U.S. patent application number 10/954718 was filed with the patent office on 2006-04-06 for air pump for an inflatable product.
This patent application is currently assigned to The Coleman Company, Inc.. Invention is credited to Andrew T. Metzger, Lauren D. Worley, Shin Tsai Wu.
Application Number | 20060073040 10/954718 |
Document ID | / |
Family ID | 36125740 |
Filed Date | 2006-04-06 |
United States Patent
Application |
20060073040 |
Kind Code |
A1 |
Metzger; Andrew T. ; et
al. |
April 6, 2006 |
Air pump for an inflatable product
Abstract
A dry cell air pump that provides in excess of ten inches water
column in pressure. A motor is used that draws fewer amps than
prior art motors, yet operates at higher revolutions per minute.
The small motor is capable of providing a high speed of rotation
with relatively low torque, especially in comparison to prior art
motors. To offset the low torque, a high efficiency fan is provided
that rotates at high speeds, yet produces high air volume and
pressure with reduced turbulence. The fan includes upper and lower
walls enclosing the blades for the fan. The upper and lower walls
minimize turbulence and maximize efficiency of the fan, providing a
maximal tip velocity of the fan and thus increased pressure for the
dry cell air pump. The fan includes a series of dimples along its
upper surface that reduce back flow in the fan housing.
Inventors: |
Metzger; Andrew T.; (Belle
Plaine, KS) ; Worley; Lauren D.; (Wichita, KS)
; Wu; Shin Tsai; (Taipei, TW) |
Correspondence
Address: |
LEYDIG, VOIT & MAYER, LTD.;(SEATTLE OFFICE)
TWO PRUDENTIAL PLAZA
SUITE 4900
CHICAGO
IL
60601-6780
US
|
Assignee: |
The Coleman Company, Inc.
Wichita
KS
|
Family ID: |
36125740 |
Appl. No.: |
10/954718 |
Filed: |
September 30, 2004 |
Current U.S.
Class: |
417/423.1 ;
417/411 |
Current CPC
Class: |
F04D 25/084 20130101;
F04D 25/0673 20130101; F04D 29/281 20130101 |
Class at
Publication: |
417/423.1 ;
417/411 |
International
Class: |
F04B 35/04 20060101
F04B035/04; F04B 17/00 20060101 F04B017/00 |
Claims
1. An air pump, comprising: at least one battery, said at least one
battery producing approximately six or less volts; a motor
connected to the battery; a fan connected to the motor for rotation
thereby; and an air outlet in fluid communication with the fan; the
motor and the fan being configured to produce at least
approximately ten inches water column in pressure at the air
outlet.
2. The air pump of claim 1, wherein the motor and the fan are
configured to produce at least approximately twelve inches water
column in pressure.
3. The air pump of claim 1, wherein the fan comprises: a first
wall; a second wall; and blades extending between the first wall
and the second wall.
4. The air pump of claim 3, wherein the fan further comprises an
air inlet on the first wall and protrusions on the first wall.
5. The air pump of claim 4, further comprising a fan housing in
which the fan rotates, and wherein the fan housing includes groves
for receiving the protrusions when the fan is rotating in the fan
housing.
6. The air pump of claim 1, wherein said at least one battery
comprises four 1.5 volt dry cell batteries.
7. The air pump of claim 6, wherein the four 1.5 volt dry cell
batteries each comprise a D-cell battery.
8. The air pump of claim 6, wherein the motor is rated for less
than 6 volts.
9. The air pump of claim 8, wherein the motor is rated for
approximately 4 volts.
10. The air pump of claim 1, wherein the motor is rated for less
than 6 volts.
11. The air pump of claim 10, wherein the motor is rated for
approximately 4 volts.
12. An air pump, comprising: at least one battery, said at least
one battery producing approximately six volts; a motor connected to
the battery and having a rated voltage of less than six volts; a
fan connected to the motor for rotation thereby and comprising: a
first wall; a second wall; and blades extending between the first
wall and the second wall.
13. The air pump of claim 12, wherein the motor and the fan are
configured to produce at least approximately ten inches water
column in pressure.
14. The air pump of claim 13, wherein the motor and the fan are
configured to produce at least approximately twelve inches water
column in pressure.
15. The air pump of claim 12, wherein the fan further comprises an
air inlet on the first wall and protrusions on the first wall.
16. The air pump of claim 15, further comprising a fan housing in
which the fan rotates, and wherein the fan housing includes groves
for receiving the protrusions when the fan is rotating in the fan
housing.
17. The air pump of claim 12, wherein said at least one battery
comprises four 1.5 volt dry cell batteries.
18. The air pump of claim 17, wherein the four 1.5 volt dry cell
batteries each comprise a D-cell battery.
