Patent Publication Number: US-11041492-B2

Title: Compressor gas cutoff

Description:
RELATED APPLICATION 
     This application is a divisional application of, and hereby claims priority under 35 U.S.C. § 120 to, pending U.S. patent application Ser. No. 15/440,847, entitled “Compressor Gas Cutoff,” by inventor Donald R. McMullen, filed on 23 Feb. 2017. 
    
    
     FIELD 
     This disclosure relates generally to compressors, and more specifically, to a mechanism for cutting off the flow of gas, liquid, or the combination thereof in the event of compressor failure or malfunction. 
     BACKGROUND 
     In today&#39;s world of pneumatic operations, it is hard to imagine a time when air compressors were nonexistent in factories or workshops. The fact is, in the context of machine-age history, air compressors are a relatively recent innovation. Not long ago, the air tools used in workshops typically drew power from complex systems comprised of belts, wheels, and other large components. For the most part, such machinery was too massive, heavy, and costly for smaller operations, and was therefore confined primarily to larger companies. 
     Today, however, air compressors are usually found at factories where products are assembled or in most places where cars are serviced, such as gas stations and auto workshops. The list of tools that run on compressed air is long, but some of the most common pneumatic tools include the following: drills, grinders, nail guns, sanders, spray guns, and staplers. The most significant benefit of the standard workshop air compressor is its compact and relatively lightweight dimensions, which stand in contrast to centralized sources of power that generally utilize large motors. Additionally, air compressors last longer, require less maintenance, are easier to move from worksite to worksite, and are far less noisy than old-fashioned machinery. 
     Air compression is essentially a twofold process in which the pressure of air rises while the volume drops. In most cases, compression is accomplished with reciprocating piston technology, which makes up the vast majority of compressors on the market. Every compressor with a reciprocating piston has the following parts: crankshaft; connecting rod; cylinder; piston; and valve head. 
     Air compressors, for the most part, are powered by either gas or electric motors—it varies by model. At one end of the cylinder are the inlet and discharge valves. Shaped like metal flaps, the two valves typically appear at opposite sides of the cylinder&#39;s top end. During the “compression” process, what the piston effectively does with its back and forth movements is create a vacuum. As the piston retracts (i.e., on its down-stroke), the space in front gets filled with air, which is sucked through the inlets from the outside or from another gas source. When the piston extends (i.e., on its upstroke), that same air is compressed and therefore given the strength to push through the discharge valve—simultaneously holding the inlet shut—and into a tank or other compressed gas receptacle. As more air is sent into the tank, the pressure gains intensity. 
     In certain air compressor models, the pressure is produced with rotating impellers. However, the models that are typically used by mechanics, construction workers, and crafts people tend to run on positive displacement, in which air is compressed within compartments that reduce its space. Even though some of the smallest air compressors consist of merely a motor and pump, the vast majority have air tanks. The purpose of the air tank is to store amounts of air within specified ranges of pressure until it is needed to perform work. In turn, the compressed air is used to power the pneumatic tools connected to the unit supply lines. While all of this is going on, the motor repeatedly starts and stops to keep the pressure at a desired consistency. 
     In order to accommodate the vast range of pneumatic tools on the market, air compressors are manufactured in both one- and two-cylinder varieties. However, compressors used by private craftspeople and contractors often contain two-cylinders that function almost identically to single cylinders, the only real difference being that two strokes occur during each revolution. Some two-cylinder machines that are marketed to the public also work in two stages, where one piston sends compressed air to another cylinder for further compression. 
     For most single-stage air compressors, the preset pressure limit is set to a specific pressure per square inch (“psi”). When this limit is reached, a pressure switch goes off to stop the motor. In most operations, however, there is no need to even reach the pressure limit. For that reason, the compressor&#39;s air line is set to a regulator, where the user inputs the appropriate pressure level for a given tool. The regulator is bookended by two gauges: one that comes in front to monitor the pressure of the tank, and another gauge at the end to keep the pressure of the air line in check. Furthermore, the tank may be equipped with an emergency valve that triggers in the event of a mishap with the pressure switch. On some models, the switch might connect with an unloader valve, which can help reduce stress to the tank at times when the machine is deactivated. 
