U.S. patent application number 15/999397 was filed with the patent office on 2019-01-03 for air mover inlet interface and cover.
The applicant listed for this patent is Gentherm Incorporated. Invention is credited to Masahiko Inaba, John David Lofy.
Application Number | 20190003491 15/999397 |
Document ID | / |
Family ID | 55079710 |
Filed Date | 2019-01-03 |
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United States Patent
Application |
20190003491 |
Kind Code |
A1 |
Lofy; John David ; et
al. |
January 3, 2019 |
Air mover inlet interface and cover
Abstract
An air mover assembly comprising: (a) an impeller having an
impeller outer diameter and a rotational axis; (b) a motor for
driving the impeller; (c) an air mover housing that encloses at
least a portion of the impeller and the motor, the air mover
housing including: at least one air inlet that receives air when
the impeller is rotating and at least one air outlet; and (d) an
air mover inlet interface adjoining the at least one air inlet and
including: (i) a height, (ii) a wall having a curvature along at
least a portion of the height of the air mover inlet interface that
extends outward in a direction of air flow, and (iii) an inner
diameter; wherein the inner diameter is less than the impeller
outer diameter.
Inventors: |
Lofy; John David;
(Claremont, CA) ; Inaba; Masahiko; (Chino Hills,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Gentherm Incorporated |
Northville |
MI |
US |
|
|
Family ID: |
55079710 |
Appl. No.: |
15/999397 |
Filed: |
August 16, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14797591 |
Jul 13, 2015 |
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15999397 |
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62031271 |
Jul 31, 2014 |
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62103662 |
Jan 15, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04D 29/667 20130101;
F04D 29/281 20130101; F04D 29/4213 20130101; F04D 25/08 20130101;
F04D 29/703 20130101; F04D 29/4246 20130101; F04D 29/424 20130101;
F04D 25/06 20130101 |
International
Class: |
F04D 29/70 20060101
F04D029/70; F04D 29/66 20060101 F04D029/66; F04D 29/42 20060101
F04D029/42; F04D 29/28 20060101 F04D029/28; F04D 25/06 20060101
F04D025/06; F04D 25/08 20060101 F04D025/08 |
Claims
1-12. (canceled)
13. An air mover cover comprising: a grill portion adapted to allow
movement of air while preventing objects of a predetermined size
from passage; wherein the grill portion includes: (1) at least one
first generally centrally disposed through hole opening having a
first geometric shape, and a plurality of radially adjoining
through hole openings having a second geometric shape different
from the first geometric shape and radially adjoining the generally
centrally disposed through hole opening; (2) a plurality of
connection structures that have a center density in a central
region of the grill portion and an adjacent density in regions
surrounding the central region, where the center density is higher
than the adjacent density when measured using a total length of the
connection structure per unit area of each region; (3) at least one
first generally centrally disposed through hole opening having a
first area, and a plurality of radially adjoining through hole
openings each having a second area that are each different than the
first area; or (4) any combination of (1) through (3).
14. The air mover cover of claim 13, wherein the air mover cover
includes a connection portion adapted to connect to an inlet or an
outlet of an air mover housing.
15. The air mover cover of claim 14, wherein the connector portion
includes a circumferential outwardly radiused wall.
16. The air mover cover of claim 13, wherein the grill portion has
a plurality of second through hole openings radially adjoining the
at least one first generally centrally disposed through hole
opening, the plurality of second through hole openings having a
second geometric shape.
17. The air mover cover of claim 13, wherein the at least one first
generally centrally disposed through hole opening is pentagonal,
and the plurality of second through hole openings are
hexagonal.
18. The air mover cover of claim 13, wherein the grill portion is
configured to have a contoured shape that is a dome shape having a
height and a diameter and the ratio of the height to the diameter
is from about 1:2 to about 1:100.
19. The air mover cover of claim 13, wherein the grill portion
includes an outer density of connection structures that are located
in an outer region that is radially disposed outside of the central
region and the region surrounding the central region where the
outer density is lower than both the center density and the
adjacent density when measured using length of the connection
structure per unit area.
20. The air mover cover of claim 13, wherein the cover is flat and
the grill portion of the cover is flat.
21. The air mover cover of claim 13, wherein the grill portion has
a generally contoured shape that is convex.
22. The air mover cover of claim 13, wherein a plurality of third
through hole openings extend around the plurality of radially
adjoining through hole openings and the third through hole openings
are a partial shape.
