U.S. patent application number 15/148647 was filed with the patent office on 2016-09-01 for air supply device and related methods of manufacture.
The applicant listed for this patent is Prolitec Inc.. Invention is credited to Matthew Ansley, Nathan Sward, Howard Tanner.
Application Number | 20160252088 15/148647 |
Document ID | / |
Family ID | 53059470 |
Filed Date | 2016-09-01 |
United States Patent
Application |
20160252088 |
Kind Code |
A1 |
Ansley; Matthew ; et
al. |
September 1, 2016 |
AIR SUPPLY DEVICE AND RELATED METHODS OF MANUFACTURE
Abstract
A pump device is provided including: a unitary pump frame; an
electromagnet arrangement that includes a winding wrapped around a
portion of the unitary pump frame; a diaphragm assembly coupled to
the unitary pump frame, which includes a movable diaphragm and a
manifold; and a pump arm having a proximal end coupled to the
unitary pump frame and a distal end supporting a permanent magnet
to interact with the electromagnet arrangement to cause the pump
arm to swing back and forth during operation to displace the
diaphragm and discharge an air stream from the pump device. Related
methods of manufacture are also provided.
Inventors: |
Ansley; Matthew; (Muskego,
WI) ; Sward; Nathan; (Milwaukee, WI) ; Tanner;
Howard; (Wauwatosa, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Prolitec Inc. |
Milwaukee |
WI |
US |
|
|
Family ID: |
53059470 |
Appl. No.: |
15/148647 |
Filed: |
May 6, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14693716 |
Apr 22, 2015 |
9358562 |
|
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15148647 |
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61982504 |
Apr 22, 2014 |
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Current U.S.
Class: |
261/30 |
Current CPC
Class: |
A61M 11/02 20130101;
F04B 45/047 20130101; B01F 3/0446 20130101; B01F 3/04021 20130101;
B05B 7/265 20130101; A61L 2209/134 20130101; B05B 1/26 20130101;
B01F 2005/0448 20130101; B05B 7/2489 20130101; B01F 5/0413
20130101; B01F 3/04007 20130101; F24F 3/16 20130101; F04B 39/0044
20130101; A61L 9/145 20130101; F24F 2003/1689 20130101; B01F
2215/009 20130101; F04B 53/003 20130101; B05B 7/0012 20130101; B05B
7/24 20130101; F04B 39/121 20130101; B01F 15/0244 20130101; F04B
39/127 20130101; A61L 9/14 20130101; F04B 53/16 20130101 |
International
Class: |
F04B 53/00 20060101
F04B053/00; B01F 15/02 20060101 B01F015/02; B01F 3/04 20060101
B01F003/04; F04B 45/047 20060101 F04B045/047; F04B 53/16 20060101
F04B053/16 |
Claims
1. An air pump comprising: a unitary pump frame having a bobbin
portion integrally formed with a remainder of the unitary pump
frame; an electromagnet arrangement including a winding wrapped
directly around the bobbin portion of the unitary pump frame such
that at least a portion of the winding is in direct contact with
the bobbin portion of the unitary pump frame; a diaphragm assembly
coupled to and supported by the unitary pump frame, the diaphragm
assembly including a movable diaphragm and a manifold; and a pump
arm having a proximal end and a distal end, the proximal end of the
pump arm coupled to the unitary pump frame and the distal end of
the pump arm including a magnet to interact with the electromagnet
arrangement to cause the pump arm to swing back and forth to
displace the movable diaphragm during operation of the air
pump.
2. The air pump of claim 1 wherein the bobbin portion of the
unitary pump frame around which the winding of the electromagnet
arrangement is wrapped resembles includes a hollow core and
opposing flanges.
3. The air pump of claim 1, further comprising: a plurality of
flexible, resilient tethers extending from the unitary pump frame
for suspending the air pump within an internal cavity of a housing
or a host device.
4. The air pump of claim 3 wherein the plurality of flexible,
resilient tethers and unitary pump frame are formed via a
multi-material injection molding process to form an integrated
frame structure with tethers extending therefrom.
5. The air pump of claim 4 wherein the plurality of flexible,
resilient tethers, the unitary pump frame and a manifold seal are
formed via a multi-material injection molding process to form an
integrated structure, and wherein the manifold of the diaphragm
assembly is engaged with the manifold seal.
6. The air pump of claim 3, wherein the plurality of flexible,
resilient tethers include barbs to selectively engage apertures of
the housing or the host device to maintain the unitary pump frame
suspended within the internal cavity.
7. The air pump of claim 1 wherein the unitary pump frame includes
a pump arm receiving aperture sized and shaped to receive a
corresponding portion of the proximal end on the pump arm in a
press-fit or friction-fit.
