AU2019202008B2

AU2019202008B2 - Air Compressor

Info

Publication number: AU2019202008B2
Application number: AU2019202008A
Authority: AU
Inventors: Anton Michele Eduardo MESSINA; James Marshal RENOU
Original assignee: Aeroklas Asia Pacific Group Pty Ltd
Current assignee: Aeroklas Asia Pacific Group Pty Ltd
Priority date: 2019-03-20
Filing date: 2019-03-22
Publication date: 2024-06-20
Anticipated expiration: 2039-03-22
Also published as: CN111720288A; AU2019202008A1; CN111720288B; AU2022100008A4

Abstract

An air compressor comprises a motor, a sleeve, a connecting rod, a piston, a valve plate, an air filter, a cover, a crankcase, an air storage tank, a plug, a cylinder head, an air tank end cap, a motor end cap, a fan, a fan cover and a safety valve. The crankcase 5 has a hole. One end of the hole communicates with a hole of the cylinder head while the other end of the hole communicates with a recess of the crankcase. The air storage tank comprises a centre void, an inner wall, an outer wall, a plurality of connecting walls and a plurality of air storage openings. The centre void serves to accommodate a motor housing. The plug is attached to a threaded hole of the outer wall. The air tank end cap is provided 10 with a plurality of recesses. The air storage opening is communicated with the recess of the crankcase and the recess of the air tank end cap. The provision of a plurality of spaces between the air tank end cap and the motor end cap. The fan is located between the motor end cap and the fan cover. The motor turns the fan to provide cooling to the internal components. The compressor is designed with an integrated storage tank. The storage tank 15 is aluminium extrusion with internal ribs to provide both conduction and convection heat dissipation when combined with the action of the cooling fan.

Description

AIR COMPRESSOR FIELD OF THE INVENTION

The present invention relates to an air compressor.

BACKGROUND OF THE RELATED ART

The present invention relates to an air compressor.

The air compressor serves to provide a high-pressure air for using in several applications, for example the inflation of the car tires, motorcycle tires, bicycle tires and the operation of pneumatic locking differentials. Moreover, the small size air compressors can be divided in many types depend on their installation such as a vehicle mount type and a portable type. In the vehicle mount type, the user can select a position to install the air compressor on the vehicle such as to a side wall of the truck bed using screw fasteners. On the other hand, the portable type air compressor will provide a base portion of the air compressor which can be stood on the flat surface. This allows the user to be able to move the air compressor for using in vary places with convenient. An example of the air compressor has previously been invented. For example, the United States Patent No. 9,476,416 by Chi-Wen Chen. The United States Patent No. 9,476,416 mentioned the air compressor which comprises a case member, a driving member and a cylinder member. The device according to the United States Patent No 9,476,416 lacks an air storage tank resulting in it may consume much time for fully inflate the work piece.

The preceding discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application.

SUMMARY OF THE INVENTION

It is an object of this invention to provide an air compressor which ameliorates, mitigates or overcomes, at least one disadvantage of the prior art, or which will at least provide the public with a practical choice.

The present invention provides a small size air compressor which is suitable for applications both vehicle mount type and portable type.

