Inter-stage coolant feed rod for a multi-stage air compressor

Abstract

Typically, multi-stage air compressor includes rotating and stationary components that require lubricating fluid to dissipate the heat generated during air compression. Thus, the lubricant fluid distribution can be inefficient when utilizing spray systems or tubes with orthogonal openings due to the challenges posed by the geometry of multi-stage air compressors. Accordingly, an inter-stage coolant feed rod for a multi-stage air compressor is disclosed wherein the non-orthogonal with non-linear shape design increases the utility and efficiency of lubricant fluid distribution and targets predetermined areas of high heat in the multi-stage air compressor.

Description

INTER-STAGE COOLANT FEED ROD FOR A MULTI-STAGE AIR COMPRESSORTECHNICAL FIELD[1] The embodiments described herein are generally directed to multi-stage air compressors, and, more particularly, to an inter-stage coolant feed rod for a multi-stage air compressor.BACKGROUND[2] A multi-stage air compressor includes multiple compression stages to achieve higher pressure ratios and efficiency. Each stage consists of rotating and stationary components, and effective cooling is vital to dissipate the heat generated during compression. Cooling oil plays a pivotal role in this process, serving as both a lubricant and a coolant. Cooling oil circulates throughout the compressor, lubricating moving parts such as rotors, bearings, and other rotating parts and / or high-friction areas while also absorbing heat. Thus, in a typical multi-stage air compressor, the cooling oil may be directed to rotors and bearings through a spray system or tubes with orthogonal (perpendicular) openings which permit a lubricant such as oil to be injected,[3] The lubricant fluid distribution can be inefficient when utilizing spray systems or tubes with orthogonal openings due to the challenges posed by the geometry of multi-stage air compressors, hi multi-stage air compressor with spray systems, the fluid’s atomization and dispersion might not be uniform, leading to uneven coverage and potential wastage. The orthogonal openings in tubes can create flow disruptions, turbulence, and dead zones, causing uneven fluid distribution along the length of the multi-stage air compressor. For example, U.S. Patent Nos. 4,452,575 and 11,215,182 disclose multi-stage oil-injection systems for multi-stage ah compressors, respectively. The utility and efficiency of lubricant fluid distribution may be increased by designing a non-orthogonal tube with non-linear shape that targets predetermined areas of high heat in the multi-stage air compressor.[4] The present disclosure is directed toward overcoming one or more of the problems discovered by the inventors.SUMMARY[5] In an embodiment, a multi-stage air compressor system comprises: a first stage air compressor located upstream from at least a second stage air compressor; a transfer volume located intermediate the first stage air compressor and the second stage air compressor: and a non-linear coolant feed rod coupled to a coolant oil supply and positioned at least partially in the transfer volume, the non-linear coolant feed rod having a first hollow tube segment with a first outer wall, a second hollow tube segment extending from the first hollow tube segment at a non-zero angle and in fluid communication with the first hollow tube segment, the second hollow tube segment further having a second outer wall having a plurality of exits extending through the second outer wall, and a third hollow tube segment extending from the second hollow tube segment at a nonzero angle and in fluid communication with the second hollow tube segment, with a third outer wall.[6] In an embodiment, a multi-stage air compressor system comprises: a first stage air compressor; a second stage air compressor located downstream from the first stage air compressor; a passage that connects an outlet of the first stage air compressor to an inlet of the second stage air compressor; and a coolant delivery rod coupled to a coolant oil supply and positioned at least partially in the passage, the coolant delivery rod having a first hollow tube segment with a first outer wall, a second hollow tube segment coupled within a passage exit of the first hollow tube segment at a non-zero angle and a passage inlet of a third hollow tube segment at a non-zero angle, the second hollow tube segment having a second outer wall with a plurality of exits extending through the second outer wall, wherein the second hollow tube segment is configured to direct the coolant oil supply in combination of the plurality of exits to at least a targeted location from the same coolant delivery rod; and the third hollow tube segment coupled with the second hollow tube segment at a non-zero angle and in fluid communication with the second hollow tube segment, the third hollow tube segment having a third outer wall.[7] In an embodiment, a method for compressing air with a multi-stage ah' compressor system comprises: routing the compressed air from a first stage to a second stage of the multi-stage air compressor system; and feeding coolant through a non-linear coolant feed rod coupled to a coolant oil supply and po sitioned at a junction of the first stage and the second stage of the multistage air compressor, the non-linear coolant feed rod having a first hollow tube segment with a first outer wall, a second hollow tube segment coupled with the first hollow tube segment at a non-zero angle and in fluid communication with the first hollow tube segment, the second hollow tube segment further having with a second outer wall having a plurality of exits extending through the second outer wall, and a third hollow tube segment coupled with the second hollow tube segment at a non-zero angle and in fluid communication with the second hollow tube segment, with a third outer wall.[8] In an embodiment, a multi-stage air compressor for compressing air comprises: a means for routing the compressed air from a first stage to a second stage of the multi-stage air compressor system; and a means for feeding coolant through a non-linear coolant feed rod coupled to a coolant oil supply and positioned at the junction of the first stage and the second stage of the multi-stage air compressor, the non-linear coolant feed rod having a first hollow tube segment with a first outer wall, a second hollow tube segment coupled with the first hollow tube segment at a non-zero angle and in fluid communication with the first hollow tube segment, the second hollow tube segment further having with a second outer wall having a plurality of exits extending through the second outer wall, and a third hollow tube segment coupled with the second hollow tube segment at a nonzero angle and in fluid communication with the second hollow tube segment, ■with a third outer wall.BRIEF DESCRIPTION OF THE DRAWINGS[9] The details of embodiments of the present disclosure, both as to their structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:

[0010] FIG . 1 illustrates a schematic diagram of a multi-stage air compressor, according to an embodiment:

[0011] FIG. 2 illustrates a perspective view of an inter-stage coolant feed rod assembly, according to an embodiment;

[0012] FIG. 3 illustrates a cross-sectional view of an inter-stage coolant feed rod assembly, according to an embodiment;

[0013] FIG. 4 and 5 illustrate an isometric view of an arched inter-stage coolant feed rod, according to an embodiment;

[0014] FIG. 6 illustrates an isometric view of a multi-arched iuter-stage coolant feed rod, according to an embodiment:

[0015] FIG. 7 illustrates an isometric view of a u-shaped inter-stage coolant feed rod, according to as embodiment;

[0016] FIG. 8 illustrates an isometric view of a helical inter-stage coolant feed rod, according to an embodiment;

[0017] FIG. SI illustrates an isometric view of an inter-stage coolant feed rod with multiple coolant sources, according to an embodiment;

[0018] FIG. 10 illustrates an isometric view of a circular inter-stage coolant feed rod, according to an embodiment;

[0019] FIG. 11 illustrates an isometric view of the plurality of exits targeting the compressed air discharge paths in an inter-stage coolant feed rod, according to an embodiment; and

[0020] FIG. 12 illustrates an inter-stage cooling process for a multi-stage air compressor, according to an embodiment.DETAILED DESCRIPTION

[0021] The detailed description set forth below, in connection with the accompanying drawings, is intended as a description of various embodiments, and is not intended to represent the only embodiments in which the disclosure may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the embodiments. However, it will be apparent to those skilled in the art that embodiments of the invention can be practiced without these specific details, hi some instances, well-known structures and components are shown in simplified form for brevity of description.

[0022] For clarity and ease of explanation, some surfaces and details may be omitted in the present description and figures. It should also be understood that the various components illustrated herein are not necessarily drawn to scale. In other words, the features disclosed in various embodiments maybe implemented using different relative dimensions within and between components than those illustrated in the drawings.

[0023] FIG . 1 illustrates a schematic diagram of a multi-stage air compressor 100, according to an embodiment. Multi-stage air compressor 100 is designed to coinpress air efficiently, finding wide application in industrial and commercial contexts. Multi-stage air compressor 100 comprises several essential components that collaborate harmoniously to accomplish elevated pressure ratiosand heightened overall efficiency when compared to their single-stage counterparts. In an embodiment, multi-stage air compressor 100 comprises, from an upstream end to a downstream end, an inlet 110, an inlet air filter 115, a first stage 120, an inter-stage coolant feed rod 200, a second stage 130, a final separator, an air receiver, and a control system. One or more, including potentially all, of these components of multi-stage air compressor 100 can be made from stainless steel and / or durable, high-temperature materials known as “superalloys.” A superalloy is an alloy that exhibits excellent mechanical strength and creep resistance at high temperatures, good surface stability, and corrosion and oxidation resistance. Examples of superalloys include, without limitation, Hastelloy, Inconel, Waspaloy, Rene alloys, Haynes alloys, Incoloy, MP98T, IMS alloys, and CMSX single crystal alloys.

[0024] Inlet 110 of multi-stage air compressor 100 serves as the entry point for ambient air into the compression system, where it undergoes the initial stages of the compression process. Inlet 110 can be equipped with inlet air filter 115 to ensure the air purification through the by removal of contaminants, particles, and dust that could potentially damage multi-stage air compressor 100 internal mechanisms. Once filtered, the incoming air is directed into first stage 120, where it will be progressively compressed to higher pressures hi second stage 130, contributing to the efficiency and reliability of the overall compression process.

[0025] Further, inlet air filter 115 of multi-stage air compressor 100 can function as a safeguard, preventing contaminants and impurities from entering first stage 120 compression system. Positioned at inlet 110 intake point, inlet air filter 115 may efficiently filter the incoming ambient ah', removing particles, dust, and debris that could potentially damage multi-stage air compressor 100 internal components. By ensuring that only clean and purified air enters multistage air compressor 100, inlet ah' filter 115 can prolong multi-stage ah' compressor 100 operational life and maintain the quality and performance of the compressed air output for various industrial applications .

