Portable pneumatic power supply and compressor systems and methods thereof

Abstract

Portable, pneumatically operable tool systems and compressors for providing pneumatic power therefor. In at least one embodiment, compressors capable of producing clean, dry compressed air/gas (e.g., either in naturally occurring atmospheric nitrogen/oxygen ratios or as purified nitrogen or in alternative ratios therebetween) employing atmospheric air as a starting material, for use by portable pneumatic tools systems. In certain additional embodiments, methods of compressing and/or purifying atmospheric air and of its use in portable pneumatic tool systems.

1 . A system for manufacturing and providing compressed air/gas to a portable, pneumatic, power supply system comprising:
 a) a compressor comprising:
 a motor operably connected to a flywheel and capable of rotating said flywheel; 
 a linearly actuated pump having a first end and a second end, said first end pivotally connected to said flywheel at a pump mount location and said second end pivotally connected to a frame member, said pump including a piston which is linearly actuated when said flywheel is caused to rotate; 
 a counterweight connected to said flywheel at a location on said flywheel generally opposite said pump mount location, said counterweight being so located such that when said flywheel is caused to rotate, said counterweight imparts a momentum to said flywheel; 
 said linearly actuated pump including an air/gas pump input capable of receiving air/gas at atmospheric pressure and an air/gas pump output capable of outputting air/gas which is pressurized by said linearly actuated pump when said piston is linearly actuated; and 
   b) a portable, pneumatic, power supply system comprising:
 a portable air/gas reservoir; 
 a pressure regulator in air/gas flow communication with said portable air/gas reservoir, said pressure regulator including an air/gas pressure adjustment mechanism capable of adjusting pressure of air/gas outflow therefrom; 
 a power supply air/gas outlet including a coupler mechanism for connecting said power supply air/gas outlet to a pneumatically operable tool; and 
 wherein said air/gas pressure adjustment mechanism is capable of operating to deliver a plurality of selected air/gas pressures which correspond to pressures useful for operating a plurality of pneumatic tools; and 
 wherein said compressor is capable of manufacturing compressed air/gas for filling said portable air/gas reservoir with compressed air/gas; and 
 wherein said air/gas pump output is selectively gas-flow connectable and disconnectable to and from said portable, pneumatic, power supply system for filling said portable air/gas reservoir with compressed air/gas. 
   
   
   
       2 . The system according to  claim 1  wherein said portable air/gas reservoir contains air/gas compressed to a high initial pressure,
 wherein said pressure regulator is connected to said portable air/gas reservoir such that compressed air/gas which exits said portable air/gas reservoir is delivered to said pressure regulator and wherein said pressure regulator is capable of receiving said compressed air/gas and thereafter delivering said air/gas to said interconnect at a reduced pressure relative to said high initial pressure as contained in said portable air/gas reservoir.   
   
   
       3 . The system according to  claim 2  wherein said air/gas pressure adjustment mechanism is capable of adjusting said air/gas flow output pressure in substantially continuously variable increments between at least an intermediate output pressure and a substantially zero output pressure. 
   
   
       4 . The system according to  claim 2  wherein said air/gas pressure adjustment mechanism is capable of effecting regulation of air/gas flow output pressure from said pressure regulator; said air/gas pressure adjustment mechanism being selectively capable of adjusting said air/gas flow output pressure within a substantially continuously variable range between said high initial pressure as contained in said portable air/gas reservoir and a substantially zero output pressure. 
   
   
       5 . The system according to  claim 3  further including an interconnect attached to and providing air/gas flow communication between said pressure regulator and a power supply air/gas outlet wherein said air/gas flow output pressure, during system operation, is delivered to said interconnect for delivery for end pneumatic use. 
   
   
       6 . The system according to  claim 5  wherein said interconnect comprises a flexible conduit, said flexible conduit having a quick connect-disconnect coupler attached proximal one end thereof capable of connecting and disconnecting to a pneumatically operable device. 
   
   
       7 . The system according to  claim 6  wherein said pressure regulator is so constructed such that said air/gas flow output pressure is regulated by said pressure regulator in a single stage regulation step comprising:
 receiving air/gas flow at said high initial pressure and thereafter delivering said air/gas flow at reduced pressures relative to said initial high pressure, said reduced pressures being selectable from within a range of air/gas pressures suitable for operating a plurality of pneumatic tools.   
   