An air compressor according to the present invention comprises; a motor with a shaft for driving a fan and a crankshaft; a sleeve that is installed to a crankcase; a connecting rod that is installed to the crankshaft, the connecting rod has a piston at one end, the piston has a reed valve installed, the piston is in the sleeve; a valve plate with a reed valve installed; an air filter that is attached to a cover; the cover that is attached to the crankcase; the crankcase comprises a plurality of recesses, each recess is located adjacent to one end of a connecting wall of an air storage tank, the crankcase has at least one hole which has two ends, one end of the hole communicates with a hole of a cylinder head, the other end of the hole communicates with the recess of the crankcase, the crankcase serves to cover the first end of the motor housing and cover the first end of the air storage tank, the crankcase has a plurality of holes for allowing the air to flow through; the air storage tank comprises a centre void, an inner wall, an outer wall, a first end, a second end and a plurality of connecting walls, the centre void serves to accommodate motor housing, each connecting wall is located apart, the connecting wall serves to connect the inner wall with the outer wall, the connecting walls extend along the length of the air storage tank to form a plurality of air storage openings, the air storage opening has two ends, the one end of the air storage opening communicates with the recess of the crankcase, the other end of the air storage opening communicates with a recess of an air tank end cap, the outer wall has at least a threaded hole pass through it; at least one plug, the plug is attached to the threaded hole of the outer wall of the air storage tank, the plug can be removed to connect a device to the threaded hole to receive compressed air; the cylinder head that is attached to the crankcase, the cylinder head has at least one hole to communicate with a hole of a safety valve; the air tank end cap that is attached to the crankcase; the air tank end cap has a plurality of recesses, each recess is located adjacent to the other end of the connecting wall of the air storage tank, the air tank end cap has mounting points to secure a motor end cap, the air tank end cap serve to cover the second end of the air storage tank; the fan that is located between the motor end cap and the fan cover, the fan serves to draw the air to flow through the holes of the crankcase, through a space between the motor housing and the air storage tank, through the space between the air tank end cap and the motor end cap, through the holes of the fan cover and out of the air compressor; the fan cover with a plurality of holes for allowing the air to flow through, wherein the fan cover is attached to the air tank end cap; and the safety valve that is installed to the cylinder head, when the air pressure inside the cylinder head rises above a defined limit, the safety valve will operate by discharging the air inside the cylinder head to outside the cylinder head. An air compressor according to the present invention comprises: a motor with a shaft for driving a fan and a crankshaft; a sleeve that is installed to a crankcase; a connecting rod that is installed to the crankshaft, the connecting rod has a piston at one end, the piston has a reed valve installed, the piston is in the sleeve; a valve plate with a reed valve installed; an air filter that is attached to a cover; the cover that is attached to the crankcase; characterized in that: the crankcase comprises a plurality of recesses , each recess is located adjacent to one end of a connecting wall of an air storage tank , the crankcase has at least one hole which has two ends, one end of the hole communicates with a hole of a cylinder head, the other end of the hole communicates with the recess of the crankcase, the crankcase serves to cover the first end of a motor housing and cover the first end of the air storage tank , the crankcase has a plurality of holes for allowing the air to flow through; and further comprises: the air storage tank comprises a centre void, an inner wall , an outer wall, the first end , the second end and a plurality of connecting walls , the centre void serves to accommodate motor housing , each connecting wall is located apart, the connecting wall serves to connect the inner wall with the outer wall, the connecting walls extend along the entire length of the air storage tank to form a plurality of air storage openings, the air storage opening has two ends, one end of the air storage opening communicates with the recess of the crankcase, the other end of the air storage opening communicates with a recess of an air tank end cap , the outer wall has at least a threaded hole pass through it; at least one plug, the plug is attached to the threaded hole of the outer wall of the air storage tank, the plug can be removed to connect a device to the threaded hole to receive compressed air; the cylinder head that is attached to the crankcase, the cylinder head has at least one hole to communicate with a hole of a safety valve; the air tank end cap that is attached to the crankcase; the air tank end cap has a plurality of recesses , each recess is located adjacent to the other end of the connecting wall of the air storage tank

, the air tank end cap has a middle hole to accommodate a motor end cap , the air tank end cap serves to cover the second end of the air storage tank ; the motor end cap that is attached to the air tank end cap, when the motor end cap is installed in the air tank end cap, there is a plurality of spaces between the air tank end cap and the motor end cap, the motor end cap covers the second end of the motor housing ; the fan that is located between the motor end cap and the fan cover, the fan serves to draw the air to flow through holes of the crankcase, through a space between the motor housing and the air storage tank, through spaces between the air tank end cap and the motor end cap, through holes of the fan cover and out of the air compressor; the fan cover with a plurality of holes for allowing the air to flow through, wherein the fan cover is attached to the air tank end cap; and the safety valve that is installed to the cylinder head , when the air pressure inside the cylinder head rises above a defined limit, the safety valve will operate by discharging the air inside the cylinder head to outside the cylinder head.

An object of the present invention is to provide an air compressor with an integrated air storage tank result in it can extend the time between power cycles of the compressor, without a large size increase of the assembly.

Another object of the present invention is to provide cooling for the air storage tank resulting in the air storage tank has low temperature and safe for the user. Especially, this helps the air storage tank not to scald the user's hand when the user inserts or removes the connector or the air fitting to/from the air storage tank.

Another object of the present invention is to provide cooling for the components of the air compressor such as the motor housing and the crankcase resulting in the components of the air compressor have low temperature. This extends the life of components including seals and increases the operation duty cycle defined as the percentage run time (versus cool-down time) in a given interval.

Another object of the present invention is to provide the air storage tank which is able to make from an aluminium extrusion.

Other objects will become apparent from the following description and drawings.

