BLOWER ASSEMBLY WITH MOTOR INTEGRATED INTO THE IMPELLER FAN AND BLOWER HOUSING CONSTRUCTIONS

Abstract

A blower comprises a blower housing, a fan, a motor and a support member. The blower housing has an air outlet opening. The fan is within the blower housing, the fan is adapted for rotation about a fan axis. The motor has a stator and a rotor. The rotor is rotatably coupled to the stator for rotation about the fan axis. The rotor and fan are coupled such that the fan rotates with the rotor. The support member is connected between the stator of the motor and the blower housing and extends generally radially from the fan axis. The support member supports both the motor and the fan.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to a blower assembly for an air handler in which an electric motor is integrated into the constructions of the impeller fan and the blower housing of the blower assembly. More specifically, the present invention pertains to a blower assembly in which an axial flux motor has its stator integrated into the construction of the blower housing of the assembly and has its rotor integrated into the construction of the impeller fan of the assembly.

2. Description of Related Art

The typical construction of a blower assembly for an air handler, for example as a furnace, includes a fan that is rotated by an electric motor and a blower housing that contains the fan.

The typical blower housing is comprised of a scroll-shaped outer wall and a pair of side walls that are connected to opposite sides of the scroll-shaped outer wall. The outer wall has opposite ends that are positioned on opposite sides of an outlet opening of the blower housing. The side walls are also positioned on opposite sides of the outlet opening. The side walls have circular, coaxial holes through the side walls that function as air inlet openings of the blower housing.

The motor is typically mounted to one of the blower housing side walls. The shaft of the motor is coaxial with the center axes of the blower housing inlet openings. This positions the motor either directly adjacent one of the side wall inlet openings, or in some constructions, the motor extends through the side wall inlet opening into a portion of the motor housing interior.

The impeller fan is mounted to the motor shaft in the blower housing interior. The typical impeller fan has a circular plate at one axial end of the fan or at an intermediate portion of the fan that is connected to the motor shaft.

The common blower assembly construction described above includes features that detract from the efficiency of the blower assembly. Positioning the motor adjacent or partially extending into one of the air inlet openings of the blower housing restricts the air flow through that inlet opening and thereby contributes to the inefficiency of the blower assembly. Additionally, the circular plate of the impeller fan that connects the fan to the motor shaft restricts the free flow of air through the interior of the impeller fan and thereby also contributes to the inefficiency of the blower assembly.

SUMMARY OF THE INVENTION

The blower assembly of the present invention overcomes disadvantages associated with the constructions of conventional blower assemblies by having the construction of the motor integrated into the constructions of intermediate portions of the impeller fan and the blower housing. This eliminates the prior art positioning of the motor adjacent one of the blower housing inlet openings or extending through one of the blower housing inlet openings and thereby eliminates the inefficiencies associated with this prior art positioning of the motor. In addition, the portion of the motor integrated into the fan construction includes a cylindrical hub with a center bore through the hub that balances pressure and the free flow of air through the interior of the fan.

The blower housing of the invention comprises a scroll-shaped outer wall having a length with opposite first and second ends that are positioned at opposite sides of the outlet opening of the housing. The housing also comprises a pair of side walls that are secured to the opposite sides of the scroll-shaped outer wall. The side walls have circular holes that are coaxially aligned and function as the air inlet openings of the blower housing. The novel construction of the blower housing of the invention includes an interior wall. The interior wall is parallel to the side walls and is secured stationary to the interior surface of the housing outer wall at a centered position between the two side walls. The interior wall has a circular hole through the wall that is coaxial with the air inlet openings of the two side walls.

The motor of the blower assembly is mounted to the interior wall of the blower housing. This eliminates the inefficiencies associated with the prior art positioning of the motor adjacent an air inlet opening of the prior art blower housing or extending into the air inlet opening of the prior art blower housing. Although other motor types which have short axial lengths could be used, the preferred motor is an axial flux motor having a circular stator construction integrated into the construction of the interior wall at the hole through the wall. The wiring associated with the stator and the control systems of the motor are run through or along the interior wall to the exterior of the blower housing. The rotor of the motor includes a hollow cylindrical hub that is mounted for rotation by one or more bearings inside the stator. The hub has a pair of annular plates connected to the axially opposite ends of the hub. The plates extend radially outwardly from the center hub over opposite sides of the interior wall. The magnets of the motor are secured to at least one of the plates.