   
       8 . The system according to  claim 6  wherein said pressure regulator is a dual stage regulator and said air/gas flow output pressure is regulated by said pressure regulator in a dual stage regulation comprising:
 receiving air/gas flow at said high initial pressure;   reducing said high initial pressure of said air/gas flow to an intermediate pressure at a first stage;   reducing said intermediate pressure of said air/gas flow to a working pressure at a second stage, said working pressure being selected from within a range of pressures suitable for operating a plurality of pneumatic tools.   
   
   
       9 . The system according to  claim 8  wherein said working pressure is selected from between approximately a value greater than 0 and a value equal to or less than 500 psi. 
   
   
       10 . The system according to  claim 7  or  8  further including:
 a plurality of pneumatically operable tools having universal connectors; and wherein said quick connect-disconnect coupler of said conduit is capable of being selectively, alternately connected to said plurality of pneumatically operable tools such that, when connected, said tools are in air/gas flow communication with said pressure regulator via said conduit.   
   
   
       11 . The system according to  claim 10  wherein said system is so configured so as to be capable of providing a workable output pressure to operate a plurality of pneumatic tools, including at least: a nail gun, an air wrench, a paint sprayer, an inflator, a stapler, a micro pinner, a pin tacker, and a drill. 
   
   
       12 . The system according to  claim 7  or  8  wherein said pressure regulator further includes an air/gas flow input which is so constructed so as to be capable of being communicably connected to said compressor so that said high pressure compressor can replenish gas pressure to said portable gas reservoir. 
   
   
       13 . The system according to  claim 1  wherein said portable air/gas reservoir has a rated pressure of at least 3000 psi and weighs less than approximately 10 lbs. 
   
   
       14 . The system according to  claim 1  wherein said portable air/gas reservoir has a rated pressure of at least 5000 psi and weighs less than 50 lbs. 
   
   
       15 . The system according to  claim 2  wherein said portable air/gas reservoir is configured to be attached to a user-wearable belt. 
   
   
       16 . The system according to  claim 2  wherein said portable air/gas reservoir is configured to be attached to a user-wearable back harness. 
   
   
       17 . The system according to  claim 8  wherein said intermediate pressure is selected from between approximately 800-4500 psi and said working pressure is less than or equal to approximately 500 psi. 
   
   
       18 . A system for manufacturing and providing compressed air/gas to a portable, pneumatic, power supply system comprising:
 a) a compressor comprising:
 a motor operably connected to a flywheel and capable of rotating said flywheel; 
 a linearly actuated pump having a first end and a second end, said first end pivotally connected to said flywheel at a pump mount location and said second end pivotally connected to a frame member, said pump including a piston which is linearly actuated when said flywheel is caused to rotate; 
 a counterweight connected to said flywheel at a location on said flywheel generally opposite said pump mount location, said counterweight being so located such that when said flywheel is caused to rotate, said counterweight imparts a momentum to said flywheel; 
 said linearly actuated pump including an air/gas pump input for receiving air/gas at atmospheric pressure and an air/gas pump output for outputting air/gas which is pressurized by said linearly actuated pump when said piston is linearly actuated; and 
   b) a portable, pneumatic, power supply system comprising:
 a portable air/gas reservoir containing air/gas compressed to a high initial pressure; a pressure regulator in air/gas flow communication with said portable air/gas reservoir, said pressure regulator including an air/gas pressure adjustment mechanism capable of adjusting pressure of air/gas outflow therefrom, said pressure regulator being so connected to said portable air/gas reservoir such that compressed air/gas which exits said portable air/gas reservoir is delivered to said pressure regulator; 
 an interconnect attached to and providing air/gas flow communication between said pressure regulator and an air/gas outlet, said interconnect comprising a flexible conduit and said air/gas outlet comprising a quick connect-disconnect coupler attached proximal one end of said flexible conduit; 
 wherein said air/gas pressure adjustment mechanism is capable of operating to deliver a plurality of selected air/gas pressures which correspond to pressures useful for a plurality of pneumatic end uses; 
 wherein said pressure regulator is capable of receiving said compressed air/gas and thereafter delivering said air/gas to said interconnect at a reduced pressure relative to said high initial pressure as contained in said portable air/gas reservoir; and 
 wherein said pressure regulator is a dual stage regulator and said air/gas flow output pressure is regulated by said pressure regulator in a dual stage regulation comprising: 
 receiving air/gas flow at said high initial pressure; 
 reducing said high initial pressure of said air/gas flow to an intermediate pressure at a first stage; 
 reducing said intermediate pressure of said air/gas flow to a working pressure at a second stage, said working pressure being selected from within a range of pressures suitable for operating a plurality of pneumatically operable tools; and 
 wherein said compressor is capable of manufacturing compressed air/gas for filling said portable air/gas reservoir with compressed air/gas; and 
 wherein said air/gas pump output is selectively gas-flow connectable and disconnectable to and from said portable, pneumatic, power supply system for filling said portable air/gas reservoir with compressed air/gas. 
   