19. The air pump of claim 12, wherein the motor is rated for
approximately 4 volts.
20. An air pump, comprising: a motor; a fan connected to the motor
for rotation thereby and comprising: a first wall; blades extending
from the top wall; and an air inlet on the first wall and
protrusions on the first wall.
21. The air pump of claim 20, further comprising a fan housing in
which the fan rotates, and wherein the fan housing includes groves
for receiving the protrusions when the fan is rotating in the fan
housing.
22. The air pump of claim 20, wherein the fan further comprises a
second wall, and the blades extend between the first and second
walls.
23. An air pump comprising: a finger guard at one of an outlet and
an inlet for the air pump, the finger guard including a structure
for blocking a finger or a foreign object from entering said one of
the outlet and the inlet, and the structure being shaped in an air
foil design.
24. The air pump of claim 23, wherein the structure comprises an
"X" shape.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention is directed to air pumps, and more
specifically to air pumps for inflatable products.
BACKGROUND OF THE INVENTION
[0002] An airbed is a large rectangular rubber or plastic bag that
is filled with air so that it may be used as a bed. An airmat is
similar in construction to an airbed, but is used as a float so
that an individual may lie on the airmat on the water. Both
products fall under the broad category of "inflatable" products.
Other nonlimiting examples of inflatable products include rafts,
inflatable furniture, inflatable pools, and inflatable boats.
[0003] One thing inflatable products have in common is that they
must be inflated for use. To this end, a valve or valves are
supplied on each inflatable product for a user to provide air or
another gas into the inflatable product. The user may utilize his
or her breath, i.e., by blowing into a valve or valves, or may
utilize a manual or electric pump. More often, for larger
inflatable products, such as airbeds or inflatable boats, a pump is
used.
[0004] Electric pumps for inflatable products generally fall into
three categories: alternating current (AC) pumps, which are
supplied electricity through an electrical outlet; rechargeable
pumps, which have rechargeable batteries that are recharged as
needed; and pumps that utilize dry cell non-rechargeable direct
current ("DC") batteries ("dry cell air pumps"). The dry cell air
pumps are popular, because they are relatively inexpensive and dry
cell batteries are easy to obtain. One popular model utilizes four
D-cell batteries. An example of such a model is shown in U.S.
Design Pat. No. D445,804.
[0005] Although the dry cell air pumps for the most part work well
for their intended purpose, often they are limited in that they may
not be able to supply a sufficient amount of pressure to adequately
inflate larger inflatable products. For example, large airbeds,
such as double-high airbeds, often require a large volume of air at
high pressure to provide sufficient firmness for some
individuals.
[0006] Manufacturers have tried to address air pressure problems by
providing as large of a motor as possible, given the voltage
provided by the batteries. As an example, a four D battery dry cell
air pump has six volts of dry cell power. One prior art four D dry
cell air pump utilizes a six volt motor drawing 7.8 amps. In
practice, it has been observed that 7.8 amps is too much of a draw
on the motor, and the four D dry cell batteries can not maintain
six volts and 7.8 amps, and more realistically produce four volts
at approximately 3.5 amps. Thus, the results are that the motor
runs too slowly, or that the batteries are stressed.
[0007] The applicants are aware of prior art dry cell air pumps
that have produced up to eight inches of water column (in WC) in
pressure. Although eight in WC may produce firmness that is
sufficient for some users of airbeds, there are users who desire a
more firm airbed.
SUMMARY OF THE INVENTION
[0008] The following presents a simplified summary of some
embodiments of the invention in order to provide a basic
understanding of the invention. This summary is not an extensive
overview of the invention. It is not intended to identify
key/critical elements of the invention or to delineate the scope of
the invention. Its sole purpose is to present some embodiments of
the invention in a simplified form as a prelude to the more
detailed description that is presented later.
[0009] In accordance with an embodiment, a dry cell air pump is
provided that provides in excess of ten inches water column in
pressure. The dry cell air pump utilizes, in one embodiment, four D
cell batteries.
[0010] In accordance with an embodiment, a motor is used that
utilizes less voltage than available from the batteries in the
pump, allowing the motor to run at maximum efficiency. In one
embodiment, a 4.0 volt motor is used with four D cell batteries.
The small motor is capable of providing a high speed of rotation
(e.g., 24,000 RPM's when loaded). However, the low voltage of the
motor results in relatively low torque, especially in comparison to
prior art motors. To offset the low torque, a high efficiency fan
is provided that produces high air volume and pressure with little
turbulence. The fan includes upper and lower walls enclosing the
blades for the fan. The upper and lower walls minimize turbulence
and maximize efficiency of the fan, providing a maximal tip
velocity of the fan and thus increased pressure for the dry cell
air pump, with very little torque requirement from the small
electrical motor.