8. The air pump of claim 1 wherein the unitary pump frame defines a
closed perimeter around the diaphragm assembly and the pump
arm.
9. The air pump of claim 1 wherein the unitary pump frame includes
retaining structures positioned to engage each of opposing ends of
the manifold of the diaphragm assembly to assist in coupling the
manifold to the unitary pump frame.
10. The air pump of claim 9 wherein a manifold seal is provided
adjacent a manifold receiving portion of the unitary pump frame and
wherein the retaining structures assist in maintaining the manifold
in sealed engagement with the manifold seal.
11. The air pump of claim 1 wherein the electromagnet arrangement
includes an electromagnet core having a pair of legs, and wherein
the unitary pump frame includes a bulkhead portion having a
corresponding pair of apertures to receive the legs of the
electromagnet core.
12. The air pump of claim 11 wherein the corresponding pair of
apertures in the bulkhead portion of the unitary pump frame are
sized and shaped to receive the legs of the electromagnet core in a
press-fit or friction-fit.
13. The air pump of claim 1 wherein the unitary pump frame includes
an upper bulkhead and terminals are provided at or proximate the
upper bulkhead for supplying power to the electromagnet
arrangement.
14. The air pump of claim 1 wherein the unitary pump frame is an
open-sided structure that is configured to receive the diaphragm
assembly and the pump arm as a pump cartridge in a direction
transverse to a plane defined by an oscillating motion of the pump
arm.
15. An air treatment system comprising: a housing; a diffusion head
received in the housing; and the air pump of claim 1 operably
connected to the diffusion head for diffusing liquid contained in
the housing.
16. The air treatment system of claim 15, further comprising: a
plurality of flexible, resilient tethers extending from the unitary
pump frame and suspending the air pump within an internal cavity of
the housing.
17. The air treatment system of claim 16, further comprising: a
sound deadening or muffling device in the housing to reduce noise
emanating therefrom.
18. The air treatment system of claim 17 wherein the sound
deadening or muffling device substantially encloses the air pump
and defines an air gap therebetween.
19. An air pump comprising: an open-sided, one-piece pump frame
defining a closed perimeter structure with an internal pump
assembly cavity, and having a bobbin portion formed integrally with
a remainder of the pump frame, an electromagnet arrangement
including a winding wrapped directly around the bobbin portion of
the pump frame such that the winding is in direct contact with the
bobbin portion; a diaphragm assembly coupled to and supported by
the pump frame within the pump assembly cavity, the diaphragm
assembly including a movable diaphragm and a manifold; and a pump
arm having a proximal end and a distal end, the proximal end of the
pump arm coupled to the pump frame to support the pump arm within
the pump assembly cavity, and the distal end of the pump arm
including a magnet to interact with the electromagnet arrangement
to cause the pump arm to swing back and forth to displace the
movable diaphragm during operation of the air pump.
20. The air pump of claim 19 wherein the diaphragm assembly and the
pump arm collectively define a pump cartridge, and wherein the pump
frame is configured to insertably receive the pump cartridge in a
direction transverse to a plane defined by an oscillating motion of
the pump arm.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to air supply devices and,
more particularly, to air supply devices (e.g., air pumps) suitable
for supplying air to liquid diffusion devices for air treatment
purposes and related methods of manufacture.
[0003] 2. Description of the Related Art
[0004] Air supply devices (e.g., air pumps) are known which include
an electromagnet assembly having a core and a coil powered by an AC
power source, a vibrating arm having a permanent magnet at its end,
which is oscillated within an alternating magnetic field of the
electromagnet assembly, a cup or bowl-shaped elastic diaphragm
fixed at the intermediate portion of the vibrating arm, and a valve
housing having inlet and outlet one-way valves to open or shut
inlet and outlet ports. The diaphragm is arranged relative to the
valve housing so as to transmit the oscillation of the vibrating
arm to supply air to an external device through a suitable conduit.
An example of such an air pump is shown and described in U.S. Pat.
No. 3,825,374. Conventional air pumps of this type, however, may
suffer from a variety of deficiencies or drawbacks, including, for
example, being overly complex or cumbersome to manufacture.
Conventional air pumps may also be unnecessarily large, noisy,
inefficient, and/or unreliable and may transmit undesirable
vibrations to surrounding structures.
BRIEF SUMMARY
[0005] The air supply devices or pumps described herein are
provided in particularly efficient form factors for use in
connection with a wide variety of applications, including, for
example, the supply of pressurized air to liquid diffusion devices
for air treatment purposes. The air supply devices may also be
particularly reliable and efficient, may have relatively small or
compact form factors, and may exhibit low noise levels and low
vibration transmission to surrounding structures.