     For certain heavy-duty industrial operations, piston compressors are considered insufficient. In order to get the pressure intensity needed for complex pneumatic and other high-powered tools, professionals will generally opt for rotary screw air compressors. Unlike the piston air compressor, which relies on pulsation, the rotary screw air compressor produces an ongoing movement to generate power. 
     In a rotary screw compressor, air is compressed with a meshing pair of rotors. As the screws move in rotation, fluids gets sucked in, compressed, and ejected. In order to keep leakage rates at an absolute minimum, fast rotational rates are vital throughout the operation. 
     While compressors often are used to compress air from the atmosphere, compressors also can be used to compress other gases and liquids, or even combinations thereof. The type of gas/liquid compressed obviously is application dependent. Nevertheless, for applications that call for compressing gas/liquid that is dangerous or otherwise harmful to humans and/or the environment, additional care must be taken to prevent exposures, whether during normal operation or during compressor breakdown or failure. Such failure or breakdown can occur when any of the compressor components such as the crankshaft, connecting rod, cylinder, piston, rotor, or valve head fail in a manner that allows gas/liquid to escape to the atmosphere or open environment. 
     One precaution taken for dangerous gas/liquid applications is to enclose the compressor in an airtight enclosure so that any catastrophic failure to the compressor that might vent gas/liquid to the atmosphere is trapped in the enclosure. This has proven cumbersome and inefficient since it significantly adds to the size of the compressor unit, detracts from easy access to the compressor, and can hold too much heat. Accordingly, a better apparatus is needed for preventing gas/liquid exposures during compressor failure or breakdown. 
     SUMMARY 
     In one embodiment, the present invention includes a means for cutting off the flow of gas or liquid (or a combination thereof) in the event of compressor failure or breakdown. In this embodiment, the gas/liquid flows from its source through one or more passageways into a first input chamber, and also through one or more other passageways into a second input chamber, where the first and second input chambers are separated by a stop plunger. During the down-stroke of the piston, the gas/liquid in the first chamber passes (or is drawn) through an inlet valve of the piston bore, and during the up-stroke of the piston, that gas/liquid is forced through an outlet valve of the piston bore to a tank or other compressed gas/liquid receptacle. So long as the compressor operates normally, the pressure in the two input chambers (i.e., on each side of the stop plunger) will be substantially equal, thereby keeping the stop plunger in place. If, however, the compressor fails in a manner that exposes gas/liquid in the piston bore to the atmosphere, or otherwise results in a decrease in pressure in the piston bore, the pressure in the first input chamber will fall below the pressure in the second input chamber, thereby causing the stop plunger to move to a position in which it blocks the flow of gas/liquid from entering the inlet valve of the piston bore. In that case, harmful gas/liquid from its source will cease (or substantially cease) flowing, thereby preventing harmful gas/liquid exposures during compressor failure or breakdown. 
    
    
     
       DRAWINGS 
       The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. While the invention in not limited to the following drawings, it may be better understood by reference to one or more of them in combination with the detailed description of specific embodiments presented herein. Moreover, while some of the descriptions of the drawings refer to “gas” being used, it should be understood that liquids (or a gas/liquid combination) could also be used without departing from the disclosed invention. 
         FIG. 1  is a cross sectional view of an exemplary embodiment of a gas block. 
         FIG. 2  is a top perspective view of an exemplary embodiment of a gas outlet. 
         FIG. 3  is a top view of an exemplary embodiment of a gas outlet. 
         FIG. 4  is a perspective view of a cross section of an exemplary embodiment of a gas outlet. 
         FIG. 5  is a perspective view of a cross section of an exemplary embodiment of a gas outlet. 
         FIG. 6  is a cross section of an exemplary embodiment of a gas outlet. 
         FIG. 7  is a perspective view of an exemplary embodiment of a stop plunger. 