[0011] In accordance with an embodiment, the fan includes a series
of dimples along its upper surface. These dimples align with
grooves in an upper part of the fan housing of the dry cell air
pump. The engagement of the dimples with the grooves minimizes
pressure loss and back air flow by interrupting air that attempts
to flow backward along the top of the fan.
[0012] Other features of the invention will become apparent from
the following detailed description when taken in conjunction with
the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a side perspective view of a dry cell air pump
incorporating an embodiment of the invention;
[0014] FIG. 2 is an exploded perspective view of the dry cell air
pump of FIG. 1;
[0015] FIG. 3 is a cross sectional view taken along the section
lines 3-3 of FIG. 5;
[0016] FIG. 4 is a side perspective view of a finger guard that may
be used with the dry cell air pump of FIG. 1 in accordance with an
embodiment of the invention; and
[0017] FIG. 5 is an exploded side perspective view of an upper
portion of the fan housing of the fan for the dry cell air pump of
FIG. 1.
DETAILED DESCRIPTION
[0018] In the following description, various embodiments of the
present invention will be described. For purposes of explanation,
specific configurations and details are set forth in order to
provide a thorough understanding of the embodiments. However, it
will also be apparent to one skilled in the art that the present
invention may be practiced without the specific details.
Furthermore, well-known features may be omitted or simplified in
order not to obscure the embodiment being described.
[0019] Referring now to the drawings, in which like reference
numerals represent like parts throughout the several views, FIG. 1
shows a dry cell air pump 20 in accordance with an embodiment of
the invention. Some aspects of the present invention may be
utilized with electric pumps or manual pumps, but throughout this
disclosure, the embodiments will be described with respect to a dry
cell air pump, specifically the dry cell air pump 20.
[0020] The dry cell air pump 20 includes a motor housing 22
underneath a fan housing 24, although the two housings may be
arranged differently, or may be provided as a single structure. In
the embodiment shown, four D cell batteries 26 are mounted within
the motor housing 22 and about a motor 28. A switch 30 is provided
on the outside of the motor housing 22 for turning on and off
operation of the dry cell air pump 20. The D cell batteries 26 are
removable from the motor housing 22 via a removable battery pan 32.
Latches 34 are provided for releasing and attaching the battery pan
32 to the bottom of the motor housing 22. As such, the battery pan
32 may be removed to provide access to the inside of the motor
housing 22 so that the D cell batteries 26 may be replaced.
Contacts 36 are provided inside the motor housing 22 for providing
power from the D cell batteries 26 to the motor 28 in accordance
with operation of the switch 30 in a manner known in the art.
[0021] In the embodiment shown, the fan housing 24 is formed by a
fan cover 48 fitting over the motor housing 26. The fan cover 48 is
shaped so that, when it fits over the motor housing 26, an internal
air chamber 50 (shown generally in FIG. 2) is formed. A fan 52 is
mounted within the air chamber 50 for rotation by the motor 28. An
outlet 54 is positioned at one edge of the air chamber 50 for
permitting flow of air out of the air chamber 50, for example into
an inflatable product via a flexible conduit (not shown, but known
in the art). An inlet 55 is provided on the top of the fan housing
24 through which air is drawn into the fan 52, which in turn is
blown out through the outlets 54.
[0022] Details of the fan 52 can be seen in FIG. 3. The fan 52
includes a lower wall 56 and an upper cover 58. The upper cover 58
serves as a wall that extends adjacent to the upper portion of the
fan 52. Blades 60 extend between the lower wall 56 and the cover 58
from a position spaced from a central access of the fan 52 outward
to outer edges or tips of the fan 52. An air inlet 62 is positioned
centrally in the cover 58 and is in fluid communication with the
blades 60. In operation, the motor 28 rotates the fan 52 so that
air is drawn through the inlet 55 in the fan housing 24 and down
into the air inlet 62 of the fan. This air is then blown through
the blades 60 and out of the tips of the fan 52. The lower wall 56
and the upper cover 58 direct the majority of the air outward, in a
more efficient manner than current designs.
[0023] In accordance with an embodiment, the motor 28 utilizes less
voltage than available from the batteries 26, allowing the motor to
run at maximum efficiency. In one embodiment, a 4.0 volt motor is
used with four D cell batteries. For example, a Nichibo DC Motor,
Model number LD3FN-5015B-C/58, produced by Nichibo Taiwan
Corporation, Taipei, Taiwan, may be used, which has a maximum
torque of 32.975 Amps and is capable of providing a high speed of
rotation (24,200 RPM's with no load). However, the low voltage of
the motor results in relatively low torque, especially in
comparison to prior art motors. To offset the low torque, the high
efficiency fan 52 is utilized that produces high air volume and
pressure with less turbulence.