[0006] At least one embodiment of an air supply device in the form
of an air pump may be summarized as including: a unitary pump
frame; an electromagnet arrangement including a winding wrapped
around a portion of the unitary pump frame; a diaphragm assembly
coupled to the unitary pump frame, the diaphragm assembly including
a movable diaphragm and a manifold; and a pump arm having a
proximal end and a distal end, the proximal end of the pump arm
coupled to the unitary pump frame and the distal end of the pump
arm including a magnet to interact with the electromagnet
arrangement to cause the pump arm to swing back and forth to
displace the movable diaphragm during operation of the air pump.
The portion of the unitary pump frame around which the winding of
the electromagnet arrangement is wrapped may resemble a bobbin
having a hollow core and opposing flanges.
[0007] The air pump may further include a plurality of flexible,
resilient tethers extending from the unitary pump frame for
suspending the air pump within an internal cavity of a housing or
other host device. The plurality of flexible, resilient tethers and
unitary pump frame may be formed via a multi-material injection
molding process to form an integrated frame structure with tethers
extending therefrom. Additionally, a manifold seal may be formed
via the multi-material injection molding process to form an
integrated structure. The plurality of flexible, resilient tethers
may include barbs to selectively engage apertures of the housing or
the host device to maintain the unitary pump frame suspended within
the internal cavity. The unitary pump frame may include a pump arm
receiving aperture that is sized and shaped to receive a
corresponding portion of the proximal end on the pump arm in a
press-fit or friction-fit. The unitary pump frame may define a
closed perimeter around the diaphragm assembly and the pump arm.
The unitary pump frame may include retaining structures positioned
to engage each of opposing ends of the manifold of the diaphragm
assembly to assist in coupling the manifold to the unitary pump
frame.
[0008] The electromagnet arrangement may include an electromagnet
core having a pair of legs, and the unitary pump frame may include
a bulkhead portion having a corresponding pair of apertures to
receive the legs of the electromagnet core. The corresponding pair
of apertures in the bulkhead portion of the unitary pump frame may
be sized and shaped to receive the legs of the electromagnet core
in a press-fit or friction-fit. The unitary pump frame may include
an upper bulkhead and terminals may be provided at or proximate the
upper bulkhead for supplying power to the electromagnet arrangement
from an AC power source. The unitary pump frame may be an
open-sided structure that is configured to receive the diaphragm
assembly and the pump arm as a pump cartridge in a direction
transverse to a plane defined by an oscillating motion of the pump
arm.
[0009] The air pump may be part of an air treatment system
including a housing and a diffusion head received in the housing
and may be operably connected to the diffusion head for diffusing
liquid contained in the housing. The air treatment system may
further include a plurality of flexible, resilient tethers
extending from the unitary pump frame to suspend the air pump
within an internal cavity of the housing. A sound deadening or
muffling device may be provided in the housing to reduce noise
emanating therefrom.
[0010] At least one embodiment of a manufacturing method may be
summarized as including: providing a unitary pump frame with a
winding of an electromagnet arrangement wrapped around a portion
thereof; coupling a pump cartridge to the unitary pump frame, the
pump cartridge including a manifold subassembly and a pump arm
subassembly; and thereafter coupling an electromagnet core of the
electromagnet arrangement to the unitary pump frame such that at
least a portion of the electromagnet core passes through the
winding of the electromagnet arrangement.
[0011] The method may further include prior to coupling the pump
cartridge to the unitary pump frame, press-fitting or
friction-fitting the manifold subassembly into a movable diaphragm
of the pump arm subassembly. Coupling the pump cartridge to the
unitary pump frame may include press-fitting or friction-fitting a
proximal end of a pump arm of the pump arm subassembly into a
corresponding aperture of the unitary pump frame. Coupling the pump
cartridge to the unitary pump frame may further include securing
the manifold subassembly to the unitary pump frame with a fastener.
Coupling the electromagnet core of the electromagnet arrangement to
the unitary pump frame may include press-fitting or
friction-fitting leg portions of the electromagnet core into
corresponding apertures of the unitary pump frame.
[0012] The method may further include suspending the unitary pump
frame within an internal housing cavity via a plurality of
flexible, resilient tethers and selectively adjusting a tension of
one or more of the plurality of flexible, resilient tethers. The
method may further include providing a sound deadening or muffling
device in the internal housing to reduce noise emanating therefrom.
The method may also include coupling an air outlet of the manifold
subassembly to a liquid diffusion device for air treatment
purposes.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] FIG. 1 is an isometric view of an air supply device,
according to one embodiment.
[0014] FIG. 2 is a front elevational view of the air supply device
of FIG. 1.
[0015] FIG. 3 is an isometric view of a frame structure of the air
supply device of FIG. 1.