         FIG. 8  is a perspective view of an exemplary embodiment of a stop plunger. 
         FIG. 9  is a perspective view of an exemplary embodiment of a cross section of a stop plunger. 
         FIG. 10  is a cross section of an exemplary embodiment of a stop plunger. 
         FIG. 11  is a perspective view of an exemplary embodiment of a gas block. 
         FIG. 12  is a cross section of an exemplary embodiment of a gas block. 
         FIG. 13  is a cross section of an exemplary embodiment of a gas block. 
         FIG. 14  is a cross section of an exemplary embodiment of a gas block. 
         FIG. 15  is a cross sectional view of an exemplary embodiment of a gas block including a poppet. 
         FIG. 16  is a top perspective view of an exemplary embodiment of a stop plunger. 
         FIG. 17  is a top view of an exemplary embodiment of a stop plunger. 
         FIG. 18  is a bottom perspective view of an exemplary embodiment of a stop plunger. 
         FIG. 19  is a cross section of an exemplary embodiment of a stop plunger. 
     
    
    
     DETAILED DESCRIPTION 
     Various features and advantageous details are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known starting materials, processing techniques, components, and equipment are omitted so as not to unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the invention, are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and/or rearrangements within the spirit and/or scope of the underlying inventive concept will become apparent to those skilled in the art from this disclosure. 
       FIG. 1  is a cross sectional view of one exemplary embodiment of one aspect of the present invention. (As noted above, while references are made to “gas”, it should be understood that liquids (or a gas/liquid combination) could also be used without departing from the disclosed invention.) Gas block  100  is shown having gas input passageway  110 , gas input passageway  120 , gas input chamber  130  (including input chamber  130   a  and input chamber  130   b ), stop plunger  140 , groove  150  for receiving a portion of stop plunger  140 , and gas outlet  160 . In operation, gas is supplied, either from the atmosphere or from an external source, to gas passageway  110  and gas passageway  120 , as depicted by the arrows showing gas flow into those passageways. Given this exemplary embodiment&#39;s structure, gas supplied to gas passageway  110  enters gas input chamber  130  at input chamber  130   a , and gas supplied to gas passageway  120  enters gas input chamber  130  at input chamber  130   b . The boundary between input chamber  130   a  and input chamber  130   b  is stop plunger  140 , which is sized and mounted in block  100  so that it can slide between various positions in input chamber  130 . In another embodiment, instead of separate passageways  110  and  120 , a single gas passageway could straddle input chamber  130   a  and input chamber  130   b  so as to supply gas to both chambers from a single passageway. 
     As gas enters input passageway  120  and input chamber  130   b , it flows to (and through) gas outlet  160 , as shown by the exiting arrows in  FIG. 1 . The gas then flows as conventionally understood, i.e., through an inlet valve in the compressor (not shown) and into the compressor&#39;s piston bore (not shown). This described gas flow occurs at least on the down-stroke of the piston and ceases upon the piston&#39;s upstroke, at which point gas is forced through an outlet valve (not shown) to a tank or other compressed gas receptacle (not shown). Throughout this cycle, i.e., during normal compressor operation, gas pressure in input chamber  130   a  and input chamber  130   b  is substantially equal, thereby causing stop plunger  140  to remain in its position (as shown) between input passageway  110  and input passageway  120 . Movement of stop plunger  140  can be retarded (to deter its movement during shipping, installation, vibration, minor gas pressure differentials, etc.) by one or more o-rings  170  and  180 . Other movement retarding mechanisms could also be used instead of (or in combination with) o-ring  170  and  180 , such as one or more springs, c-rings, or even merely friction between stop plunger  140  and grove  150 . 
     If the compressor fails in a manner that exposes gas in the piston bore (or anywhere at or downstream of gas outlet  160 ) to the atmosphere, or otherwise results in a decrease in pressure in the piston bore, the pressure in input chamber  130   b  will fall below the pressure in input chamber  130   a  because chamber  130   b  will essentially be open to the atmosphere due to its connection to the piston bore. The pressure differential between chamber  130   a  and  130   b  will then cause stop plunger  140  to move to a position against gas outlet  160 , thereby blocking the flow of gas from entering gas outlet  160  and the inlet valve of the piston bore. In that case, harmful gas from the gas source (being delivered through gas passageways  110  and  120 ) will cease flowing, thereby preventing harmful gas exposures during compressor failure or breakdown. 