The impeller fan of the blower assembly is comprised of a pair of centrifugal or squirrel-cage fans. These fans may have different width dimensions for air flow purposes. The fans are positioned on the opposite sides of the interior wall and are connected to the pair of plates that extend radially from the cylindrical hub of the rotor.

The blower assembly of the invention described above has no obstructions to the free flow of air through the inlet openings of the blower housing side walls into the interior of the fan contained in the blower housing. The blower assembly also has a smaller size than comparable prior art blower assemblies that have motors that project out from one side of their blower housings. This enables the blower assembly of the invention to be used in a narrower air handler enclosure. This is accomplished by the positioning of the motor in the interior of the housing on the interior wall of the housing. Employing the axial flux motor construction allows for the free flow of air through the interior of the blower housing between the two centrifugal fans. This eliminates the inefficiencies associated with prior art centrifugal fans due to the center plates of the fans restricting air flow through the fans.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features of the invention are set forth in the following detailed description of blower assemblies of the invention and in the drawing figures.

FIG. 1 is a side elevation view of one side of a blower assembly of the invention, with the opposite elevation view being a mirror image of FIG. 1.

FIG. 2 is an end elevation view of the blower assembly from the left end of the blower assembly as shown in FIG. 1.

FIG. 3 is an upper, left perspective view of the blower assembly relative to the blower assembly as shown in FIG. 2.

FIG. 4 is an upper, right perspective view of the blower assembly relative to the blower assembly as shown in FIG. 2.

FIG. 5 is a left perspective view of the blower assembly relative to the blower assembly as shown in FIG. 2.

FIG. 6 is a right perspective view of the blower assembly relative to the blower assembly as shown in FIG. 2.

FIG. 7 is a lower, left perspective view of the blower assembly relative to the blower assembly as shown in FIG. 2.

FIG. 8 is a lower, right perspective view of the blower assembly relative to the blower assembly as shown in FIG. 2.

FIG. 9 is a partially sectioned view of the blower assembly showing portions of the blower housing, fans and motor and showing the interior wall in its entirety.

FIG. 10 is a view similar to that of FIG. 9, but from the opposite side of the blower housing as shown in FIG. 9.

FIG. 11 is an end elevation view of the blower assembly as shown partitioned in FIGS. 9 and 10.

FIG. 12 is a schematic representation of one embodiment of the blower assembly of the invention.

FIG. 13 is a schematic representation of a further embodiment of the blower assembly.

FIG. 14 is a schematic representation of a further embodiment of the blower assembly.

FIG. 15 is a schematic representation of a further embodiment of the blower assembly.

FIG. 16 is a schematic representation of a further embodiment of the blower assembly.

FIG. 17 is a schematic representation of a further embodiment of the blower assembly.

FIG. 18 is a schematic representation of a further embodiment of the blower assembly.

FIG. 19 is a side elevation of a further embodiment of the blower assembly.

FIG. 19a is a section view taken through the plane of line 19a-19a of FIG. 19.

FIG. 19b is an enlarged fragment view of FIG. 19a, showing motor features.

FIG. 19c is a perspective view of the motor of the blower assembly of FIG. 19.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The blower assembly of the present invention is basically comprised of a blower housing 12, a fan 14 contained inside the blower housing, and a motor 16.

The blower housing 12 has an outer wall 18 having a scroll-shaped length that extends from a first end edge 22 of the outer wall to an opposite second end edge 24 of the outer wall. As best seen in drawing FIGS. 3-8, the outer wall first end edge 22 forms the cutoff of the blower housing. Additionally, the first 22 and second 24 end edges of the outer wall 18 define opposite sides of a rectangular outlet opening 26 of the blower housing.