[0016] FIGS. 4 through 7 provide a sequence of isometric views
illustrating a method of manufacturing the air supply device of
FIG. 1, according to one embodiment.
[0017] FIGS. 8 and 9 are perspective views of a manifold portion of
the air supply device of FIG. 1 from each of opposing sides
thereof.
[0018] FIG. 10 is a perspective view of the air supply device of
FIG. 1 shown suspended within a housing and surrounded by a sound
deadening or muffling device, according to one example
embodiment.
DETAILED DESCRIPTION
[0019] In the following description, certain specific details are
set forth in order to provide a thorough understanding of various
disclosed embodiments. However, one skilled in the relevant art
will recognize that embodiments may be practiced without one or
more of these specific details. In other instances, well-known
devices, structures and techniques associated with air supply
devices (e.g., air pumps), components thereof and related methods
of manufacture may not be shown or described in detail to avoid
unnecessarily obscuring descriptions of the embodiments.
[0020] Unless the context requires otherwise, throughout the
specification and claims which follow, the word "comprise" and
variations thereof, such as, "comprises" and "comprising" are to be
construed in an open, inclusive sense, that is as "including, but
not limited to."
[0021] Reference throughout this specification to "one embodiment"
or "an embodiment" means that a particular feature, structure or
characteristic described in connection with the embodiment is
included in at least one embodiment. Thus, the appearances of the
phrases "in one embodiment" or "in an embodiment" in various places
throughout this specification are not necessarily all referring to
the same embodiment. Furthermore, the particular features,
structures, or characteristics may be combined in any suitable
manner in one or more embodiments.
[0022] As used in this specification and the appended claims, the
singular forms "a," "an," and "the" include plural referents unless
the content clearly dictates otherwise. It should also be noted
that the term "or" is generally employed in its sense including
"and/or" unless the content clearly dictates otherwise.
[0023] The present disclosure relates generally to air supply
devices and more particularly to air supply devices suitable for
supplying air for a variety of different purposes and related
methods of manufacture. For example, the air supply devices 10
described herein may be included or otherwise coupled to a liquid
diffusion device for supplying air to the liquid diffusion device
for air treatment purposes. Such liquid diffusion devices may
include, for example, those shown and described in Applicant's
co-pending application Ser. Nos. 14/612,066 and 14/612,072, both
filed on Feb. 2, 2015, which are incorporated herein by reference
in their entireties.
[0024] With reference to FIGS. 1 and 2, one example embodiment of
an air supply device 10 in the form of an air pump is provided. The
air supply device 10 includes a frame structure 12 coupleable to a
housing 102 (FIG. 10) or other host device via a plurality of
flexible, resilient tethers 14 that extend from the frame structure
12 for suspending the air supply device 10 within an internal
cavity 110 of the housing 102 or other host device. The frame
structure 12 may include a unitary frame body 20 that provides a
generally rigid foundation for other components of air supply
device 10. For example, the unitary frame body 20 provides a
foundation for an electromagnet arrangement 22 and a pump cartridge
24 that is provided adjacent the electromagnet arrangement 22 to
interact with the same during operation of the air supply device
10. The electromagnet arrangement 22 may include an electromagnet
core 26 with opposing leg portions 28, 30 that define opposing
poles and a winding 32 (e.g., 1,250 turns of 32 gauge wire)
surrounding one of the leg portions 30 and a bobbin or bobbin-like
structure 82 of the unitary frame body 20. The electromagnet core
26 may comprise a laminated stack of plates pinned or otherwise
secured together. The electromagnet arrangement 22 may further
include electrical terminals 34 coupled to the winding 32 for
supplying AC power to the electromagnet arrangement 22 during
operation to create an alternating magnet field. The electrical
terminals 34 may be folded down in front of the winding 32 to
reduce the size of the air supply device 10.
[0025] With continued reference to FIGS. 1 and 2, the pump
cartridge 24 may include a pump arm subassembly 40 coupled to a
manifold subassembly 42. The manifold subassembly 42 may include a
manifold 44 with internal valving 46, 48 (FIGS. 8 and 9) arranged
to operate in conjunction with a movable diaphragm 50 of the pump
arm subassembly 40 to draw air into the manifold 44 via an air
inlet 52 provided at one end of the manifold 44 and to discharge
air out via an outlet conduit 54 coupled to an air outlet 56 of an
outlet nipple 57 provided at the other end of the manifold 44. More
particularly, the pump arm subassembly 40 may include a pump arm 60
having a proximal end 62 and a distal end 64 with the proximal end
62 of the pump arm 60 being coupled to the unitary frame body 20
and with the distal end 64 of the pump arm 60 including a permanent
magnet 66 to interact with the electromagnet arrangement 22 to
cause the pump arm 60 to swing back and forth during operation of
the air supply device 10, as indicated by arrows labeled 36 in FIG.
