compartment  116  between the heat exchanger  156  and the blower  124  to distribute the air passing therethrough. In a preferred embodiment, the air outlet opening  148  in the second compartment  120  is an aperture in the air plenum box  160 . The blower  124  causes the pressure within the air plenum box  160  to be less than atmospheric pressure. A majority of the air drawn into the housing  104  by the blower  124  flows through the first compartment  116  to cool the heat exchanger  156 , into the low pressure air plenum box  160 , through the blower  124 , and then out of the air outlet opening  112  in the housing  104 . A smaller percentage of the air drawn into the housing  104  by the blower  124  flows through the second compartment  120  to cool the compressor  136  and motor  140 , into the low pressure plenum box  160 , through the blower  124 , and then out of the air outlet opening  112  in the housing  104 .  
         [0022]    In an alternative embodiment, as illustrated in FIG. 3, the air inlet opening  144  of the second compartment  120  can be an opening for an air directing device  162 . The air directing device  162  includes a first air flow channel (shown by arrow  164 ) for a first stream of air to be discharged from a first air exit opening  168  into an air inlet opening (not shown) of the compressor  136 , and a second air flow channel (shown by arrow  172 ) for a second stream of air to be discharged from a second air exit opening  176  into the second compartment  120  to cool the compressor  136  and motor  140 . Preferably, a partition  180  is provided in the flow path  164  to regulate the amount of air flowing through the flow path  164 . The openings  144 ,  168 ,  176 , and  148  (FIG. 2), and the restricted flow passageway created by the partition  180 , are sized to provide a flow of air through the second compartment  120  to prevent the compressor  136  and motor  140  from overheating, and to ensure that the right amount of air flows into the air inlet opening of the compressor  136  so that the compressor  136  does not starve because of a lack of air.  
         [0023]    In conjunction with the description associated with the compressor system  100  of FIGS.  2 - 3 , FIGS.  4 - 9  illustrate a preferred compressor system  200 . Referring to FIGS.  4 - 5 , the compressor system  200  includes a housing  204  having a top side panel  208 , a back side panel  212 , a front side panel  216 , a right side panel  220 , and a left side panel  224 . An air intake opening  228  is provided in the back side panel  212 , and an air outlet opening  232  is provided in the top side panel  208 . Referring to FIGS.  6 - 9 , the top  208 , back  212 , front  216 , and right  220  side panels have been removed to show the inner compartments and equipment of the compressor system  200 .  
         [0024]    The compressor system  200  includes a compressor  236  (FIGS. 7 and 9), a motor  240  (FIG. 6) operatively connected to the compressor  236 , a separator tank  244  (FIGS.  6 - 9 ) in fluid flow communication with the compressor  236  for separating the compressed air and oil from the air/oil mixture received from the compressor  236 , an air and oil cooler  248  (FIGS. 6 and 8) for cooling the compressed air received from separator tank  244  via hose  252  (FIGS.  6 - 9 ) and for cooling the oil received from the separator tank  244  via hose  256  (FIGS.  6 - 9 ), a hose  260  (FIGS.  6 - 9 ) for transporting the cooled lubricant oil from the air and oil cooler  248  back to the compressor  236 , an air plenum box  264  (FIGS. 6 and 8), and a blower device  268  (FIGS.  6 - 9 ).  
         [0025]    The compressor system  200  further includes an air intake directing device or enclosure  272  (FIG. 6 and see also  162  in FIG. 3) removably mounted within the housing  204 . The air intake enclosure  272  includes an air inlet opening  276  (FIG. 6 and see also  144  in FIG. 3) to receive a stream of air flowing through the air intake opening  228  (FIG. 4) of the housing  204 . The air intake enclosure  272  includes a first air flow channel  164  (FIG. 3) between the air inlet opening  276  and a first air exit opening  168  (FIG. 3), and a second air flow channel  172  between the air inlet opening  276  and a second air exit opening  176  (FIG. 3). The air intake enclosure  272  is preferably lined with sound absorbing material to reduce the amount of noise which may travel therethrough. A tube or hose  280  (FIGS. 7 and 9, and see also FIG. 3) is connected to the first air exit opening  168  of the air intake enclosure  272  and an air inlet opening  284  (FIG. 7) of the compressor  236 . Preferably, an air filter  288  (FIGS. 7 and 9) communicates with the tube  280  to filter the air before it enters the compressor  236 .  
         [0026]    Having described most of the components of the compressor system  200 , certain features of the present invention are explained as follows. The blower  268  draws air in through the air intake opening  228  of the housing  204  (shown by arrow  292  in FIGS. 6 and 8) to cool the air and oil cooler  248 . The blower  268  draws the air through the air and oil cooler  248 , into the air plenum box  264 , and then blows the air out of the air outlet opening  232  of the housing  204  (shown by arrow  296  in FIGS. 6 and 8- 9 ). The blower  268  also draws air in through the air inlet opening  276  of the air intake enclosure  272  (shown by dashed line  297  in FIG. 6), out the second air exit opening  176  in the air intake enclosure  272  (shown by dashed line  298  in FIG. 6), over the compressor  236  and motor  240  to cool the compressor  236  and motor  240  (shown by dashed line  299  in FIG. 8), through an aperture  300  (FIG. 9) provided in the air plenum box  264 , into the air plenum box  264  (see FIG. 8), and then blows the air out of the air outlet opening  232  of the housing  204  (see FIG. 8). Some of the air drawn into the air inlet opening  276  of the air intake enclosure  272  flows through the first air flow channel  164  (shown by dashed line  302  in FIG. 6). The stream of air flowing through the air flow channel  164  exits the first air exit opening  168  in the air intake enclosure  272 , flows through the hose  280  and air filter  288 , and into the air inlet opening  284  of the compressor  236 .  
         [0027]    Variations and modifications of the foregoing are within the scope of the present invention. For example, although a blower has been described to cause air to flow through the compressor system, a fan or the like could be used. As another example, although the air intake directing device has been described as being a silencer box or enclosure, the air intake directing device could comprise a series of baffles to direct the appropriate amount of air to the compressor for compression and to the compressor compartment for cooling purposes. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.  
         [0028]    Various features of the invention are set forth in the following claims.