   
   
       19 . The system according to  claim 18  wherein said working pressure is selected from between approximately a value greater than 0 and a value equal to or less than 500 psi. 
   
   
       20 . The system according to  claim 19  further including:
 a plurality of pneumatically operable tools having universal connectors; and wherein said quick connect-disconnect coupler of said conduit is capable of being selectively, alternately connected to said plurality of pneumatically operable tools such that, when connected, said tools are in air/gas flow communication with said pressure regulator via said conduit.   
   
   
       21 . The system according to  claim 18  wherein said system is so configured so as to be capable of providing a said working output pressure to operate a plurality of pneumatic tools, including at least: a nail gun, an air wrench, a paint sprayer, an inflator, a stapler, a micro pinner, a pin tacker, and a drill. 
   
   
       22 . The system according to  claim 18  wherein said pressure regulator further includes an air/gas flow input which is so constructed so as to be capable of being communicably connected to said compressor so that said compressor can replenish air/gas pressure to said portable air/gas reservoir. 
   
   
       23 . The system according to  claim 1  or  18  wherein said portable air/gas reservoir is constructed, at least in part, from a material selected from the group consisting of: steel, aluminum, and carbon fiber. 
   
   
       24 . The system according to  claim 1  or  18  wherein said linearly actuated pump comprises a shell housing and a linearly extendable and retractable piston, said piston being linearly translatable to effect a pressurization of air/gas. 
   
   
       25 . The system according to  claim 24  wherein, during operation, said flywheel has a rotational direction which causes alternating push and pull strokes of said piston and wherein said counterweight is connected to said flywheel in such a location generally opposite said pump mount location such that when said flywheel is rotating to cause a push stroke of said piston, said counterweight is located such that gravity acts on said counterweight in a direction which is generally co-directional with said rotational direction of said flywheel; and
 when said flywheel is rotating to cause a pull stroke of said piston, said counterweight is located such that gravity acts on said counterweight in a direction which is generally opposite said rotational direction of said flywheel.   
   
   
       26 . The system according to  claim 25  further wherein during a push stroke of said piston, said counterweight assists in effecting a completion of said push stroke and during a pull stroke of said piston, said counterweight adds resistance to effecting a completion of said pull stroke. 
   
   
       27 . The system according to  claim 25  wherein said position and location of counterweight causes said counterweight, during directional motion of said flywheel, to alternately assist and resist push and pull strokes of said piston thereby to effect a generally consistent rotational velocity of said flywheel during compressor operation. 
   
   
       28 . The system according to  claim 18  wherein said compressor is capable of pressuring air up to a pressure of at least approximately 6000 psi. 
   
   
       29 . The system according to  claims 18  or  28  wherein said linearly actuated pump includes a coolant fluid path through which a coolant can be transmitted thereby to temperature regulate said linearly actuated pump during operation. 
   
   
       30 . The system according to  claim 29  wherein said coolant fluid path is a fluid passageway located internal to said shell housing in proximity to said linearly extendable and retractable piston. 
   
   
       31 . The system according to  claim 30  further including a coolant reservoir in fluid communication with said coolant fluid path and a coolant pump for transmitting coolant from said coolant reservoir and through said coolant fluid path.