2, to displace the movable diaphragm 50 and force air to move
through the manifold 44 from the inlet 52 to the outlet 56.
[0026] Additional details of the frame structure 12 of the air
supply device 10 are described with reference to FIG. 3. As shown,
the frame structure 12 may include the unitary frame body 20 and
the plurality of flexible, resilient tethers 14 for suspending the
air supply device 10 within the internal cavity 110 of the housing
102 or other host device. In some instances, the plurality of
flexible, resilient tethers 14 and unitary frame body 20 may be
formed via a multi-material injection molding process to form an
integrated frame structure 12 with tethers 14 extending therefrom,
as shown in FIG. 3. The frame structure 12 may also include a
manifold seal 45 that is formed via a multi-material injection
molding process with the unitary frame body 20 and the tethers 14
to form an integrated frame structure 12 having tethers 14 and the
manifold seal 45. In this manner, the frame structure 12 shown in
FIG. 3 can be supplied for assembly as a single unitary part having
different portions with different material properties and related
functionality. For example, the unitary frame body 20 may be formed
of a rigid or semi-rigid material for providing a foundation or
support structure for other components of the air supply device 10,
the tethers 14 may be formed of a flexible, resilient material that
is configured to suspend the air supply device 10 and isolate
and/or dampen motion of the air supply device 10 relative to the
housing 102 (FIG. 10) or other host device or structure, and the
manifold seal 45 may be formed of compressible seal materials for
forming an air-tight seal between the manifold 44 and a manifold
backing portion 47 of the frame body 20.
[0027] The tethers 14 may be formed to include barbs 15 or other
structures for assisting in fastening the air supply device 10 to
the housing 102 or other host device. Advantageously, the tethers
14 of the illustrated embodiment may be conveniently fed through
corresponding apertures 108 in the housing 102 or other host device
and selectively brought into a generally taut or stretched
configuration by pulling the tethers 14 until an appropriate one of
the barbs 15 passes through the corresponding aperture 108 in a
compressed form and then expands to engage the structure of the
housing 102 or other host device that surrounds the aperture
108.
[0028] The manifold seal 45 may be formed to be generally planar
and may have an overall profile that substantially corresponds to
that of the manifold 44, which is held in contact with the manifold
seal 45 upon assembly. Each of the manifold seal 45 and the
manifold backing portion 47 of the frame body may also be provided
with an aperture 49 for receiving a fastener 43 therethrough for
retaining the manifold 44 of the manifold subassembly 42 in
engagement with the manifold seal 45. For this purpose, the
manifold 44 may include a boss 55 with an aperture 58 provided
therein for receiving the fastener 43, as shown best in FIG. 4.
With reference again to FIG. 3, the unitary frame body 20 may
further include retaining structures 51, 53 which are positioned to
engage each of opposing ends of the manifold 44 of the manifold
subassembly 42 to assist in coupling the manifold 44 to the unitary
frame body 20 and maintaining a seal at the interface between the
manifold 44 and the manifold seal 45.
[0029] With reference to FIGS. 1 through 3, other features of the
unitary frame body 20 include a pump arm receiving aperture 63
provided at a lower end of the frame body 20 which may be sized and
shaped to receive the proximal end 62 on the pump arm 60 with a
press-fit or friction-fit. In this manner, the proximal end 62 of
the pump arm 60 of the pump arm subassembly 40 may be inserted into
the pump arm receiving aperture 63 and secured to the frame body 20
without mechanical fasteners. In some instances, including the
illustrated embodiment shown in FIG. 3, the pump arm receiving
aperture 63 may extend partially or completely through the frame
body 20 in a direction generally perpendicular to a plane defined
by the direction in which the pump arm 60 oscillates during
operation. The pump arm receiving aperture 63 and the proximal end
62 of the pump arm 60 may have complementary shapes. In some
instances, the pump arm receiving aperture 63 and the proximal end
62 of the pump arm 60 may be T-shaped, plus-shaped, or otherwise
include projections and corresponding grooves to securely anchor
the pump arm 60 in the frame body 20 to prevent rotation of the
proximal end 62 of the pump arm 60 as the remaining portion of the
pump arm 60 oscillates during operation. For this purpose, the
proximal end 62 of the pump arm 60 may include an anchoring device
65 formed around a lower end of a thin flexible arm member 67 of
the pump arm 60, such as, for example, by injection molding
techniques. The thin flexible arm member 67 may be, for example,
spring steel or other similar material, and may be configured to
elastically deform during operation while the anchoring device 65
remains effectively static. The thin flexible arm member 67 may be
configured to flex in excess of ten million cycles without
appreciable deterioration. The pump arm 60 may further include a
pump arm body 69 formed around a mid-section and upper end of the
thin flexible arm member 67, such as, for example, by injection
molding techniques. The permanent magnet 66 may be secured to or
otherwise retained in the upper end of the pump arm body 69
opposite the anchoring device 65. A diaphragm coupling structure 70
may be provided in the pump arm body 69 at a mid-section region of
the thin flexible arm member 67 for coupling to the movable
diaphragm 50. For example, the diaphragm coupling structure 70 may
include a boss extending from a side of the pump arm body 69 that
includes an aperture for receiving a fastener 72 for interfacing
with the movable diaphragm 50 and fixing the movable diaphragm 50
to the pump arm 60 to move in unison therewith during
operation.