The blower housing also includes first 28 and second 32 side walls. As seen in the drawing figures, portions of the peripheries of the two side walls 28, 32 are connected to the opposite sides of the outer wall 18. The first 28 and second 32 side walls also have respective straight edge portions 34, 36. The straight edge portions 34, 36 of the two side walls are also positioned at opposite sides of the blower housing outlet opening 26 and with the outer wall first end edge 22 and second end edge 24 define the rectangular configuration of the outlet opening. Each of the side walls 28, 32 is also provided with a circular hole 38, 42 through the side wall. The circular holes 38, 42 are coaxially aligned and function as the air inlet openings of the blower housing 12.

An interior wall 44 of the blower housing 12 is shown in FIGS. 5-11. The interior wall 44 is a flat, planar wall having a circular center hole 46 through the wall. The interior wall 44 is secured to the interior surface of the blower housing outer wall 18 and is positioned in the interior of the blower housing 12 parallel to the side walls 28, 32. The interior wall center hole 46 is coaxial with the inlet openings 38, 42 in the respective side walls 28, 32. The hole 46 through the wall 44 allows a balance of air pressure and air flow on opposite sides of the blower housing interior. In alternate embodiments, the wall 44 could be replaced by a ring having the center hole 46 with the ring connected to the housing interior by three or more circumferentially spaced spokes or webs. In addition, the interior wall 44 is shown in the drawing figures centered in the blower housing 12 relative to the side walls 28, 32. In alternate embodiments of the invention, the interior wall 44 could be positioned off center in the blower housing 12 and more toward one or the other of the side walls 28, 32. Optimum efficiency is achieved when the interior wall concept is employed in a high efficiency blower housing such as those described in pending patent application Ser. Nos. 11/935,726; 12/178,161 and 12/631,415; all of which are incorporated herein by reference.

The motor 16 of the blower assembly is an axial flux motor. The stator 52 of the motor is integrated into the construction of the housing interior wall 44 at the center hole 46 through the wall. The interior wall 44 can be constructed in such a manner that allows for the wiring associated with the stator 52 and the control systems of the motor 16 to be run through the interior of the interior wall 44. Alternatively, the wiring can be run across the exterior surface of the interior wall 44. The stator windings 54 extend radially inwardly from the interior wall 44 into the center hole 46. In the illustrated embodiment of the blower assembly, the stator has thirty six slots and eighteen windings 54. The rotor 56 of the motor includes a hollow cylindrical hub 58 having a bore 62 through the hub 58. The hub 58 is mounted by bearings on the stator 52 for rotation of the hub 58 inside the stator 52. A pair of first and second annular plates 64, 66 project radially outwardly from the opposite ends of the hub 58 over opposite sides of the stator 52 and opposite sides of the interior wall 44. The hub interior bore 62 defines center holes through the plates 64, 66. The hub interior bore 62 and the holes through the plates 64, 66 are all coaxially aligned with the inlet openings 38, 42 through the respective side walls 28, 32 of the blower housing 12. The permanent magnets 68 of the rotor 56 are secured to the interior surface of at least one of the plates 64, 66 that opposes the stator windings 54. In the illustrated embodiment thirty magnets are employed on the rotor 56. In alternate embodiments of the blower assembly, permanent magnets could be provided on both of the plates 64, 66. The circular peripheral edges 72, 74 of the respective plates 64, 66 are secured to the fan 14 of the blower assembly. In addition, the motor 16 need not be positioned at the center of the blower housing interior and could be positioned to either side of the interior by relocating the interior wall 44 supporting the motor 16.

The impeller fan 14 of the blower assembly is comprised of a first centrifugal or squirrel-cage fan 76 and a second centrifugal or squirrel-cage fan 78. The two fans 76, 78 are basically the same in construction. As shown in FIGS. 9-11, the first fan 76 is connected to the peripheral edge 72 of the first annular plate 64 and the second fan 78 is connected to the peripheral edge 74 of the second annular plate 66. This connects the two fans 76, 78 to the rotor 56 with the fans positioned on opposite sides of the blower housing interior wall 44. On operation of the motor 16, the rotor 56 rotates freely relative to the stator 52 and drives the fans 76, 78 in rotation relative to the blower housing interior wall 44 and the blower housing 12.