     While various dimensions and geometries of gas block  100  and its constituent components are shown in  FIG. 1  (and the other Figures), it should be understood that the invention is not limited to such dimensions and geometries. As one example only, while stop plunger  140  is shown having a flat, circular front surface for blocking gas outlet  160 , the front surface of stop plunger  140  alternately could be spherical or otherwise shaped so long as its shape operates to block gas outlet  160  at the appropriate time. Gas block  100  and its other components could likewise be altered and still fall within the spirit and scope of the present invention. 
       FIG. 2  is a top perspective view of one exemplary embodiment of gas outlet  160 . As shown in this particular example, gas outlet  160  has four channels  200  through which gas is received from input chamber  130 / 130   b  and from which gas is output to one or more inlet valves in the compressor. The size, shape, and number of channels  200  is optional and can be tailored to specific implementations, as will be appreciated by those skilled in the art. 
       FIG. 3  is a top view of an exemplary embodiment of gas outlet  160 .  FIG. 4  is a perspective view of a cross section of an exemplary embodiment of gas outlet  160 . This embodiment includes inset  210 , which is sized to receive the top of stop plunger  140 . In other words, the width/diameter of inset  210  is only slightly larger than the width/diameter of the top of stop plunger  140 , with the goal being to form a better seal between the two to better stop the flow of gas from input chamber  130 / 130   b  to the channels  200  of gas outlet  160 . 
       FIG. 5  is a perspective view of another cross section of an exemplary embodiment of gas outlet  160 . This cross section shows channels  200  extending all the way through gas outlet  160 , as described above. 
       FIG. 6  is a cross section of an exemplary embodiment of gas outlet  160  showing channels  200  and inset  210 .  FIG. 6  shows threading  610  for securing gas outlet  160  to gas block  100 . These threads, like the size, shape, and number of channels  200 , and like the optional nature of inset  210 , are optional since other securing means could be used. Likewise, in yet another embodiment, gas block  100  and gas outlet  160  could be machined from the same block. 
       FIGS. 7 and 8  are perspective views of one exemplary embodiment of one aspect of stop plunger  140 . As shown, stop plunger  140  includes openings  720 , through which gas in input chamber  130   a  passes. While stop plunger  140  is shown with four openings  720 , a different number (or shape) of openings could be used, as well as the use of no openings since gas in input chamber  130   a  will still exert pressure against surfaces  740  and  750  to cause stop plunger  140  to close when there is sufficiently more pressure in input chamber  130   a  than there is in input chamber  130   b . As also shown, stop plunger  140  includes surface  730 , which is shaped to block the flow of gas from entering channels  200  (in gas outlet  160 ) when stop plunger  140  moves to a closed position against gas outlet  160 . This embodiment of stop plunger  140  also includes an elongated body  710 , which is sized to fit within grove  150  of gas block  100  so that stop plunger  140  is able to slide in a controlled manner between its open and closed position. As noted above, in one embodiment, this sliding action may be tempered by one or more o-rings  170  and  180  (shown in  FIG. 1 ) or other movement retarding mechanisms, as described above. 
       FIG. 9  is a perspective view of an exemplary embodiment of a cross section of stop plunger  140 . This embodiment shows a hollowed out area  910  in the top portion of stop plunger  140 , which acts as an additional surface against which the input gas will push, thereby assisting in pushing stop plunger  140  into its closed position against gas outlet  160  when there is sufficiently more pressure in input chamber  130   a  than there is in input chamber  130   b.    
       FIG. 10  is a cross section of an exemplary embodiment of stop plunger  140 , which also shows area  910  in the top portion of stop plunger  140 . 