[0026] First stage 120 of multi-stage ah’ compressor 100 initiates the compression process by raising the air pressure from ambient levels to an intermediate point. First stage 120 of multi-stage air compressor 100 may consists of components designed to initiate the compression process multistage ah' compressor 100. First stage 120 can include a motor or engine to drive the coinpression, an inlet valve to regulate airflow, and first stage rotor 125 or piston mechanism responsible for- compressing the air. Additionally, inter-state coolant feed rod 200 can be present to manage heatgenerated during compression, ensuring efficient operation, and extending the longevity of the components through its targeted plurality of exits 210 directing coolant or lubricant fluid to reduce stress and heat . First stage 120 can achieve raising air pressure through the use of a piston or rotary mechanism. First stage 120 sets the foundation for second stage 130 and subsequent compression stages, where the compressed air is further pressurized before eventual delivery for various industrial, commercial, or mechanical applications. The compressed air flows from upstream of second stage 120 (outlet) into the upstream air flow of second stage 130 (inlet). Further, each stage may be connected through a junction that may comprise a void space that allows the compressed air flow to travel between first stage 120 and second stage 130, as shown in FIG. 1. Alternatively, the junction may comprise a pipe system or any similar connection. While first stage 120 may not achie ve the final desired pressure level, it significantly reduces the volume of air, making it easier for second stage 130 to further compress the air to the required pressure. Furthermore, first stage's 120 compression may generate heat due to the mechanical work involved. This heat is carried over to the area where inter-stage coolant feed rod 200 is located, where it is dissipated during the cooling process.

[0027] Interceding in multi-stage air compressor 100 involves the cooling of compressed air between successive stages to enhance efficiency and performance through inter-stage coolant feed rod 200. Intercooling in multi-stage air compressor 100 has a transfer volume located intermediate first stage 120 and second stage 130. Inter-stage coolant feed rod 200 is positioned strategically between first stage 120 and second stage 130, employing inter-stage coolant feed rod 200 with plurality of exits 210 through which a cooling medium, like coolant or lubricant fluid, flows. Interstage coolant feed rod 200 can be interchangeable to accommodate different designs in multi-stage air compressor 100 and to interchange between compressor stages. As the hot compressed air mixes with the coolant or lubricant fluid from plurality of exits 210, heat is transferred, causing the air’s temperature to decrease significantly. Inter-stage coolant feed rod 200 cooling process not only prepares the air for second stage 130 and subsequent stages of compression, reducing the energy required for further compression, but also facilitates moisture condensation, which is removed through separators within multi-stage air compressor 100.

[0028] Second stage 130 of multi-stage air compressor 100 follows the initial compression and intercoolmg with inter-stage coolant feed rod 200, further elevating the air pressure to higher levels. Second stage 130 of multi-stage air compressor 100 can include inter-stage coolant feedrod 200 to reduce the temperature of the compressed air from first stage 120. a check valve to prevent backflow, and second stage rotor 135 or piston mechanism to further compress the ah to higher pressures. Second stage’s 130 key function is to continue the compression process from first stage 120, increasing air pressure significantly while managing heat, accumulation through intercooling. before the compressed air advances to subsequent stages for eventual utilization in diverse industrial, commercial, or mechanical applications.

[0029] The final separator in multi-stage air compressor 100 plays a vital role as the last line of defense before the compressed air reaches its destination. Positioned after second stage 130 or the final compression stage, the final separator is responsible for meticulously removing any remaining moisture, oil, or contaminants that might have accumulated during the compression process or during inter-stage coolant feed rod 200 cooling process. By ensuring the delivery of clean and high-quality compressed air, the final separator guarantees optimal performance of downstream equipment, prevents potential corrosion, and upholds the integrity of the compressed air for its intended applications, making it an essential element in maintaining the overall efficiency and reliabdny of multi-stage air compressor 100.

[0030] The air receiver in a multi-stage air compressor 100 system serves as a crucial storage vessel that holds the compressed air after it exits second stage 130. Positioned downstream from the final compression and purification processes, the air receiver plays a pivotal role in stabilizing presstire variations and providing a reservoir of compressed air for immediate usage. By maintaining a steady supply of compressed ah’, the receiver ensures consistent performance for connected equipment and mitigates the impact of fluctuating demand.