BRIEF DISCRIPTION OF THE DRAWINGS

Further features of the present invention are more fully described in the following description of a non-limiting embodiment thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:

Fig. 1 is a rear perspective view showing the air compressor according to an embodiment of the present invention;

Fig. 2 is a rear view of the fan cover according to the embodiment of figure 1;

Fig. 3 is a rear perspective view showing the motor end cap according to the embodiment of figure 1;

Fig. 4 is a rear perspective view showing the cylinder head, the crankcase, the seal and the air storage tank according to the embodiment of figure 1;

Fig. 5 is a rear view of the crankcase;

Fig. 6 is a rear perspective view showing the air tank end cap according to the embodiment of figure 1;

Fig. 7 is a front perspective view showing the air tank end cap according to the embodiment of figure 1;

Fig. 8 is a partial cross sectional view and a perspective view showing the air compressor according to the embodiment of figure 1;

Fig. 9 is an enlarge view taken from the circular chain line in Fig. 8 showing the safety valve;

Fig. 10 is a top view showing the air compressor according to the embodiment of figure 1;

Fig. 11 is a cross sectional view taken along line 11-11 in Fig. 10;

Fig. 12 is a cross sectional view and a rear perspective view showing the air compressor according to the embodiment of figure 1;

Fig. 13 is a rear view showing the air compressor according to the embodiment of figure 1;

Fig. 14 is a cross sectional view taken along line 14-14 in Fig. 13;

Fig. 15 is a partial cross sectional view taken along line 15-15 in Fig. 13; and

Fig. 16 is a cross sectional view taken along line 16-16 in Fig. 13.

In the drawings like structures are referred to by like numerals throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present invention.

FULL DISCLOSURE OF THE INVENTION

The present invention will be described in the following content with reference to the drawings. Each drawing includes numbers designating various parts. The same numbers shown in the drawings refer to the same parts.

The present invention provides the small size air compressor which is suitable for both applications, vehicle mount type and portable type.

Fig. 1 shows the air compressor 30 according to the present invention. Fig. 1 also shows the components such as the crankcase 31, the cylinder head 32, the air storage tank 33, the air tank end cap 35, the fan cover 36, the base 39 and the wire 60. When the user wants to use the device, the user need to remove at least one plug such as plug 57 or plug 58 of the air storage tank 33. After that, the user need to connect a connector or an air fitting of an air hose to the threaded hole 61 or 62 at the air storage tank for replacement of the plug. After that the user need to connect the wire 60 to a power supply, using a supplied wire loom (not shown). Upon actuating the loom power switch (not shown) the motor begins to operate, cause the part that attached with the shaft 40 rotate. The parts that attached to the shaft 40 are the fan 37 and the crankshaft 42.

Fig. 2 shows the fan cover 36 that comprises a plurality of holes 92 for insertion of screws 67, a plurality of holes 93 for allowing the air to flow through and a plurality of holes 94 for insertion of screws 68.

Fig. 3 shows the motor end cap 38 that comprises a middle hole 114 for insertion of the shaft 40 and two holes 115 for insertion of screws 113.

Fig. 4 shows the crankcase 31, the cylinder head 32, the seal 120 and the air storage tank 33 before assembled together.

The crankcase 31 comprises a top hole 71 communicates with a hole 97 which extends from front to back. The hole 97 allows air to enter the cylinder via air filter cover 50, and accommodates the crankshaft 42 and the piston rod 43. At the rear of crankcase 31, there is a plurality of recesses 72 and a plurality of threaded holes 73 for insertion of screws 66, resulting in the air tank end cap 35 is attached to the crankcase 31 . At the top of crankcase 31, there is a hole 74 and a hole 75 for allowing the air to flow through and there is a plurality of threaded hole 76 for insertion of screws 70 for attachment of the cylinder head 32 to the crankcase 31 . After the components are assembled together, the positions of each recess 72 will adjacent to the connecting wall 87 of the air storage tank. The hole 74 serves to communicate between the hole 79 and the recess 72 (Fig. 14). The hole 75 serves to communicate between the hole 78 and the recess 72 (Fig. 16). The crankcase 31 further comprises an edge 106 to cover the first end 108 of the air storage tank 33 and seal 120.

The cylinder head 32 comprises a plurality of holes 81 for insertion of screws 70. There is a high-pressure chamber 77 (Fig. 8) above the valve plate 45. There is a threaded hole 63 (Fig. 4) for installation of the plug 52. There is a threaded hole 65 for installation of the plug 56. There is a hole 80 (Fig. 9) which communicates with the hole 110. The hole 110 is adjacent to the threaded hole 63. The hole 110 serves to accommodate the valve 54 and the spring 53. The cylinder head has the hole 78 for communication with the threaded hole 64 of the cylinder head.