       FIG. 11  is a perspective view of an exemplary embodiment of gas block  100  (shown in  FIG. 1 ), without gas outlet  160 . As indicated above, gas outlet  160  can be either detachable from or an integrated part of gas block  100 . While this embodiment of gas block  100  is illustrated as having a cylinder-like shape, other shapes are possible (and perhaps even desirable depending on the application) and still within the scope of the present invention. Likewise, while gas passageways  110  and  120  are shown as having the same radial placement on the outside of gas block  100 , other embodiments could have different radial placements and/or different numbers of gas passageways  110  and  120 . 
       FIG. 12  is a cross section of an exemplary embodiment of gas block  100 .  FIG. 12  shows supporting cross-sectional designations for  FIG. 13  and  FIG. 14 . Like  FIG. 11 ,  FIG. 12  shows gas passageways  110  and  120 . 
       FIG. 13  is a cross section of an exemplary embodiment of gas block  100  taken along gas passageway  120 , as illustrated in  FIG. 12 .  FIG. 14  is a cross section of an exemplary embodiment of gas block  100  taken along gas passageway  110 , as illustrated in  FIG. 12 . These Figures (like  FIGS. 1, 11, and 12 ) show gas passageways  120  being smaller in diameter than gas passageways  110 . In this particular embodiment, this size differential is intended, i.e., gas passageways  110  are made larger than gas passageways  120 , although in other embodiments they could be the same. 
     In yet another embodiment, the sum of the cross-sectional size of gas passageways  120  are made smaller than the sum of the cross-sectional size of the inlets to the piston bore. This size relationship ensures that in the event the piston bore loses pressure (or is exposed to the atmosphere) the gas pressure in input chamber  130   b  will drop below the gas pressure in input chamber  130   a . As described above, the pressure differential between chamber  130   a  and  130   b  will then cause stop plunger  140  to move to a closed position against gas outlet  160 , thereby blocking the flow of gas from entering gas outlet  160  and the inlet valve of the piston bore. In that case, gas from the gas source (being delivered through gas passageway  110  and  120 ) will cease flowing, thereby preventing gas exposures during compressor failure, breakdown, or other pressure losses. 
       FIG. 15  is a cross sectional view of another exemplary embodiment of another aspect of the present invention. (As noted above, while references are made to “gas”, it should be understood that liquids (or a gas/liquid combination) could also be used without departing from the disclosed invention.) Gas block  151  is shown having gas input passageway  152 , stop plunger  153 , gas passageway  154 , gas stop  155 , gas passageway  156 , poppet  157 , spring  158 , and gas output passageway  159 . Stop plunger  153  is mounted in gas block  151  so that it is able to slide between an open position (as shown) and a closed position (not shown) against gas stop  155 . Gas flow is substantially blocked from flowing when stop plunger  153  is in its closed position. 
     In operation, gas is supplied from an external source to gas input passageway  152 , as depicted by the arrow showing gas flow into that passageway. Given this exemplary embodiment&#39;s structure and assuming stop plunger  153  is in its open position, gas supplied to gas input passageway  152  enters stop plunger  153 , flows through gas passageway  154 , and then flows through gas passageway  156 . Pressure from the supplied gas will exert a force against poppet  157  and, if that pressure exerts a force on poppet  157  greater than the combined force exerted on poppet  157  by spring  158  and the gas pressure in gas output passageway  159 , poppet  157  will open, thereby allowing gas to flow into gas output passageway  159 . Except as described in more detail below, gas will continue to flow from gas input passageway  152  to gas output passageway  159  as long as the force exerted on poppet  157  by the input gas exceeds the combined force exerted on poppet  157  by spring  158  and the gas in gas output passageway  159 . 