[0031] FIG. 2 illustrates a perspective view of an inter-stage coolant feed rod 200 assembly, according to an embodiment. Inter-stage coolant feed rod 200 can be positioned between first stage 120 and second stage 130. Inter-stage coolant feed rod 200 can comprise a plurality of exits 210 throughout inter-stage coolant feed rod 200, a first hollow tube segment 220, a second hollow tube segment 230, and a third hollow tube segment 240, each hollow tube segment with an inner wall 250 and an outer wall 260. In multi-stage ah compressor 100, inter-stage coolant feed rod’s 200 role is to maintaining the temperature and lubrication at adequate levels to increase efficiency and performance of the compression process. Inter-stage coolant feed rod 200 can be positioned strategically between compression stages, employing tubes with plurality of exits 210 through which a cooling medium, like coolant or lubricant fluid, flows. As the hot compressed air mixeswith the coolant or lubricant fluid from plurality of exits 210, heat is transferred, causing the air's temperature to decrease significantly,

[0032] At least an inter-stage coolant feed rod 200 is strategically positioned between first stage 120 and second stage 130 to ensure that the compressed air's temperature is effectively reduced before entering the subsequent stage. Further, inter-stage coolant feed rod 200 is coupled to a coolant oil supply and positioned at least partially in the transfer volume. Inter-stage coolant feed rod 200 is designed to facilitate the exchange of heat between the compressed air and coolant or lubricant fluid through its non-linear design. Inter-stage coolant feed rod 200 has at least an angled portion. For example, inter-stage coolant feed rod 200 can have two bended portions in 45 degrees to allow direct oil flow to a given area of multi-stage air compressor 100. A non-linear inter-stage oil feed rod 200 can offer significant mechanical advantages over a straight oil feed rod in various applications. These advantages include its ability to direct oil flow more precisely and efficiently to lubrication points of multi-stage air compressor 100. By doing so, inter-stage coolant feed rod 200 improves lubrication distribution, reducing friction and wear on critical components of multi-stage air compressor 100. Moreover, angled feed rods can prevent oil pooling, ensuring a more even distribution of lubrication and preventing issues like overheating or excess oil consumption.

[0033] As the hot, compressed air flows through inter-stage coolant feed rods 200, the coolant or lubricant fluid absorb the heat, causing the air’s temperature to decrease. The primary function of inter-stage coolant feed rods 200 is to prevent the buildup of excessive heat during the compression process. When air is compressed, its temperature increases significantly due to the mechanical work involved. If this heat is not adequately managed, it can lead to increased energy consumption, reduced efficiency, and even potential damage to compressor components. Interstage coolant feed rod 200 mitigates these issues by maintaining the compressed air at a manageable temperature, which also allows for denser air’ to be compressed in subsequent stages, reducing the overall work required for further compression.

[0034] Plurality of exits 210 are present at multiple points of inter-stage coolant feed rod 200 within multi-stage air compressor 100 system to for enhance coolant or lubricant fluid distribution and temperature regulation. Further, plurality of exits 210 may have a non-orthogonal orientation and a noir- axial orientation towards the longitudinal axis . By introducing plurality of exits 210 to inter-stage coolant feed rod 200, the dispersal of coolant or lubricant fluid throughout multi-stageaii' compressor 100 is facilitated, effectively thwarting the emergence of localized overheating areas. Plurality of exits 210 may extend from first hollow tube segment 220 through third hollow tube segment 240 from inner wall 250 out to outer wall 260. This approach is particularly adept at extending coolant or lubricant fluid coverage to intricate or hard-to-reach components, thereby accommodating irregular shapes and optimizing heat dissipation within multi-stage air compressor 100. Strategically positioning plurality of exits 210 enables a customized cooling process, adept at addressing varying heat generation demands across multi-stage air compressor 100, ultimately leading to superior temperature reduction and a reduction in the likelihood of overheating, particularly in high-stress areas like first stage rotors 125 and second stage rotors 135. Further, the coolant or lubricant fluid may be directed to any type of rotating part or high- friction area, such as rotors, bearings, gear train, or meshing gear. As illustrated in FIG. 5, plurality of exits 210 can be uniformly distributed through one or multiple segments. Alternatively, as illustrated in FIG. 11, plurality of exits 210 may be non-unifoimly distributed through one or multiple segments. Furthermore, plurality of exits 210 design fosters streamlined pressure regulation that targets high- heat areas in multi-stage air compressor 100, augments the mixing of coolant or lubricant fluid, and bolsters system reliability through the provision of alternative pathways, collectively culminating in the optimized performance.

[0035] First hollow tube segment 220 in inter-stage coolant feed rod 200 is an integral component that can connect the coolant feed with inter-stage coolant feed. First hollow tube segment 220 is the starting point or the initial extremity of inter-stage coolant feed rod 200. First hollow tube segment 220 it's the end from which the tube originates or enters a system, component, or connection point. In the context of fluid flow, first hollow tube segment 220 is where coolant or lubricating fluid enters the inter-stage coolant feed rod 200. For example, in multi-stage air compressor 100, first hollow tube segment 220 of inter-stage coolant feed rod 200 is where coolant or lubricant fluid enters the tube from a pump, fir st hollow tube segment 220 of inter-stage coolant feed rod 200 establishes the point of origin for the coolant or lubricating fluid circulated through inter-stage coolant feed rod 200.