The air storage tank 33 has a length "L" and comprises the centre void 82, the inner wall 98, the outer wall 99, the first end 108, the second end 109 and a plurality of connecting walls 87. The centre void 82 serves to accommodate the motor housing 34. The air storage tank 33 further comprises a plurality of fins 111 . The fin 111 extends from the inner wall 98 in the direction towards the middle axis of the air storage tank. The fin is positioned along the entire length of the air storage tank. The fins 111 provide stiffness and conduct heat to the air flow for convection heat transfer to the flowing air. Each connecting wall 87 is located apart. The connecting wall 87 serves to connect the inner wall 98 and the outer wall 99. The connecting walls 87 are positioned along the entire length of the air storage tank, resulting in forming a plurality of air storage openings. The air storage opening has two ends. The one end of the air storage opening communicates with the recess 72 of the crankcase. The other end of the air storage opening communicates with the recess 95 of the air tank end cap 35. The outer wall 99 has at least a through threaded hole. Fig. 4 shows four connecting walls 87 resulting in forming of four air storage openings namely the first air storage opening 83, the second air storage opening 84, the third air storage opening 85 and the fourth air storage opening 86. Fig. 4 shows a plurality of threaded holes which pass through the outer wall 99 namely the threaded hole 61 and the threaded hole 62 for installation two different sizes of air fitting to connect a hose or device.

The air storage tank 33 can be made from various materials. The present invention provides the air storage tank 33 which made from an aluminium extrusion with internal ribs to provide both conduction and convection heat dissipation when combined with the action of the cooling fan.

Fig. 5 shows the crankcase 31 comprising a plurality of holes 96. The hole 96 serves for allowing the air to flow through. Fig. 5 shows four recesses 72 locate at top, bottom, left and right side. The recess 72 serves as a passage way for the air to flow from an air storage opening to the next air storage opening.

Fig. 6 is the rear perspective view of the air tank end cap 35 which comprises the holes 89 for insertion of screws 66, the threaded holes 90 and 102 for screws which are dual purpose. The screws secure the fan cover 36 to the air tank end cap 35 and also connect the fan cover 36 to the base 39. Multiple mount orientations of the base are possible. Fig. 6 shows the threaded holes 91 for tightening of screws 113 to secure the motor end cap 38 to the air tank end cap 35 and shows the threaded holes 102 for tightening of screws 68 for securing the first end of base 39 to the air tank end cap 35.

Fig. 7 is the front perspective view of the air tank end cap 35 which comprises a plurality of recesses 95. The present invention provides four recesses 95. After the air tank end cap 35 is assembled with the air storage tank 33, each recess 95 will adjacent to the connecting wall 87 of the air storage tank 33 in a manner that the connecting wall 87 is aligned at middle of the recess 95, resulting in the recess 95 opens to two air storage openings which is divided by the connecting wall. The air tank end cap 35 further comprises an edge 107 for cover the second end 109 of the air storage tank 33 and a seal 121 (Fig. 16).

