Abstract: A blower includes a housing including an inlet and an outlet, a stationary component provided to the housing, an impeller positioned between the inlet of the housing and the stationary component, and a motor adapted to drive the impeller. The housing and the stationary component cooperate to define a volute that directs air towards the outlet. The housing includes a separating wall constructed and arranged to divide the volute into a high speed airpath region and a low speed airpath region.

Abstract: A method for making a poly-phase field winding for a slotless stator includes: forming the first coil group by winding an insulated wire for each coil winding in a first direction around a mandrel; axially shifting along the mandrel the insulated wire from a trailing edge of each coil winding a distance substantially equal to one half of twice the number of coil groups multiplied by the number of coil windings minus one times the width of one of the completed windings to position the wires at a leading edge of each of coil winding in the second coil group; forming the second coil group by winding the insulated wire for each coil winding in the first direction; removing the mandrel from the wound coil groups; collapsing the wound coil groups to a single layer web, and wrapping the single layer web into a cylinder to form the field winding.

Abstract: An insulator for a stator assembly includes at least a first insulator adapted to be mounted to the stator core and structured to insulate the stator core from the coils. The at least one insulator includes structure to perform at least one additional function. For example, the structure may include a support member to support and/or locate the PCBA on the stator core, a wire guide to guide cross-over wires that form a connection between coils, and/or positioning structure to precisely position the PCBA with respect to the coils.

Abstract: A blower includes an electric motor case, a housing having a housing inlet and a housing outlet between which is defined a flow path for gas, a first impeller adapted to accelerate gas tangentially and to direct it radially outward, and a stationary portion. The stationary portion includes an annular gas flow path of sufficient width to allow a flow of gas therethrough without introducing excessive pressure drop. The stationary portion includes a first stator vane structure defining a plurality of stator vane leading edges, the first stator vane structure located on the second side of the motor and arranged to smoothly direct gas flow along a curved path. The motor case provides a shielding function for the stator vane leading edges from an impeller blade pressure pulse.

Abstract: A blower includes a housing including an inlet and an outlet, a motor to drive a rotatable shaft, first and second impellers provided to the shaft, the first and second impellers each including a plurality of impeller blades, a first stationary component provided to the housing and including stator vanes downstream of the first impeller, and a second stationary component provided to the housing and including stator vanes downstream of the second impeller. A first set of stator vanes of the first stationary component is provided around the motor and are configured and arranged to direct airflow along the motor, to de-swirl the airflow and to decelerate air to increase pressure. A blower including a third impeller and third stationary component positioned above the first impeller is also described.

Abstract: A blower includes an electric motor having a shaft, a housing having an inlet and outlet between which is defined a gas flow path, the outlet structured to direct gas exiting the blower in an axial first direction, a first impeller attached to the shaft and adapted to accelerate air tangentially and direct it radially outward, a stationary portion, and a shield. The stationary portion includes a first stator vane structure defining a plurality of stator vane leading edges and a stator vane outer radial edge. The first stator vane structure is arranged to direct gas flow along a curved path that directs flow at an inner end thereof in a radially inward direction. The shield has an outer edge extending radially beyond the outer radial edge of the first stator vane structure and is adapted to isolate the stator vane leading edges from an impeller blade pressure pulse.

Abstract: An impeller comprising: a top shroud; a bottom shroud, a plurality of vanes extending from the top shroud to the bottom shroud, each said vane including a top edge at a radially inner portion of the vane in contact with the top shroud and a bottom edge at a radially outer portion of the vane in contact with the bottom shroud, such that a radially inner portion of the vane at the bottom edge of each vane is not in contact with or adjacent the bottom shroud and a radially outer portion of the vane at the top edge of each vane is not in contact with or adjacent the top shroud.

Abstract: A method for forming windings of a stator assembly in a blower includes providing a stationary portion for the blower including a tube adapted to support a rotor and using the tube as a mandrel to form the windings of the stator assembly.

Abstract: A PAP device for generating a supply of pressurized gas to be provided to a patient for treatment includes a housing, a core including a motor and at least one impeller, and a vibration isolation system to support the core within the housing in a flexible, vibration-isolated manner.