[0036] Second hollow tube segment 230 can define the design, strategically used to replicate the intricate shapes of its internal components of multi-stage air compressor 100. Second hollow tube segment 230 in inter-stage coolant feed rod 200 enables efficient heat transfer through coolant or lubricant fluid contact by closely following the contours of critical areas like rotors (125, 135)and pistons. Second hollow tube segment 230 in inter-stage coolant feed rod 200 serve to not only mimic component shapes but also to optimize the dissipation of heat, effectively preventing the formation of overheated regions and allow plurality of exits 210 to target the coolant or lubricant fluid. The utilization of second hollow tube segment 230 in inter-stage coolant feed rod 200 extends beyond mere shape replication. Second hollow tube segment 230 in inter-stage cocdant feed rod 200 introduce controlled turbulence in the flow of coolant or lubricant fluid, promoting a thorough mixing of the fluid and ensuring uniform heat distribution. This is particularly advantageous when dealing with irregularly shaped components within multi-stage air compressor 100, as it guarantees comprehensive cooling and lubricating coverage. Additionally, the precise alignment of second hollow tube segment 230 with fluid dynamics principles minimizes flow resistance and maximizes coolant or lubricant fluid circulation.

[0037] Conversely to fust hollow tube segment 220, third hollow tube segment 240 of interstage coolant feed rod 200 is the opposite extremity or the terminal point of inter-stage coolant feed rod 200. Third hollow tube segment 240 it’s where inter-stage coolant feed rod 200 terminates, connects, or releases the coolant or lubricant fluid entered through first hollow tube segment 220. Continuing with multi-stage air compressor 100 example, third hollow tube segment 240 of interstage coolant feed rod 200 is where the coolant or lubricant fluid exits inter-stage coolant feed rod 200 and is distributed to the intended destination, such as second stage 130. Third hollow tube segment 240 signifies the conclusion of the flow or transport process within inter-stage coolant feed rod 200.

[0038] Inner wall 250 of inter-stage coolant feed rod 200 refers to the surface formed by the hollow space or cavity within inter-stage coolant feed rod 200 through which coolant or lubricant fluid. Inner wall 250 is the inner part of inter-stage coolant feed rod 200 that creates a pathway for the transport of cooling or lubricant fluid from first hollow tube segment 220 through second hollow tube segment 230 to third hollow tube segment 240 of inter-stage coolant feed rod 200. The size, shape, and characteristics of inner wall 250 is determined by the contour of inter-stage coolant feed rod 200. Furthermore, the dimensions of inner wall 250 include its diameter, length, and any variations in width along inner wall’s 250 course. These dimensions determine how much coolant or lubricant fluid can flow through inter-stage coolant feed rod 200 at a given time and influence factors such as flow rate, pressure, and resistance.

[0039] Outer wall 260 of inter-stage coolant feed rod 200 refers to the external part of interstage coolant feed rod 200, Outer wall 260 acts as a protective barrier, shielding the inner components of the rod from external environmental factors, such as dust, contaminants, or physical damage. Additionally, outer wall 260 facilitates efficient heat transfer by containing the flow of coolant or fluid through the inner channel of inter-stage coolant feed rod 200. By insulating and directing the flow, outer wall 260 helps maintain optimal operating temperatures, preventing overheating and ensuring the smooth functioning of multi-stage air compressor 100, thus contributing to the overall efficiency ami longevity of the system.

[0040] FIG. 3 illustrates a cross-sectional view of an inter-stage coolant feed rod 200 assembly, according to an embodiment. Inter-stage coolant feed rod 200 can be positioned between first stage 120 and second stage 130. biter-stage coolant feed rod 200 can comprise a plurality of exits 210 throughout inter-stage coolant feed rod 200, a first hollow tube segment 220, a second hollow tube segment 230, and a third hollow tube segment 240, each hollow tube segment with an inner wall 250 and an outer wall 260. These components may be similar or identical to those that have already been described herein, and therefore, will not be redundantly described herein.

[0041] A cross-sectional view of inter-stage coolant feed rod 200 reveals crucial components within multi-stage air compressor 100. Inter-stage coolant feed rod 200 operates to enhance multistage air compressor’s 100 efficiency and performance by cooling down the compressed air before it enters second stage 130. The cross-sectional view showcases multi-stage air compressor 100, positioned between first stage 120 and second stage 130, which dissipates the heat generated during the compression process. As the high -temperature, high-pressure air passes through multistage air compressor 100, inter-stage coolant feed rod 200 expels cooling or lubricant fluid through plurality of exits 210 to mix with the air and absorb the excess heat.

[0042] FIG. 4 and 5 illustrate an isometric view of an arched inter-stage coolant feed rod 200, according to an embodiment. The arched design of inter-stage coolant feed rod 200 allows for more efficient distribution of the cooling or lubricant fluid expelled through plurality of exits 210. This is especially important in tight spaces where a straight coolant feed rod might not fit optimally. Additionally, the curvature of inter-stage coolant feed rod 200 can promote smoother fluid flow, reducing the likelihood of turbulence and pressure dr op that can occur- with sharp angles or abrupt transitions.