[0030] With continued reference to FIGS. 1 through 3, other
features of the unitary frame body 20 include the provision of a
closed perimeter structure that surrounds the pump cartridge 24,
including the pump arm subassembly 40 and the manifold subassembly
42. The closed perimeter structure may define a central cavity or
aperture 74 that extends completely through the frame body 20 such
that opposing sides of the frame structure 12 are open. The central
cavity or aperture 74 may have a profile that generally reflects a
combination of a side profile of the manifold 44 and a swept side
profile of the pump arm 60 and movable diaphragm 50 resulting from
oscillation of the pump arm 60 and movable diaphragm 50 during
operation.
[0031] At least one of the tethers 14 may be provided at a lower
end of the unitary frame body 20 to extend away from the frame body
20 in a direction parallel to the plane defined by the direction in
which the pump arm 60 oscillates during operation. In addition, at
least one of the tethers 14 may be provided at an upper end of the
unitary frame body 20 to extend away from the frame body 20 in a
direction parallel to the plane defined by the direction in which
the pump arm 60 oscillates during operation.
[0032] An upper end of the frame body 20 may further include a
lower platform or flange structure 76, a hollow stem or core
portion 78 and an upper flange or bulkhead 80 that defines a bobbin
or bobbin-like structure 82 around which the winding 32 of the
electromagnet arrangement 22 may be wound. Advantageously, the
bobbin or bobbin-like structure 82 is integrally formed as a
portion of the frame body 20 which supports all other functional
components of the air supply device 10. Each of the lower platform
or flange structure 76 and the upper flange or bulkhead 80 may be
provided with respective apertures 77a, 77b, 79a, 79b for
insertably receiving the opposing leg portions 28, 30 of the
electromagnet core 26 of the electromagnet arrangement 22. The
apertures 77a, 77b, 79a, 79b may be correspondingly sized and
shaped to receive corresponding portions of the opposing leg
portions 28, 30 of the electromagnet core 26 of the electromagnet
arrangement 22 in a press-fit or friction fit. Respective ends of
the opposing leg portions 28, 30 of the electromagnet core 26 may
extend beyond the lower platform or flange structure 76 after the
air supply device 10 is fully assembled, as shown best in FIG. 2.
Lower surfaces of the opposing leg portions 28, 30 of the
electromagnet core 26 may be concave and may be correspondingly
shaped to reflect a convex surface of the permanent magnet 66 at
the distal end 64 of the pump arm 60. The curvature of the convex
surface of the permanent magnet 66 and the concave lower surfaces
of the opposing leg portions 28, 30 may be selected to maintain a
constant air gap between the lower end of electromagnet core 26 and
the permanent magnet 66 at the distal end 64 of the pump arm 60,
which may advantageously improve efficiency of the air supply
device 10.
[0033] The unitary frame body 20 may further include terminal
structures 84 at or near the upper flange or bulkhead 80 for
receiving and/or supporting the electrical terminals 34 of the
winding 32 for electrically coupling the electromagnet arrangement
22 with an external AC power source (e.g., 15V AC power
source).
[0034] In view of the above, it will appreciated that various
methods may be provided for manufacturing the air supply devices 10
described herein. As an example, FIGS. 4 through 7 illustrate one
example embodiment of a method of manufacturing the air supply
device 10 of FIGS. 1 and 2, with additional features of the
manifold subassembly 42 being shown in FIGS. 8 and 9. As depicted
in FIG. 4, the method may include coupling the pump arm subassembly
40 to the manifold subassembly 42 to form a pump cartridge 24.
Coupling the pump arm subassembly 40 to the manifold subassembly 42
may include inserting (e.g., press-fitting, friction-fitting) a rim
91 of a diaphragm chamber 90 of the manifold subassembly 42 into
the movable diaphragm 50 of the pump arm subassembly 40 to create a
diaphragm assembly and pump cartridge 24. Prior to coupling the
pump arm subassembly 40 to the manifold subassembly 42, the method
may include securing the movable diaphragm 50 to the pump arm 60,
such as, for example, by fastening the movable diaphragm 50 to the
pump arm 60 with a fastener 72 that engages the diaphragm coupling
structure 70 of the pump arm body 69.
