Air Compressor

Abstract

A compact lightweight air compressor is provided with a DC motor to provide versatile use in the field where no AC power source is available. The air compressor includes a intercooler storage vessel for cooling and storing the compressed air as well as a cooling fan arrangement that allows cooling of all the air compressor components.

1 . An air compressor, comprising:
 an electric motor including a drive shaft;   a crank assembly connected to a first end of said drive shaft;   a connecting rod attached to said crank assembly;   a piston connected to said connecting rod;   a cylinder assembly fixedly mounted relative to a first end of said electric motor and receiving said piston therein;   a fan drivingly attached to a second end of said drive shaft;   a shroud surrounding said fan for directing cooling air axially along said motor housing from said second end toward said first end; and   an intercooler assembly connected to said cylinder assembly for receiving compressed air from said cylinder assembly.   
   
   
       2 . The air compressor according to  claim 1 , wherein said intercooler assembly includes a storage vessel and a plurality of cooling fins disposed on a surface of said storage vessel. 
   
   
       3 . The air compressor according to  claim 1 , wherein said intercooler assembly is disposed above said electric motor. 
   
   
       4 . The air compressor according to  claim 1 , wherein said intercooler assembly is connected to said cylinder assembly by a pipe attached to said cylinder assembly and extending a length of said intercooler assembly and attached to an end of said intercooler assembly furthest from said cylinder assembly. 
   
   
       5 . The air compressor according to  claim 4 , further comprising a cover plate covering said pipe. 
   
   
       6 . The air compressor according to  claim 1 , further comprising a base including a base wall and a plurality of sidewalls receiving said electric motor therein. 
   
   
       7 . The air compressor according to  claim 6 , further comprising a handle assembly mounted to said base. 
   
   
       8 . The air compressor according to  claim 6 , wherein said handle assembly includes a pair of end support members mounted to opposite ends of said base and a handle extending between said end support members. 
   
   
       9 . The air compressor according to  claim 6 , wherein said base includes a plurality of vent openings therein. 
   
   
       10 . The air compressor according to  claim 1 , wherein said motor is a DC electric motor. 
   
   
       11 . The air compressor according to  claim 1 , further comprising a crankcase attached to said first end of said electric motor, said cylinder assembly being mounted to said crankcase and said intercooler assembly being mounted to said crankcase. 
   
   
       12 . The air compressor according to  claim 1 , wherein said compressor has a height of no greater than 12 inches, a length of no greater than 14 inches and a width of no greater than 10 inches. 
   
   
       13 . The air compressor according to  claim 1 , wherein said compressor has a weight of no greater than 45 pounds. 
   
   
       14 . An air compressor, comprising:
 an electric motor including a drive shaft;   a crank assembly connected to a first end of said drive shaft;   a connecting rod attached to said crank assembly;   a piston connected to said connecting rod;   a cylinder assembly fixedly mounted relative to a first end of said electric motor and receiving said piston therein; and   an intercooler assembly connected to said cylinder assembly for receiving compressed air from said cylinder assembly, said intercooler assembly including a storage vessel and a plurality of cooling fins disposed on a surface of said storage vessel.   
   
   
       15 . The air compressor according to  claim 14 , wherein said intercooler assembly is disposed above said electric motor. 
   
   
       16 . The air compressor according to  claim 14 , wherein said intercooler assembly is connected to said cylinder assembly by a pipe attached to said cylinder assembly and extending a length of said intercooler assembly and attached to an end of said intercooler assembly furthest from said cylinder assembly. 
   
   
       17 . The air compressor according to  claim 16 , further comprising a cover plate covering said pipe. 
   
   
       18 . An air compressor, comprising:
 an electric motor including a drive shaft;   a crank assembly connected to a first end of said drive shaft;   a connecting rod attached to said crank assembly;   a piston connected to said connecting rod;   a cylinder assembly fixedly mounted relative to a first end of said electric motor and receiving said piston therein;   a storage vessel connected to said cylinder assembly for receiving compressed air from said cylinder assembly; and   a base including a base wall and a plurality of sidewalls receiving said electric motor therein.   
   
   
       19 . The air compressor according to  claim 18 , further comprising a handle assembly mounted to said base. 
   
   
       20 . The air compressor according to  claim 19 , wherein said handle assembly includes a pair of end support members mounted to opposite ends of said base and a handle extending between said end support members. 
   
   
       21 . The air compressor according to  claim 18 , wherein said base includes a plurality of vent openings therein. 
   
   
       22 . An air compressor, comprising:
 an electric motor including a drive shaft;   a crank assembly connected to a first end of said drive shaft;   a connecting rod attached to said crank assembly;   a piston connected to said connecting rod;   a cylinder assembly fixedly mounted relative to a first end of said electric motor and receiving said piston therein;   a vessel connected to said cylinder assembly for receiving compressed air from said cylinder assembly, wherein said compressor has a height of no greater than 12 inches, a length of no greater than 14 inches and a width of no greater than 10 inches.   
   
   
       23 . The air compressor according to  claim 22 , wherein said compressor has a weight of no greater than 45 pounds. 
   
   
       24 . The air compressor according to  claim 22 , wherein said electric motor is a DC electric motor. 
   
   
       25 . The air compressor according to  claim 23 , further comprising a base for receiving said electric motor and a handle mounted to said base.