[0043] Moreover, arched inter-stage coolant feed rod 200 can contribute to improved thermal management within multi-stage air compressor 100. The bending of arched inter-stage coolant feed rod 200 can facilitate better distribution of coo lant or lubricant fluid across the multi-stage air compressor's 100 surface, ensuring more even heat dissipation and preventing hotspots that could negatively impact performance.

[0044] FIG. 6 illustrates an isometric view of a multi-arched inter-stage coolant feed rod 200, according to an embodiment. Multi-arched inter-stage coolant feed rod 200 can offer several advantages in multi-stage air compressor 100 applications where efficient cooling, space optimization, and performance are crucial. For example, different sections of multi-stage air compressor 100 may experience varying levels of beat generation. By utilizing multi-arched interstage coolant feed rods 200 strategically positioned in high-heat zones, the cooling can be tailored to address specific temperature rise areas, ensuring uniform operating conditions and extending the lifespan of multi-stage air compressor 100.

[0045] Further, multi-stage air compressor 100 may have limited space available for cooling components. In this case, multi-arched inter-stage coolant feed rods 200 can be bent and routed to fit within the available space while still delivering effective cooling through the expulsion of coolant or lubricant fluid via plurality of exits 210 to different sections of multi-stage air compressor 100. Additionally, multi-stage air compressor 100 can overheat if compressed air temperatures become too high. Multi-arched inter-stage coolant feed rods 200, strategically placed in areas prone to excessive heat buildup, prevent this by dissipating heat effectively by targeting coolant or lubricant fluid towards these areas and maintaining the operating temperature within safe limits. Effective cooling, achieved through multi-arched inter-stage coolant feed rods 200, minimizes thermal stress on parts and decreases the need for frequent maintenance and repairs in multi-stage air compressor 100.

[0046] FIG. 7 illustrates an isometric view of a u-shaped inter-stage coolant feed rod 200, according to an embodiment. In multi-stage air compressor 100, first stage 120 and second stage 130 generate heat as air is progressively compressed. Placing u-shaped inter-stage coolant feed rod 200 between stages enables the compressed air to be cooled as it flows and mixes with coolant or lubricant fluid through u-shaped inter-stage coolant feed rod 200, preparing air for second stage 130 or subsequent compression stages. As well, the u- shape configuration can increase the amount of coolant or lubricant fluid that conies into close contact with round parts of multi-stage aircompressor 100 such as first stage rotors 125 and second stage rotors 135, promoting efficient heat transfer and rapid cooling. This can be particularly beneficial when quick cooling is required.

[0047] FIG. 8 illustrates an isometric view of a helical inter-stage coolant feed rod 200, according to an embodiment. A spiral design of inter-stage coolant feed rod 200 creates a longer path for the coolant or lubricant fluid to travel through. Helical inter-stage coolant feed rod 200 extended path allows for increased contact areas with the cooling or lubricant fluid exiting plurality of exits 210, maximizing heat transfer and cooling efficiency. Helical inter-stage coolant feed rod 200 is especially effective in multi-stage air compressor 100 because the spiral path can accommodate multiple sections within the same length, making it suitable for sequential cooling between first stage 120 and second stage 130.

[0048] Further, helical inter-stage coolant feed rod 200 distributes cooling more evenly compared to straight tubes, minimizing the risk of localized overheating and reducing the potential for thermal stress on multi-stage air compressor 100 components. The spiral design inherently promotes high flow rates and efficient mixing of the coolant or lubricant oil exiting plurality of exits 210 with the compressed air, further enhancing heat transfer capabilities. For compressors with sections that generate varying amounts of heat, helical inter-stage coolant feed rod 200 can be designed with varying pitch or diameter along its length to accommodate the different cooling requirements within multi-stage air compressor 100.

[0049] FIG . 9 illustra tes an isometric view of an inter-stage coolant feed rod 200 with multiple coolant sources, according to an embodiment. Multiple coolant sources in inter-stage coolant feed rod 200 connect different sections of the inter-stage coolant feed rod 200 to facilitate the transfer of coolant or lubricant fluid and allow for intercooling. Inter-stage coolant feed rod 200 with multiple coolant sources can be customized to route around existing components, obstacles, or connections within multi-stage air compressor 100 by adding fourth hollow tube segment 270 and fifth hollow tube segment 280. Adding extra hollow tube segments can allow inter-stage coolant feed rod’s 200 efficient integration without major modifications to multi-stage air compressor’s 100 layout. Additionally, by placing fourth hollow tube segment 270 and fifth hollow tube segment 280 in inter-stage coolant feed rod 200 in a specific location, lubricant can flow in different directions to reach further sections of multi-stage air compressor 100 or increase pressure flow when needed. This reduces the temperature rise between stages and improves overall multi-stageail' compressor 100 efficiency. Alternatively, inter-stage coolant feed rod 200 can be combined with multiple inter-stage coolant feed rods 200 and intersect to exchange lubricant or coolant flow.