[0035] With reference to FIGS. 8 and 9, prior to coupling the pump
arm subassembly 40 to the manifold subassembly 42, the manifold 44
may be fitted with an air filter and/or muffler element 41 and
internal valves 46, 48 for coordinating the flow of air through the
manifold 44 during operation. The air filter and/or muffler element
41 may be insertably received in a corresponding air filter/muffler
chamber portion 92 of the manifold 44 to filter air entering inlet
52 before it reaches an inlet chamber 93 that is separated from the
diaphragm chamber 90 via a first one-way valve 46, and before
reaching an outlet chamber 95 that is separated from the diaphragm
chamber 90 via a second one-way valve 48 and also separated from
the inlet chamber 93 by a bulkhead 94. Flapper members 96, 98 of
the internal valves 46, 48 may be installed and held in place with
compressible valve retainer members 97, 99 that are compressed into
corresponding spaces formed in the diaphragm chamber 90 and the
outlet chamber 95, respectively.
[0036] With reference to FIG. 5, after coupling the pump arm
subassembly 40 to the manifold subassembly 42 to form the pump
cartridge 24, the pump cartridge 24 may be coupled to the unitary
frame body 20, such as, for example, by installing the pump
cartridge 24 from one of opposing sides of the frame body 20 such
that the anchoring device 65 at the proximal end 62 of the pump arm
60 engages the corresponding pump arm receiving aperture 63
provided in the frame body 20. Coupling the pump cartridge 24 to
the frame body 20 may further include securing the pump cartridge
24 to the frame body 20 via the manifold 44 of the manifold
subassembly 42 via a fastener 43 (e.g., a screw), as show in FIG.
6. For this purpose, each of the manifold seal 45 and the manifold
backing portion 47 of the frame body 20 may be provided with an
aperture 49 for receiving the fastener 43 therethrough for
retaining the manifold 44 in engagement with the manifold seal 45
and frame body 20, as previously described. Coupling the pump
cartridge 24 to the frame body 20 may further include inserting the
pump cartridge 24 such that the retaining structures 51, 53 which
are positioned to engage each of opposing ends of the manifold 44
of the pump cartridge 24 contact the manifold 44 and hold the
manifold 44 into sealed engagement with the manifold seal 45.
Coupling the pump cartridge 24 to the frame body 20 may further
include fixedly attaching the pump cartridge 24 to the frame body
20 with the free end (i.e., the distal end 64) of the pump arm 60
supporting the permanent magnet 66 in close proximity to the lower
platform or flange structure 76 of the frame body 20.
[0037] With reference to FIGS. 5 and 6, prior to or after coupling
the pump cartridge 24 to the frame body 20, the method may include
establishing the winding 32 about the bobbin or bobbin-like
structure 82 of the frame body 20 and connecting the winding 32 to
the electrical terminals 34 such that power may be supplied to the
electromagnet arrangement 22 from an external AC power source
during operation. According to the illustrated embodiment, the
winding 32 is established around the hollow stem or core portion 78
of the frame body 20 between the lower platform or flange structure
76 and the upper flange or bulkhead 80, and the electrical
terminals 34 may be insertably received in respective terminal
structures 84 of the frame body 20.
[0038] With reference to FIG. 7, after the pump cartridge 24 is
fixedly secured to the frame body 20, the method may continue by
inserting the electromagnet core 26 of the electromagnet
arrangement 22 into the frame body 20 until ends of the opposing
leg portions 28, 30 are in close proximity but slightly spaced away
from the permanent magnet 66 supported at the free end (i.e., the
distal end 64) of the pump arm 60. Inserting the electromagnet core
26 of the electromagnet arrangement 22 into the frame body 20 may
include press-fitting or friction-fitting the electromagnet core 26
within corresponding apertures 77a, 77b, 79a, 79b provided in the
lower platform or flange structure 76 and the upper flange or
bulkhead 80. Inserting the electromagnet core 26 of the
electromagnet arrangement 22 into the frame body 20 may further
include passing one leg portion 30 of the electromagnet core 26 to
pass through the winding 32 and the hollow stem or core portion 78
of the frame body 20, which is provided between the lower platform
or flange structure 76 and the upper flange or bulkhead 80. Upon
installation of the electromagnet core 26, the air supply device 10
may be substantially complete and ready for operation.