Fig. 8 shows the components after assembly of the air compressor 30 which comprises; the motor with the shaft 40 for driving the fan 37 and the crankshaft 42; the sleeve 44 that is installed to the crankcase 31 ; the connecting rod 43 that is installed to the crankshaft 42, the connecting rod 43 is cast in a single piece with the piston 112, the piston has the reed valve 46 installed, the piston is in the sleeve 44; the valve plate 45 with at least one reed valve 117 installed; the air filter that is attached to the cover 48; the cover 48 that is attached to crankcase 31 by screws 69 (Fig. ); the crankcase 31 comprises a plurality of recesses 72, each recess 72 is located adjacent to the end of connecting wall 87 of the air storage tank 33, the crankcase has at least one hole which has two ends, one end of the hole communicates with the hole of the cylinder head, the other end of the hole communicates with the recess 72 of the crankcase, the present invention provides the hole 74 communicates with the hole 79 of the cylinder head and provides the hole 75 communicates with the hole 78 of the cylinder head, the hole 74 and 75 communicate with the top recess 72, the crankcase 31 serve to cover the first end 41 of the motor housing 34 and cover the first end 108 of the air storage tank 33, the crankcase 31 has a plurality of holes 96 for allowing air flow; the air storage tank 33 comprises the centre void 82, the inner wall 98, the outer wall 99, the first end 108, the second end 109 and a plurality of connecting walls 87, the centre void 82 serves to accommodate the motor housing 34, each connecting wall 87 is located apart, the connecting wall 87 serves to connect the inner wall 98 with the outer wall 99, the connecting wall 87 extends along the entire length of the air tank forming a plurality of air storage openings, the air storage opening has two ends, one end of the air storage opening communicates with the recess 72 of the crankcase, the other end of the air storage opening communicates with the recess 95 of the air tank end cap 35, the outer wall 99 has at least a through threaded hole; at least one plug, the plug is attached to the through threaded hole of the outer wall 99 of the air storage tank, the plug can be removed to connect a device to the threaded hole to receive compressed air; the cylinder head 32 that is attached to the crankcase, the cylinder head has at least one hole which communicates with the hole of a safety valve; the air tank end cap 35 that is attached with the crankcase; the air tank end cap has a plurality of recesses 95, each recess 95 is located adjacent to the end of connecting wall 87 of the air storage tank 33, the air tank end cap has the middle hole 88 to accommodate the motor end cap 38, the air tank end cap serves to cover the second end 109 of the air storage tank 33; the motor end cap 38 that is attached to the air tank end cap, when installed the motor end cap with the air tank end cap, resulting in forming of a plurality of space 105 between the air tank end cap and the motor end cap, the motor end cap covers the second end 47 of the motor housing 34; the fan 37 which is located between the motor end cap 38 and the fan cover 36, the fan 37 serves to draw the air to flow through the holes 96 of the crankcase, through the space 104 between the motor housing and the air storage tank, through the space 105 between the air tank end cap and the motor end cap, through the holes 93 of the fan cover and leave the air compressor; the fan cover 36 with a plurality of holes 93 for allowing air to flow through, wherein the fan cover is attached to the air tank end cap; the screws 119 which serves to securing the front end of base 39 to the crankcase

31 ; and the safety valve which is installed to the cylinder head 32, when the air pressure inside the cylinder head rises above a defined limit, the safety valve will operate by discharging the air inside the cylinder head to outside the cylinder head.

When the user connects the wire 60 to the power supply, the motor rotates result in the components attached to the shaft 40 rotate. The components attached to the shaft 40 are the fan 37 and the crankshaft 42. After the fan 37 rotates resulting in the outside air is drawn to flow in the direction of arrows 300 through the holes 96 into the air compressor. After that, the air will flow through the space 104 between the motor housing and the air storage tank, result in forming heat convection, cooling the motor housing 34 and the air storage tank 33. The air continues flow through the spaces 105 between the motor end cap and the air tank end cap, through the holes 93 and out of the air compressor 30 in the direction of arrows 400. When the crankshaft 42 rotates, the connecting rod 43 and piston 112 will move. In the intake stroke, the piston will move away from the valve plate 45, creating low pressure in space 100. The reed valve 46 will open, the ambient air outside the air compressor 30 will flow in the direction of arrows 200 through the holes of air filter cover 50, through an air filter material 51, through the hole 103 of the base of air filter 49 and flow into the hole 97, and through open valve 46 into the space 100. After that, the compression stroke for compressing the air in the space 100 will begin. The piston will move towards the valve plate 45, the reed valve 46 will close. When pressure inside space 100 is above the pressure in the high-pressure chamber 77, the reed valve 117 will open resulting in the air from the space 100 flows through the hole of the valve plate 45 into the high-pressure chamber 77 above the valve plate. The high-pressure air in the high-pressure chamber 77 will flow via the hole 78 and 79 into the air storage tank.

Fig. 8 also shows the air tank end cap 35 which is attached to the crankcase 31 by screws 66. The screw 66 is inserted through the hole 89 of the air tank end cap, through the air storage opening and fasten to the threaded hole 73 of the crankcase 31 .

Furthermore, Fig. 8 shows the valve plate 45 which is installed at the location between the cylinder head 32 and the sleeve 44.

Fig. 9 shows the components of the safety valve. The cylinder head 32 comprises the hole 80 communicates with the hole 110. The hole 110 communicates with the threaded hole 63. In the case of the air compressor 30 is operated without a pressure cut-off switch, air will be compressed until the air pressure in the air storage tank rises above the defined limit. The safety valve will operate for discharging the air outside the cylinder head 32.