The bore 62 through the stator hub 58 allows for the balancing of pressure between the interiors of the two fans 76, 78. The bore 62 also allows for the free flow of air between the interiors of the two fans 76, 78 and the two sides of the blower housing interior on opposite sides of the interior wall 44.

The blower assembly constructed in the manner above has no obstructions to the free flow of air through the inlet openings of the blower housing side walls into the interiors of the fans contained in the blower housing. The blower housing assembly also has a smaller size than comparable prior art blower assemblies have motors projecting from one side of their blower housings. This enables it to be used in a narrower air handler enclosure. This is accomplished by positioning the motor in the interior of the blower housing on the inner wall of the housing.

FIGS. 12-18 are schematic representations of the possible positioning of controls 82 for the motor 16 of the blower assembly and the wiring 84 or other electronics communicating the controls with the motor.

In FIG. 12 the motor controls 82 are shown mounted to the exterior of the blower housing outer wall 18. The wiring 84 for the stator 52 extends through the interior of the housing interior wall 44. In other embodiments, the housing interior wall 44 could be replaced by a circular ring with a center opening that supports the motor 16 in the same manner as the interior wall 44, with the ring being secured to the interior of the blower housing outer wall 18 by a plurality of spokes or webs spatially arranged around the ring and extending radially from the ring to the blower housing outer wall 18. In this variant embodiment, the wiring 84 would extend through one of the radially extending spokes or webs. The wiring 84 extending through the interior wall or one of the spokes or webs provides EMI shielding of the wiring.

FIG. 13 is a representation of the controls 82 being mounted on the blower housing interior wall 44 or one of the interior spokes or webs. In this arrangement the controls 82 are contained in a housing having a flat or aerodynamic shape so as not to obstruct air flow. The wiring 84 runs through the interior of the interior wall 44 to the motor 16, or through one of the spokes or webs used as an alternate to the interior wall 44. Power and signal connections to the controls 82 would also extend through the interior wall 44 or supporting spoke or web to the exterior of the blower housing 12.

FIG. 14 represents the motor controls 82 being mounted on the exterior of the blower housing 12. A heat sink 86 for the controls 82 extends through the blower housing 12 to the interior of the blower housing for access to cooling air. The wiring 84 for the stator 52 extends through the interior wall 44 or through one of the alternative spokes or webs directly to the controls 82. If the wiring is routed through the interior of the blower housing 12, it must be positioned to be protected from the blades of the fan 14. In addition, some EMI shielding of the wiring would likely be required. With the controls 82 positioned on the exterior of the blower housing 12, the power and signal cables for the controls are easily accessible.

FIG. 15 is also a representation of the controls 82 being mounted on the exterior of the blower housing 12 with a heat sink 86 extending into the blower housing. In the arrangement shown in FIG. 15, the controls 82 are not an integral part of the interior wall 44 supporting the motor 16 as shown in FIG. 12. Here again, with the controls 82 positioned on the exterior of the blower housing 12, the power and signal cables are easily accessible.

FIG. 16 is a representation of a blower arrangement where the motor is supported by a stationary shaft and the controls 82 being mounted in the center hub 84 of the motor construction, thereby closing the center hub bore 62. A hollow, stationary shaft 88 extends through the motor controls 82 and supports the motor controls in the interior of the blower housing 12. The shaft 88 is connected to the blower housing 12 by three circumferentially spaced rods 92 that connect one end of the shaft 88 to the blower housing 12 and three circumferentially spaced rods 94 that connect the opposite end of the shaft 88 to the blower housing 12. The motor stator 52 is also attached to the stationary shaft 88. Thus, in the construction represented in FIG. 16, there is no need for the interior wall 44 in the blower housing 12. The power and signal connections for the controls 82 would be routed through the interior of the shaft 88 to the exterior of the blower housing 12.

FIG. 17 represents a further arrangement where the center bore 62 is obstructed by the controls 82 positioned at the center of the stator 52. As in the previously-described embodiments, the stator 52 is supported in the blower housing 12 by the interior wall 44, or by the alternative spokes or webs. The power and signal connections for the motor controls 82 are routed through the interior of the interior wall 44, or through the interior of one of the alternative spokes or webs.