[0039] According to some embodiments, methods of manufacture may
further include suspending the frame structure 12 within an
internal housing cavity 110 via the tethers 14, as shown, for
example, in FIG. 10. The method may further include providing a
sound deadening or muffling device 104 or devices in the internal
housing cavity 110 to reduce or minimize sound emanating from the
housing 102. The method may further include coupling an outlet
conduit 54 to the manifold 44, such as, for example, by attaching
the outlet conduit 54 to an outlet nipple 57 of the manifold 44. An
opposing end of the outlet conduit 54 may be connected directly or
indirectly to a functional component of a host device, such as, for
example, an air inlet port of a liquid diffusion device for air
treatment purposes. The method may also include coupling the
electromagnet arrangement 22 to an AC power source (e.g., 15V AC
power source) and to a controller for controllably applying power
to the electromagnet arrangement 22 during operation to generate an
air stream as may be desired for a given application.
[0040] FIG. 10 shows an example pump assembly 100 wherein the air
supply device 10 of FIG. 1 is suspended within an internal cavity
110 of a housing 102 and surrounded by a sound deadening or
muffling device 104. The housing 102 provides a generally rigid
enclosure and may include external mounts 106 for securing the
housing 102 to a host device, such as, for example, an air
treatment device having a diffusion head for diffusing a supply of
liquid and discharging the diffused liquid into a surrounding
environment for air treatment purposes. The housing 102 may further
include a plurality of apertures 108 or other coupling features for
receiving the tethers 14 of the example air supply device 10. The
apertures 108 may be sized to receive the tethers 14 with the barbs
15 thereof compressed, such that, upon passing through the
apertures 108, the barbs 15 may expand and retain the air supply
device 10 within the internal cavity 110 of the housing 102. The
housing 102 may further include one or more other apertures (not
visible) for routing electrical wires or a cable to the air supply
device from an AC power source and for routing the outlet conduit
54 to an exterior of the housing 102. The housing 102 may be
provided in multiple pieces that are coupleable together to form a
generally enclosed space. As an example, the housing 102 shown in
FIG. 10 includes two opposing pieces that join together to enclose
the air supply device 10, although one of the opposing pieces is
not shown to reveal the internal cavity 110 and the air supply
device 10 suspended therein. In some embodiments, the air supply
device 10 may be oriented with the distal end 62 of the pivot arm
60 at a lower end of the housing 102 with the pump arm 60 standing
generally upright.
[0041] With continued reference to FIG. 10, the sound deadening or
muffling device 104 may be provided within the internal cavity 110
of the housing 102 to reduce sound emanating from the housing 102
during operation of the air supply device 10. For example, a foam
structure may be provided within the internal cavity 110 to
substantially surround and enclose the air supply device 10 apart
from the tethers 14, outlet conduit 54 and electrical wires or
cable (not shown) which may pass through the foam structure via one
or more corresponding sized apertures 118, 120. The tethers 14,
outlet conduit 54 and electrical wires or cable (not shown) may be
particularly flexible to reduce or substantially eliminate the
transmission of vibration from the air supply device 10 to the
housing 102 or other surrounding structures. In some instances, the
sound deadening or muffling device 104 may provide an air gap or
space around the air supply device 10. A width of the air gap or
space 122 may be generally constant or may vary around a perimeter
of the air supply device 10. In some embodiments, the air gap or
space may be greater than 3 mm but less than 8 mm. The sound
deadening or muffling device 104 may also be provided in two or
more pieces and may be coupled together or otherwise arranged
together to substantially surround and enclose the air supply
device 10 apart from the tethers 14, outlet conduit 54 and
electrical wires or cable (not shown). The sound deadening or
muffling device 104 may further include one or more coupling
features, such as, for example, apertures 116, for attaching the
sound deadening or muffling device 104 (or pieces thereof) to the
housing 102.
[0042] Although embodiments of the air supply devices 10 described
herein have been described in some instances as being suitable for
use in connection with air treatment systems, particularly those
including a diffusion head configured to diffuse liquid with the
aid of an air stream moving there thorough, it will be appreciated
that the air supply devices 10 may be used in a wide range of
applications to provide an air stream for a variety of
purposes.
[0043] Moreover, aspects, features and/or techniques of the various
embodiments described above can be combined to provide further
embodiments. All of the U.S. patents, U.S. patent application
publications, U.S. patent applications, foreign patents, foreign
patent applications and non-patent publications referred to in this
specification and/or listed in the Application Data Sheet are
incorporated herein by reference, in their entirety. Aspects of the
embodiments can be modified, if necessary to employ features,
structures, functionality or concepts of the various patents,
applications and publications to provide yet further
embodiments.
[0044] These and other changes can be made to the embodiments in
light of the above-detailed description. In general, in the
following claims, the terms used should not be construed to limit
the claims to the specific embodiments disclosed in the
specification and the claims, but should be construed to include
all possible embodiments along with the full scope of equivalents
to which such claims are entitled. Accordingly, the claims are not
limited by the disclosure.
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