Abstract: A blower includes a housing including an inlet and an outlet, a bearing-housing structure provided to the housing and adapted to rotatably support a rotor, a motor provided to the bearing-housing structure and adapted to drive the rotor, and an impeller provided to the rotor. The bearing-housing structure includes a bearing shaft having a bearing surface that rotatably supports the rotor. The bearing shaft provides only a single bearing of the non-ball bearing type for the rotor.

Abstract: A brushless DC motor including a rotor, a magnet provided to the rotor, a pair of bearings to rotatably support the rotor, a stator assembly that at least partly surrounds the rotor and magnet thereof and adapted to control movement of the rotor, and a bearing tube having an exterior surface and an interior surface that defines a tube interior. The stator assembly is provided along the exterior surface of the tube and the bearings are provided along the interior surface of the tube to support the rotor and magnet within the tube interior. The motor has sample application for use in PAP devices for delivery of positive airway pressure therapy for users or patients.

Abstract: A blower includes a stationary portion including an inlet and an outlet, a rotating portion provided to the stationary portion, and a motor adapted to drive the rotating portion. The inlet and outlet are co-axially aligned. The stationary portion includes a housing, a stator component provided to the housing, and a tube providing an interior surface. The rotating portion includes one or more bearings that are provided along the interior surface of the tube to support a rotor within the tube. In an embodiment, the blower is structured to supply air at positive pressure.

Abstract: An impeller comprising: a top shroud; a bottom shroud, a plurality of vanes extending from the top shroud to the bottom shroud, each said vane including a top edge at a radially inner portion of the vane in contact with the top shroud and a bottom edge at a radially outer portion of the vane in contact with the bottom shroud, such that a radially inner portion of the vane at the bottom edge of each vane is not in contact with or adjacent the bottom shroud and a radially outer portion of the vane at the top edge of each vane is not in contact with or adjacent the top shroud.

Abstract: A blower includes a housing including an inlet and an outlet, a stationary component provided to the housing, an impeller positioned between the inlet of the housing and the stationary component, and a motor adapted to drive the impeller. The stationary component includes a tube portion structured to retain and align a pair of bearings that rotatably support a rotor to which the impeller is coupled. The tube portion includes a diameter in a side closest to the impeller that is sufficient size to accommodate adhesive to retain one of the bearings.

Abstract: An insulator for a stator assembly includes at least a first insulator adapted to be mounted to the stator core and structured to insulate the stator core from the coils. The at least one insulator includes structure to perform at least one additional function. For example, the structure may include a support member to support and/or locate the PCBA on the stator core, a wire guide to guide cross-over wires that form a connection between coils, and/or positioning structure to precisely position the PCBA with respect to the coils.

Abstract: An insulator for a stator assembly includes at least a first insulator adapted to be mounted to the stator core and structured to insulate the stator core from the coils. The at least one insulator includes structure to perform at least one additional function. For example, the structure may include a support member to support and/or locate the PCBA on the stator core, a wire guide to guide cross-over wires that form a connection between coils, and/or positioning structure to precisely position the PCBA with respect to the coils.

Abstract: A method for making a poly-phase field winding for a slotless stator includes: forming the first coil group by winding an insulated wire for each coil winding in a first direction around a mandrel; axially shifting along the mandrel the insulated wire from a trailing edge of each coil winding a distance substantially equal to one half of twice the number of coil groups multiplied by the number of coil windings minus one times the width of one of the completed windings to position the wires at a leading edge of each of coil winding in the second coil group; forming the second coil group by winding the insulated wire for each coil winding in the first direction; removing the mandrel from the wound coil groups; collapsing the wound coil groups to a single layer web, and wrapping the single layer web into a cylinder to form the field winding.

Abstract: A blower includes an electric motor having a shaft, a housing having an inlet and outlet between which is defined a gas flow path, the outlet structured to direct gas exiting the blower in an axial first direction, a first impeller attached to the shaft and adapted to accelerate air tangentially and direct it radially outward, a stationary portion, and a shield. The stationary portion includes a first stator vane structure defining a plurality of stator vane leading edges and a stator vane outer radial edge. The first stator vane structure is arranged to direct gas flow along a curved path that directs flow at an inner end thereof in a radially inward direction. The shield has an outer edge extending radially beyond the outer radial edge of the first stator vane structure and is adapted to isolate the stator vane leading edges from an impeller blade pressure pulse.