     The gas in gas output passageway  159  then flows as conventionally understood, i.e., into a compressor&#39;s piston bore (not shown). This described gas flow occurs at least on the down-stroke of the piston and ceases upon the piston&#39;s upstroke, at which point gas is forced through an outlet valve (not shown) to a tank or other compressed gas receptacle (not shown). (Note that due to the design of gas block  151 , during the piston&#39;s upstroke, gas will not reverse flow across/through poppet  157  because poppet  157  will remain closed due to the combined force exerted on poppet  157  by spring  158  and the gas in gas output passageway  159  exceeding the input gas pressure.) Throughout this cycle, i.e., during normal compressor operation, gas pressure in each of gas passageways  152 ,  154 , and  156  is substantially equal, thereby causing stop plunger  153  to remain in its open position (as shown). Movement of stop plunger  153  can be retarded (to deter its movement during shipping, installation, minor pressure differentials, vibration, etc.) by one or more o-rings  161 . Other movement retarding mechanisms could also be used instead of (or in combination with) o-ring  161 , such as one or more springs, c-rings, or even merely friction between stop plunger  153  and gas block  151 . 
     If the compressor fails in a manner that exposes gas in the piston bore (or anywhere at or downstream of poppet  157 ) to the atmosphere, or otherwise results in a decrease in pressure in the piston bore, the pressure in gas output passageway  159  will fall below the pressure in gas passageways  152 ,  154 , and  156  because gas output passageway  159  will essentially be open to the atmosphere due to its connection to the piston bore. This pressure differential will then cause poppet  157  to temporarily open until the pressure differential causes stop plunger  153  to move to its closed position against gas stop  155 , thereby blocking the flow of gas from entering gas passageway  156 , gas output passageway  159 , and the piston bore. In that case, harmful gas from the gas source (being delivered through gas passageways  152 ,  154 ,  156 , and  159 ) will cease flowing, thereby preventing harmful gas exposures during compressor failure or breakdown. 
     While various dimensions and geometries of gas block  151  and its constituent components are shown in  FIG. 15  (and the other Figures), it should be understood that the invention is not limited to such dimensions and geometries. As one example only, while stop plunger  153  is shown having a flat, circular front surface with a plurality of gas passageways  154  for mating with gas stop  155 , the front surface of stop plunger  153  alternately could be spherical or otherwise shaped so long as its shape suitably mates with gas stop  155  to block gas flow when stop plunger  153  is closed. Gas block  151  and its other components could likewise be altered and still fall within the spirit and scope of the present invention. 
       FIG. 16  is a top perspective view of one exemplary embodiment of stop plunger  153 . A plurality of gas passageways  154  are shown, but it will be appreciated that a different number of passageways and different geometries could be used to accomplish the same task, so long as those passageways and geometries are inversely reflected by gas stop  155 . In other words, stop plunger  153  and gas stop  155  should be designed, in this particular embodiment, to allow gas to flow through gas passageway  154  and gas passageway  156  when stop plunger  153  is open, and to substantially block gas flow through gas passageway  154  and gas passageway  156  when stop plunger  153  is closed. 
       FIG. 17  is a top view of one exemplary embodiment of stop plunger  153  showing gas passageways  154 .  FIG. 18  is a bottom perspective view of an exemplary embodiment of stop plunger  153 . This embodiment shows a circular passageway  162  for receiving gas from gas input passageway  152 . Other shapes are possible.  FIG. 19  is a cross section of an exemplary embodiment of stop plunger  153  showing the coupling between (a) the circular passageway  162  for receiving gas from gas input passageway  152  and (b) gas passageways  154 . 
     Although the invention(s) is/are described herein with reference to specific embodiments, various modifications and changes can be made without departing from the scope of the present invention(s), as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention(s). Any benefits, advantages, or solutions to problems that are described herein with regard to specific embodiments are not intended to be construed as a critical, required, or essential feature, or element of any or all the claims. 
     Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The terms “coupled” or “operably coupled” are defined as connected, although not necessarily directly, and not necessarily mechanically. The terms “a” and “an” are defined as one or more unless stated otherwise. The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a system, device, or apparatus that “comprises,” “has,” “includes,” or “contains” one or more elements possesses those one or more elements but is not limited to possessing only those one or more elements. Similarly, a method or process that “comprises,” “has,” “includes,” or “contains” one or more operations possesses those one or more operations but is not limited to possessing only those one or more operations.