The safety valve comprises; the plug 52 with a hole 101, the plug 52 is fastened to the threaded hole 63 of the cylinder head; the spring 53, wherein the one end of the spring pushes the shoulder of the valve 54, the other end of the spring pushes the plug 52; and the valve 54 that is a cylindrical shaped bar with the shoulder; at the valve-close position, the valve 54 will close the hole 80, prevents the air from the high-pressure chamber 77 in the cylinder head to flow into the hole 110, at the valve-open position, the high-pressure air from the high-pressure chamber 77 inside the cylindrical head will flow into the hole 80 and push the valve 54 and move the valve 54 towards the plug 52 resulting in the spring 53 is compressed and the air from the space inside the cylinder head can flow through the hole 80, through the hole 110 and through the hole 101 of the plug and leave the cylinder head.

Fig. 10 shows the air compressor 30 which comprises a plurality of plugs 57 resulting in several air hoses or devices can be installed to the air compressor 30, thus compressed air can be supplied to several applications simultaneously.

Fig. 11 shows the components of air compressor 30 especially the positions of all four recesses 72 which align with each connecting walls 87.

Fig. 11 also shows the top recess 72 which is overlapped by the vertical connecting wall 87 in the middle position of recess 72, thus forms the left portion recess 72L communicates with the first air storage opening 83 and forms the right portion recess 72R communicates with the second air storage opening 84.

Fig. 11 also shows the left recess 72 which is overlapped by the horizontal connecting wall 87 in the middle position of recess 72, thus forms the top portion recess 72T communicates with the first air storage opening 83 and forms the bottom portion recess 72B communicates with the third air storage opening 85.

Fig. 11 also shows the right recess 72 which is overlapped by the horizontal connecting wall 87 in the middle position of recess 72, thus forms the top portion recess 72T communicates with the second air storage opening 84 and forms the bottom portion recess 72B communicates with the fourth air storage opening 86.

Fig. 11 also shows the bottom recess 72 which is overlapped by the vertical connecting wall 87 in the middle position of recess 72, thus forms the left portion recess 72L communicates with the third air storage opening 85 and forms the right portion recess 72R communicates with the fourth air storage opening 86.

The alignment of recesses and connecting walls as mentioned above resulting in the air in all four air storage openings can be communicated to each other.

Fig. 11 also shows the plug 57 attached to the threaded hole 62 and shows each screw 66 passes through each air storage opening. Furthermore, shows the hole 79 communicates with the hole 74, the hole 78 communicates with the hole 75. The hole 74 and the hole 75 communicate with the top recess 72. Fig. I also shows plugs 59 installed at bottom region of the air storage tank. The threaded holes 61 and 62 in the bottom of the air storage tank are mirror opposites of the holes in the top, so that, depending on mounting configuration, there are 4 to 8 ports available to connect devices.

Fig. 12 shows the components of the air compressor 30, shows the first air storage opening 83, the second air storage opening 84, the third air storage opening 85 and the fourth air storage opening 86 which are located surround the motor housing 34. There is the space 104 between the inner wall 98 of air storage tank and the motor housing. The outside cool air flows through space 104 thus can remove heat from the air storage tank 33 and the motor housing 34 efficiently.

Fig. 12 also shows the positions of the components of the air compressor 30, shows three plugs installed to the cylinder head 32 namely plug 56, plug 52 and plug 55, shows four screws 66, each screw pass through the first air storage opening 83, the second air storage opening 84, the third air storage opening 85 and the fourth air storage opening 86 respectively.

Fig. 13 shows position of the hole 79 of the cylinder head which communicates to the hole 74 of the crankcase, the hole 74 of the crankcase communicates to the recess 72, the recess 72 communicates to the hole 75 of the crankcase and the hole 75 of the crankcase communicates to the hole 78 of the cylinder head.

Fig. 14 and Fig. 16 are the cross sectional view which show components of the air compressor 30 when accumulating the high-pressure air in the air storage tank 33. The working concept is that after the user connects the air compressor 30 to the power supply, the motor will operate to rotate the crankshaft 42. When the piston 112 moves towards the valve plate 45, the air in the space 100 is compressed and in the same time, the air is drawn through the air filter into the hole 97 of the crankcase.

Compression of air in the space 100 is done by the piston 112 moves towards valve plate 45 while the reed valve 46 close. When pressure in space 100 is greater than high pressure chamber 77, the reed valve 117 open, resulting in the compressed air in the space 100 flows through the hole of the valve plate 45 into the high-pressure chamber 77.