FIG. 18 is a representation of an arrangement where the motor stator 52 is mounted to one side of the blower housing 12 and the motor rotor 56 is mounted to one side of the fan 14 adjacent the stator. The motor controls 82 are mounted to the stator 52 at the side of the blower housing 12. One end of the fan 14 is supported by bearings 96 positioned between the fan and the stator 52. The opposite end of the fan 14 is constructed with a center ring 98 and three spokes 102 that extend radially from the ring to the fan. A bearing 104 mounts the fan ring 98 on a shaft 106. The shaft 106 is held stationary to the blower housing 12 by three rods 108 that connect the shaft 106 to the housing.

FIGS. 19-19c show a blower assembly 110 similar to the blower assembly of FIGS. 1-11, but with the center brace being a fin-shaped mount 144 instead of the interior wall 44. For simplicity, the reference numbers for the elements of the blower assembly 110 are the same as corresponding elements of the blower assembly of FIGS. 1-11 except the reference numbers for the blower assembly 110 contain the prefix “1”. The fin-shaped mount 144 supports the motor 116 and the blower housing 112. The fin-shaped mount extends radially from an arcuate portion (shown in FIG. 19c) of the outer periphery of the stator 152. An end portion of the mount 144 extends radially from the blower housing 112. The mount end portion is configured for supporting the motor control circuit 182. Preferably, the mount 144 includes a removable cover member 144a for enclosing the motor control circuit. Referring to FIGS. 19b and 19c, the permanent magnets 168 of the rotor 156 are arranged to form a magnet ring. Each magnet 168 includes an inner edge 168a and an outer edge 168b (see FIG. 19b). The inner edges 168a combine to generally define an inner circumference of the magnet ring. The outer edges 168b combine to generally define an outer circumference of the magnet ring. The diameter of the outer circumference is represented as D_o and the diameter of the inner circumference is represented as D_i. Preferably, the ratio of the diameters of the outer and inner circumferences D_o, D_i is not more than approximately 1.2. Preferably, the blower assembly 110 has nothing obstructing the two inlet openings 138, 142.

In view of the foregoing, it should be appreciated that the invention achieves several advantages over prior art blowers.

As various modifications could be made in the constructions herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.

It should also be understood that when introducing elements of the present invention in the claims or in the above description of exemplary embodiments of the invention, the terms “comprising,” “including,” and “having” are intended to be open-ended and mean that there may be additional elements other than the listed elements. Moreover, use of identifiers such as first, second, and third should not be construed in a manner imposing any relative position or time sequence between limitations.

Claims

1. A blower comprising:

a blower housing having an air outlet opening;

a fan within the blower housing, the fan being adapted for rotation about a fan axis, the fan comprising a first set of impeller blades and a second set of impeller blades, the first set of impeller blades being spaced axially from the second set of impeller blades;

a motor having a stator and a rotor, the rotor being rotatably coupled to the stator for rotation about the fan axis, the rotor and fan being coupled such that the fan rotates with the rotor; and

a support member connected between the stator of the motor and the blower housing and extending generally radially from the fan axis, the support member supporting both the motor and the fan, the support member being between the first set of impeller blades and the second set of impeller blades.

2. A blower as set forth in claim 1 wherein the rotor includes an outer diameter and an axial length, the axial length extending along an axial extent of the fan axis, the axial length of the rotor being not more than approximately one-half of the outer diameter of the rotor.

3. A blower as set forth in claim 2 wherein the axial length of the rotor is not more than approximately one-quarter of the outer diameter of the rotor.

4. A blower as set forth in claim 2 wherein the support member does not extend axially beyond the axial extent of the fan axis.

5. A blower as set forth in claim 1 comprising a single bearing, the bearing transmitting load between the rotor and the stator and transmitting load between the fan and the blower housing.

6. A blower as set forth in claim 5 wherein the motor comprises an axial flux motor.

7. A blower as set forth in claim 1 wherein the support member comprises a wall extending radially outward from adjacent the stator to adjacent the blower housing.