[0050] FIG. 10 illustrates an isometric view of a circular inter-stage coolant feed rod 200, according to an embodiment. Circular inter-stage coolant feed rod 200 offers a continuous flow path and ensures uniform cooling tlirongliout its looped trajectory, efficiently dissipating heat as coolant or lubricant fluid circulates and exits via plurality of exits 210. Circular' inter-stage coolant feed rod 200 space-efficient design accommodates to limited installation areas, while its adaptability allows for integration with cooling fluids for enhanced heat dissipation. Further, circular inter-stage coolant feed rod 200 can surround high-heat components that may require coolant or lubricant constant contact in all areas of the component.

[0051] FIG. 11 illustrates an isometric view of the plurality of exits 210 targeting the compressed air discharge paths in an inter-stage coolant feed rod 200, according to an embodiment. Plurality of exits 210 within inter-stage coolant feed rod 200 play a pivotal role in efficiently directing and channeling the flow of coolant or lubricant fluid to specific areas within multi-stage ah compressor 100. Plurality of exits 210, essentially non-orthogonal and / or a non-axial orientation openings or punctures strategically placed along inter-stage coolant feed rod’s 200 length, serve as controlled exit points for the coolant or lubricant fluid being transported. Plurality of exits 210 primary function is to precisely target and distribute the coolant or lubricant fluid to designated areas where it is required within inter-stage coolant feed rod 200. By meticulously adjusting the size, number, and positioning of plurality of exits 210. inter-stage coolant feed rod 200 can exercise precise control over the flow rate, ensuring that the appropriate amount of coolant or lubricant fluid reaches each intended destination. Moreover, plurality of exits 210 facilitate even distribution, preventing uneven supply allocation that might lead to imbalances or wastage. Plurality of exits 210 customizable nature allows for tailoring to different multi-stage air compressor 100 demands, accommodating variations in flow rates and pressure levels.

[0052] FIG. 12 illustrates an inter-stage cooling process 300 for a multi-stage air compressor 100, according to an embodiment. In subprocess 310, first stage 120 of process 300 draws ambient air into multi-stage ah' compressor 100 and subjected to compression, elevating its pressure, hi subprocess 320, the compressed ah', now at an elevated pressure, is then directed to second stage

[0053] Next, subprocess 330 introduces the coolant into the system through inter-stage coolant feed rod 200. Inter- stage coolant feed rod 200 allows precise control over the flow of coolant. As the coolant travels through inter-stage coolant feed rod 200, it is strategically expelled into the path of the compressed air dur ing subprocess 340, promoting a controlled mixing of the two. This mixing process is essential for the primary objective of reducing temperature of the compressed air in subprocess 350.

[0054] The compressed air, now combined with the expelled coolant, undergoes a substantial temperature reduction. After, subprocess 355 directs the cooled and conditioned compressed air into a specially designed compressed air tank if no further stages of compression are present in a given system. The compressed air tank serves as a reservoir for storing the treated air until it is needed for specific operational requirements in subprocess 360. However, if further subsequent stages exist, the process or certain subprocesses may be repeated.Industrial Applicability

[0055] A multi-stage air compressor 100 includes multiple compression stages to achieve higher pressure ratios and efficiency. Each stage consists of rotating and stationary components, and effective cooling is vital to dissipate the heat generated during coinpression. hr a typical multistage air compressor, the coolant or lubricant fluid may be directed to rotors, bearings, and other rotating parts and / or high-fiiction areas through a spray system or tubes with orthogonal openings which permit a lubricant such as oil to be injected. The coolant or lubricant fluid distribution can be inefficient when utilizing spray systems or tubes with orthogonal openings due to the challenges posed by the geometry of multi-stage air compressors. The orthogonal openings in tubes can create flow disruptions, turbulence, and dead zones, causing uneven fluid distribution along the length of the multi-stage air compressor.

[0056] Accordingly, an inter-stage coolant feed rod 200 for a multi-stage air compressor 100 is disclosed wherein the non-orthogonal with non-linear shape design increases the utility and efficiency of coolant or lubricant fluid distribution and targets predetermined areas of high heat in multi-stage air compressor 100. In particular, inter-stage coolant feed rod 200 can comprise a plurality of exits 210 throughout inter-stage coolant feed rod 200, a first hollow tube segment 220, a second hollow tube segment 230, and a third hollow tube segment 240, each hollow tube segment with an inner wall 250 and an outer wall 260. The utility and efficiency of lubricant fluid distribution may be increased by designing a non-orthogonal tube with non-linear shape thattargets predetermined areas of high heat in the multi-stage air compressor . As a result, inter-stage coolant feed rod 200 minimizes thermal stress on parts and decreases the need for frequent maintenance arid repairs in multi-stage air compressor 100.

[0057] It will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. Aspects described in connection with one embodiment are intended to be able to be used with the other embodiments . Any explanation in connection with one embodiment applies to similar features of the other embodiments, and elements of multiple embodiments can be combined to form other embodiments. The embodiments are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages.