Ambient air is drawn into the hole 97 of the crankcase by the piston moves away from valve plate 45 because this motion creates low pressure in space 100, causing reed valve 46 open. So, the outside air flow passes through the holes of the air filter cover 50, through the filter material, through the hole 103 of the filter base 49 and flow into the hole 97 of the crankcase, through reed valve 46 into space 100.

When the motor continues operate, the high-pressure air from the high-pressure chamber 77 will flow into all four air storage openings namely; the high-pressure air from the high-pressure chamber 77 flows through the hole 79, through the hole 74, pass the left portion recess 72L into the first air storage opening 83 in the direction as shown by the arrows 500 in Fig. 14; the high-pressure air from the high-pressure chamber 77 flow through the hole 78, through the hole 75, pass the right portion recess 72R into the second air storage opening 84 in the direction as shown by the arrows 500 in Fig. 16; the high-pressure air from the first air storage opening 83 flows through the top portion recess 72T into the bottom portion recess 72B and flows into the third air storage opening 85; the high-pressure air from the second air storage opening 84 flows through the top portion recess 72T into bottom portion recess 72B and flows into the fourth air storage opening 86; the high-pressure air from each air storage opening flow from the first end 108 to the second end 109 until hit the air tank end cap 35. From the above described, each recess 95 of the air tank end cap is positioned adjacent to the other end of the connecting wall 87, thus form the left portion recess 95L, the right portion recess R, the top portion recess 95T and the bottom portion recess 95B. Therefore all four air storage openings, all four recesses 72 of the crankcase and all four recesses 95 of the air tank end cap can communicate to each other. Therefore the high-pressure air can flow pass through all four air storage openings, through all four recesses 72 of the crankcase and through all four recesses 95 of the air tank end cap. Using this arrangement means that devices can be fitted to any port 61 or 62, the pressure inside the tank will be uniform.

Fig. 15 is a cross sectional view which shows the screw 68 pass through the hole 116 of the base 39, through the hole 94 of the fan cover 36 and fasten to the threaded hole 102 of the air tank end cap 35, thus the rear portion of the base 39 is attached to the air tank end cap 35.

Since the air compressor according to the present invention provides the air storage tank, thus the number of power cycles to run a device such as a pneumatic locking differential is reduced.

Since the air compressor according to the present invention provides cooling to the air storage tank, thus the air storage tank has low temperature and safe for the user. Especially, help the air storage tank not to scald the user's hand when the user inserts or removes the connector or air fitting to/from the air storage tank.

Since the air compressor according to the present invention provides cooling to the components of the air compressor, thus the components have low temperature. Therefore the components including seals have long life and the duty cycle of operation is increased.

Also, the air compressor according to the present invention provides the air storage tank which can be made from the aluminium extrusion.

Modifications and variations such as would be apparent to the skilled addressee are considered to fall within the scope of the present invention. The present invention is not to be limited in scope by any of the specific embodiments described herein. These embodiments are intended for the purpose of exemplification only. Functionally equivalent products, formulations and methods are clearly within the scope of the invention as described herein. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well known processes, well-known device structures, and well-known technologies are not described in detail.

Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprise", "comprises," "comprising," "including," and "having," or variations thereof are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Claims