[0024] Applicants have found that such a motor 28, when operating
with the fan 52, can produce a significant amount of pressure out
of the outlet 54 of the fan housing 24. This pressure is provided
in part because the motor 28 has sufficient power from the four D
cell batteries 26 and in part because the fan 52 is a stable
structure that is capable of rotating at high revolutions per
minute, for example when loaded at approximately 14,000 revolutions
per minute. By rotating the fan 52 at high speed, the tip velocity
of the fan 52 is increased, thereby increasing the pressure of the
air flowing out of the outlet 54 of the fan housing 24. Applicants
have found that utilizing the motor 28 described herein and a fan
52 having the following dimensions: TABLE-US-00001 Diameter 68.2
millimeters Height 8.5 millimeters Outer Slope of Upper Cover 7
degrees Air Inlet Opening Diameter 24.818 millimeters Total Wieght
0.024 pounds
that a pressure of at least 10 inches of water can be provided and
up to at least 12 inches of water. Utilizing such a structure, the
dry cell air pump 20 is capable of inflating a double-high queen
sized airbed in less than four minutes, with the airbed having
significant firmness. Applicants are not aware of any prior art
non-rechargeable dry cell air pump 20 that is capable of generating
this type of air pressure, and particularly is not aware of four D
cell battery models that are capable of producing this type of air
pressure.
[0025] In accordance with an embodiment, the cover 58 of the fan 52
includes dimples 64 positioned about the cover 58 of the fan 52.
The dimples 64 reduce pressure loss during rotation of the fan 52,
and reduce back air flow. As discussed above, in operation of the
dry cell air pump 20, air is blown out of the outlet 54. As an
inflatable product is filled, there is some air pressure push back
from the inflatable product. The air that is push back-attempt to
try to go over and under the fan. The air at the bottom of the fan
52 stabilizes, but the air at the top of the fan 52 attempts to go
out the outlet 55 of the fan housing. It is believed that the
dimples 64 partially block this travel of air to the outlet 55,
thus reducing back flow.
[0026] In accordance with an embodiment, an aerodynamic finger
guard 70 (FIG. 4) is provided for the dry cell air pump 20. The
finger guard 70 may be used at the outlet 54, the inlet 55, or
both. The finger guard 70 includes a structure for blocking a
finger or a foreign object from entering the outlet 54 and/or the
inlet 55. In the embodiment shown, the structure is an "X" 72, but
other structures may be provided. In accordance with an embodiment,
the structure blocking the user's finger or other foreign objects
from entering the outlet 54 and/or the inlet 55 is shaped in an air
foil design, minimizing turbulence for air flowing past the
structure. As such, air flow volume and air pressure drop over the
finger guard 70 is minimized.
[0027] Other variations are within the spirit of the present
invention. Thus, while the invention is susceptible to various
modifications and alternative constructions, a certain illustrated
embodiment thereof is shown in the drawings and has been described
above in detail. It should be understood, however, that there is no
intention to limit the invention to the specific form or forms
disclosed, but on the contrary, the intention is to cover all
modifications, alternative constructions, and equivalents falling
within the spirit and scope of the invention, as defined in the
appended claims.
[0028] All references, including publications, patent applications,
and patents, cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically indicated to be incorporated by reference and were set
forth in its entirety herein.
[0029] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the invention (especially in
the context of the following claims) are to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. The terms "comprising,"
"having," "including," and "containing" are to be construed as
open-ended terms (i.e., meaning "including, but not limited to,")
unless otherwise noted. The term "connected" is to be construed as
partly or wholly contained within, attached to, or joined together,
even if there is something intervening. Recitation of ranges of
values herein are merely intended to serve as a shorthand method of
referring individually to each separate value falling within the
range, unless otherwise indicated herein, and each separate value
is incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate embodiments of the invention
and does not pose a limitation on the scope of the invention unless
otherwise claimed. No language in the specification should be
construed as indicating any non-claimed element as essential to the
practice of the invention.
[0030] Preferred embodiments of this invention are described
herein, including the best mode known to the inventors for carrying
out the invention. Variations of those preferred embodiments may
become apparent to those of ordinary skill in the art upon reading
the foregoing description. The inventors expect skilled artisans to
employ such variations as appropriate, and the inventors intend for
the invention to be practiced otherwise than as specifically
described herein. Accordingly, this invention includes all
modifications and equivalents of the subject matter recited in the
claims appended hereto as permitted by applicable law. Moreover,
any combination of the above-described elements in all possible
variations thereof is encompassed by the invention unless otherwise
indicated herein or otherwise clearly contradicted by context.
* * * * *