[0058] The preceding detailed description is merely exemplary in nature and is not intended to Emit the invention or the application and uses of the invention. The described embodiments are not limited to usage in conjunction with a particular type of machine. Hence, although the present embodiments are, for convenience of explanation, depicted and described as being implemented in a multi-stage air compressor system, it will be appreciated that it can be implemented in various other types of compressors and machines with inter-stage cooling and lubrication needs, and in various other systems and environments. Furthermore, there is no intention to be bound by any theory presented in any preceding section. It is also understood that the illustrations may include exaggerated dimensions and graphical representation to better illustrate the referenced items shown, and are not considered limiting unless expressly stated as such.

Claims

CLAIMSWhat is claimed is:

1. A multi-stage air compressor system comprising; a first stage air compressor located upstream from at least a second stage air compressor; a transfer volume located intermediate the first stage air compressor and the second stage air compressor; and a non-linear coolant feed rod coupled to a coolant oil supply and positioned at least partially in the transfer volume, the non-linear coolant feed rod having a first hollow tube segment with a first outer wall, a second hollow tube segment extending from the first hollow tube segment at a non-zero angle and in fluid communication with the first hollow tube segment, the second hollow tube segment further having a second outer wall having a plurality of exits extending through the second outer wall, and a third hollow tube segment extending from the second hollow tube segment at a non-zero angle and in fluid communication with the second hollow tube segment, with a third outer wall .2 , The multi-stage air compressor system of Claim 1, wherein the plurality of exits have a noii-orthogonal orientation towards a longitudinal axis of the second hollow tube segment.

3. The multi-stage air compressor system of Claim 1, wherein the plurality of exits have a non-axial orientation towards a longitudinal axis of the second hollow tube segment.

4. The multi-stage air compressor system of Claim 1, wherein the first hollow tube segment has a plurality of exits extending through the first outer wall and the third hollow tube segment has a plurality of exits extending through the third outer wall.The multi-stage air compressor system of Claim 1, wherein the non-linear coolant feed rod is interchangeable between different compressor stages.6, The multi-stage air compressor system of Claim 1. wherein the second hollow tube segment is configured to direct the coolant oil supply in combination of the plurality of exits to at least a targeted location from the same non-linear coolant feed rod,7. The multi-stage air compressor system of C laim 1 , wherein the second hollow tube segment is formed in a circular shape coupled at a first location with the first hollow tube segment, and coupled at a second location with the third hollow tube segment .S, The multi-stage air compressor system of Claim 1, wherein the plurality of exits are non-uniformly distributed in the second hollow tube segment.

9. The multi-stage air compressor system of Claim 1. wherein the second hollow tube segment is arched shaped.

10. The multi-stage air compressor system of Claim 1. wherein the second hollow tube segment is u-shaped.

11. The multi-stage air compressor system of Claim 1 , wherein the second hollow tube segment is helically shaped.

12. The multi-stage air compressor system of Claim 1 , further comprising: a fourth hollow tube segment coupled to the third hollow tube segment at an end of the third hollow tube segment opposite the second hollow tube segment, at a non-zero angle and in fluid communication with the third hollow tube segment; and a fifth hollow tube segment coupled to the third hollow tube segment at a non-zero angle and in fluid communication with the third hollow tube segment.

13. The multi-stage air compressor system of Claim 1 , wherein the non-linear coolant feed rod can be combined with multiple non-linear coolant teed rods.

14. A multi-stage air compressor system comprising: a first stage air compressor; a second stage air compressor located downstream from the first stage air compressor;a passage that connects an outlet of the first stage air compressor to an inlet of the second stage air compressor: and a coolant delivery7rod coupled to a coolant oil supply and positioned at least partially in the passage, the coolant delivery rod having a first hollow tube segment with a first outer wall, a second hollow tube segment coupled within a passage exit of the first hollow tube segment at a non-zero angle and a passage inlet of a third hollow tube segment at a nonzero angle, the second hollow7tube segment having a second outer wall with a plurality of exits extending through the second outer wall, wherein the second hollow tube segment is configur ed to direct the coolant oil supply in combination of the plurality of exits to at least a targeted location from the same coolant delivery rod; and the third hollow tube segment coupled ■with the second hollow7tube segment at a non-zero angle and in fluid communication with the second hollow tube segment, the third hollow tube segment having a tliird outer wall.

15. A method for compressing air with a multi-stage air compressor system comprising: routing the compressed air from a first stage to a second stage of the multi-stage air compressor system: and feeding coolant through a non-linear coolant feed rod coupled to a coolant oil supply and positioned at a junction of the first stage and the second stage of the multi-stage air compressor, the non-linear coolant feed rod having a first hollow tube segment with a first outer wall, a second hollow tube segment coupled with the first hollow tube segment at a nonzero angle and in fluid communication with the first hollow tribe segment, the second hollow tube segment further having with a second outer wall having a plurality of exits extending through the second outer wall, and a third hollow7tube segment coupled with the second hollow tube segment at a nonzero angle and in fluid communication with the second hollow tube segment, with a thir d outer wall

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