8. A blower as set forth in claim 7 wherein the wall circumscribes the stator.

9. A blower as set forth in claim 1 wherein the support member comprises a fin-shaped mount extending radially from an arcuate portion of the outer periphery of the stator.

10. A blower as set forth in claim 1 wherein the fan extends along a fan axial extent of the fan axis, and wherein the motor is generally axially centered in the fan axial extent of the fan axis.

11. A blower as set forth in claim 1 wherein the rotor of the motor comprises a plurality of magnets arranged to form a magnet ring, each of the plurality of magnets having an inner edge and an outer edge, the inner edges of the magnets combining to generally define an inner circumference and an inner diameter of the magnet ring, the outer edges of the magnets combining to generally define an outer circumference and an outer diameter of the magnet ring, the outer diameter of the magnet ring being not more than approximately 1.2 times the inner diameter.

12. A blower comprising:

a blower housing having an air outlet opening;

a fan within the blower housing, the fan being adapted for rotation about a fan axis;

a motor having a stator and a rotor, the rotor being rotatably coupled to the stator for rotation about the fan axis, the rotor and fan being coupled such that the fan rotates with the rotor; and

a support member connected between the stator of the motor and the blower housing and extending generally radially from the fan axis, the support member supporting both the motor and the fan.

13. A blower as set forth in claim 12 wherein the rotor includes an outer diameter and an axial length, the axial length extending along an axial extent of the fan axis, the axial length of the rotor being not more than approximately one-half of the outer diameter of the rotor.

14. A blower as set forth in claim 12 wherein the axial length of the rotor is not more than approximately one-quarter of the outer diameter of the rotor.

15. A blower as set forth in claim 12 wherein the support member does not extend axially beyond the axial extent of the fan axis.

16. A blower as set forth in claim 12 comprising a single bearing, the bearing transmitting load between the rotor and the stator and transmitting load between the fan and the blower housing.

17. A blower as set forth in claim 16 wherein the motor comprises an axial flux motor.

18. A blower as set forth in claim 12 wherein the support member comprises a wall extending radially outward from adjacent the stator to adjacent the blower housing.

19. A blower as set forth in claim 18 wherein the wall circumscribes the stator.

20. A blower as set forth in claim 12 wherein the support member comprises a fin-shaped mount extending radially from an arcuate portion of the outer periphery of the stator.

21. A blower as set forth in claim 12 wherein the fan extends along a fan axial extent of the fan axis, and wherein the motor is generally axially centered in the fan axial extent of the fan axis.

22. A blower as set forth in claim 12 wherein the rotor of the motor comprises a plurality of magnets arranged to form a magnet ring, each of the plurality of magnets having an inner edge and an outer edge, the inner edges of the magnets combining to generally define an inner circumference and an inner diameter of the magnet ring, the outer edges of the magnets combining to generally define an outer circumference and an outer diameter of the magnet ring, the outer diameter of the magnet ring being not more than approximately 1.2 times the inner diameter.

23. A blower comprising:

a blower housing having an air outlet opening;

a fan within the blower housing, the fan being adapted for rotation about a fan axis;

an axial flux motor having a stator and a rotor, the rotor being rotatably coupled to the stator for rotation about the fan axis, the rotor and fan being coupled such that the fan rotates with the rotor; and

a support structure operatively connecting the stator of the motor to the blower housing.

24. A blower as set forth in claim 23 comprising a single bearing, the bearing transmitting load between the rotor and the stator and transmitting load between the fan and the blower housing.

25. A blower as set forth in claim 23 wherein the fan is integrally connected to the rotor.

26. A blower comprising:

a blower housing having an air outlet opening;

a fan within the blower housing, the fan being adapted for rotation about a fan axis, the fan extending along a fan axial extent of the fan axis; and

a motor having a stator and a rotor, the rotor being rotatably coupled to the stator for rotation about the fan axis, the rotor and fan being coupled such that the fan rotates with the rotor, the rotor including an outer diameter and an axial length, the axial length extending along a rotor axial extent of the fan axis, the axial length of the rotor being not more than approximately one-half of the outer diameter of the rotor, the motor being generally axially centered in the fan axial extent of the fan axis.