1. An air compressor comprises: a motor with a shaft for driving a fan and a crankshaft; a sleeve that is installed to a crankcase; a connecting rod that is installed to the crankshaft, the connecting rod has a piston at one end, the piston has a reed valve installed, the piston is in the sleeve; a valve plate with a reed valve installed; an air filter that is attached to a cover; the cover that is attached to the crankcase; characterized in that: the crankcase (31) comprises a plurality of recesses (72), each recess (72) is located adjacent to one end of a connecting wall (87) of an air storage tank (33), the crankcase has at least one hole which has two ends, one end of the hole communicates with a hole of a cylinder head (32), the other end of the hole communicates with the recess (72) of the crankcase, the crankcase (31) serves to cover the first end (41) of a motor housing (34) and cover the first end (108) of the air storage tank (33), the crankcase (31) has a plurality of holes (96) for allowing the air to flow through; and further comprises: the air storage tank (33) comprises a centre void (82), an inner wall (98), an outer wall (99), the first end (108), the second end (109) and a plurality of connecting walls (87), the centre void (82) serves to accommodate motor housing (34), each connecting wall (87) is located apart, the connecting wall (87) serves to connect the inner wall (98) with the outer wall (99), the connecting walls (87) extend along the entire length of the air storage tank to form a plurality of air storage openings, the air storage opening has two ends, one end of the air storage opening communicates with the recess (72) of the crankcase, the other end of the air storage opening communicates with a recess (95) of an air tank end cap (35), the outer wall (99) has at least a threaded hole pass through it; at least one plug, the plug is attached to the threaded hole of the outer wall (99) of the air storage tank, the plug can be removed to connect a device to the threaded hole to receive compressed air; the cylinder head (32) that is attached to the crankcase, the cylinder head has at least one hole to communicate with a hole of a safety valve; the air tank end cap (35) that is attached to the crankcase; the air tank end cap has a plurality of recesses (95), each recess (95) is located adjacent to the other end of the connecting wall (87) of the air storage tank (33), the air tank end cap has a middle hole (88) to accommodate a motor end cap (38), the air tank end cap serves to cover the second end (109) of the air storage tank (33); the motor end cap (38) that is attached to the air tank end cap, when the motor end cap is installed in the air tank end cap, there is a plurality of spaces (105) between the air tank end cap and the motor end cap, the motor end cap covers the second end (47) of the motor housing (34); the fan (37) that is located between the motor end cap (38) and the fan cover (36), the fan (37) serves to draw the air to flow through holes (96) of the crankcase, through a space (104) between the motor housing and the air storage tank, through spaces (105) between the air tank end cap and the motor end cap, through holes (93) of the fan cover and out of the air compressor; the fan cover (36) with a plurality of holes (93) for allowing the air to flow through, wherein the fan cover is attached to the air tank end cap; and the safety valve that is installed to the cylinder head (32), when the air pressure inside the cylinder head rises above a defined limit, the safety valve will operate by discharging the air inside the cylinder head to outside the cylinder head.

2. The air compressor according to claim 1, wherein the air storage tank comprises four connecting walls (87) and four air storage openings namely the first air storage opening (83), the second air storage opening (84), the third air storage opening (85) and the fourth air storage opening (86).

3. The air compressor according to claim 1 or 2, wherein the air storage tank (33) is made from an aluminium extrusion.

4. The air compressor according to claim 1, 2 or 3, wherein the cylinder head (32) has the hole (78) which communicates with the hole (75) of the crankcase (31), the hole (78) of the cylinder head also communicates with a threaded hole (64) of the cylinder head, the air compressor further comprises the plug (55) which is attached to the threaded hole (64) of the cylinder head (52).

5. The air compressor according to any one of claims 1 to 4, wherein the cylinder head (32) comprises a hole (80) communicates with a hole (110), the hole (110) communicates with a threaded hole (63), the safety valve comprises: a plug (52) that comprises a hole (101), the plug (52) is attached to the threaded hole (63) of the cylinder head; a spring (53), wherein one end of the spring pushes a shoulder of a valve (54), the other end of the spring pushes the plug (52); and the valve (54) that is a cylindrical shaped bar with the shoulder, at the valve-close position, the valve (54) will close the hole (80), prevents the air from a high-pressure chamber (77) in the cylinder head to flow into the hole ( 110), at the valve-open position, the air from the high-pressure chamber inside the cylindrical head will push the valve (54) to move towards the plug (52) resulting in the spring (53) is compressed and the air from the high-pressure chamber inside the cylinder head can flow through the hole (80), through the hole (110) and through the hole (101) of the plug and leave the cylinder head.

6. The air compressor according to any one of claims I to 5, the air storage tank further comprises a plurality of fins (111), each fin is located apart, each fin protrudes from the inner wall (98) in the direction towards the middle axis of the air storage tank, and the fin extends along the entire length of the air storage tank.

7. The air compressor according to any one of claims 1 to 6, wherein the air tank end cap has a plurality of holes. The air tank end cap (35) is attached to the crankcase (31) by a plurality of screws (66). Each screw (66) is inserted through the hole (89) of the air tank end cap, through the air storage opening and is tightened into the threaded hole (73) of the crankcase (31).

8. The air compressor according to any one of claims I to 7, wherein the valve plate (45) is located between the cylinder head (32) and the sleeve (44).

9. The air compressor according to claim 1 to 8, wherein the crankcase (31) further comprises an edge (106) for covering the first end (108) of the air storage tank.

10. The air compressor according to claim 1 to 9, wherein the air tank end cap (35) further comprises an edge (107) for covering the second end (109) of the air storage tank.

32 93 93 36 93 55 92 92

57 30 58 52 56 35 67 94 33 93 1/8

57 94 93 94 67 Fig. 2 31 60 38 115 93 114 36

39 68 115 Fig. 1 94 Fig. 3