23. The air mover cover of claim 13, wherein the second area of
each of the plurality of radially adjoining through hole openings
is greater than the first area of the at least one first generally
centrally disposed through hole opening.
24. The air mover cover of claim 13, wherein the plurality of
connection structures have a cross-sectional shape that is
hexagonal.
25. The air mover cover of claim 13, wherein the plurality of
connection structures have a cross-sectional shape that is
circular.
26. The air mover cover of claim 13, wherein the air mover cover is
integrally connected to an air mover inlet interface of an air
mover assembly.
27. The air mover cover of claim 22, wherein the plurality of third
through hole openings each have a third area that is less than the
second area of each of the plurality of radially adjoining through
hole openings and greater than the first area of the at least one
first generally centrally disposed through hole opening.
28. The air mover cover of claim 22, wherein the plurality of third
through hole openings are each a partial hexagonal shape.
29. The air mover cover of claim 18, wherein the ratio of the
height to the diameter is from about 1:6 to about 1:10.
30. The air mover cover of claim 18, wherein the height of the
grill portion is substantially equal to a thickness of the
plurality of connection structures.
31. The air mover cover of claim 18, wherein the height of the
grill portion is greater than a thickness of the plurality of
connection structures,
32. The air mover cover of claim 13, wherein the at least one first
generally centrally disposed through hole is a single generally
centrally disposed through hole having a pentagonal shape.
Description
FIELD
[0001] The present teachings relate to an air mover with an
improved inlet interface at an inlet, an outlet, or both that
reduces noise and specifically aerodynamic noise created by the
blower, and an improved cover for the inlet, the outlet, or both
that prevents foreign objects from entering the air mover while
reducing noise.
BACKGROUND
[0002] Air movers include a motor with a rotor and a stator.
Generally, a shaft of the rotor extends through the stator and the
rotor rotates about the stator. The rotor is in communication with
an impeller that when rotated moves air. The motor and impeller are
typically located within a housing having an inlet and an outlet so
that air is pulled into the inlet and forced out the outlet by the
impeller. Air as it enters and/or exits the housing generates
aerodynamic noise that may be of sufficient decibels that the noise
may be audible by a user, vibrations may be felt by a user, or
both. Additionally, the inlets and outlets of the blower housing
may include a cover that prevents foreign objects from entering the
housing. The covers may restrict air flow, may exacerbate
aerodynamic noise, or both created by the air mover. A majority of
all air mover noise that is generated is due to aerodynamic noise
created by the movement of air into, within, or out of the air
mover. Examples of air movers and covers are disclosed in U.S. Pat.
Nos. 2,001,522; 2,393,933; 4,531,890; 5,336,050; 6,003,950; and
6,547,519 and U.S. Patent Application Publication No. 2006/0171804;
2010/0098544; and 2012/0114512 the contents of which are expressly
incorporated by reference herein in their entirety for all
purposes.
[0003] What is needed is an air mover that includes an air mover
interface that reduces the overall noise of the blower without
unduly impeding the flow of air into the air mover. What is needed
is an air mover interface that directs air to the impeller so that
aerodynamic noise created by the air mover is reduced. What is
needed is a cover that reduces noise of the blower without unduly
impeding air movement into the blower. It would be desirable to
have a cover that increases the amount of available area to feed
the air mover inlet while maintaining an overall height of the air
mover within a predetermined packaging space.
SUMMARY
[0004] The teachings herein surprisingly solve one or more of these
problems by providing: an air mover assembly comprising: (a) an
impeller having an impeller outer diameter and a rotational axis;
(b) a motor for driving the impeller; (c) an air mover housing that
encloses at least a portion of the impeller and the motor, the air
mover housing including: at least one air inlet that receives air
when the impeller is rotating and at least one air outlet; and (d)
an air mover inlet interface adjoining the at least one air inlet
and including: (i) a height, (ii) a wall having a curvature along
at least a portion of the height of the air mover inlet interface
that extends outward in a direction of air flow, and (iii) an inner
diameter; wherein the inner diameter is less than the impeller
outer diameter.
[0005] One possible embodiment of the present teachings includes:
An air mover cover comprising: a grill portion adapted to allow
movement of air while preventing objects of a predetermined size
from passage; wherein the grill portion includes: (1) a generally
contoured shape that is convex; (2) at least one first generally
centrally disposed through hole opening having a first geometric
shape, and a plurality of radially adjoining through hole openings
having a second geometric shape different from the first geometric
shape and radially adjoining the generally centrally disposed
through hole opening; (3) a plurality of connection structures that
have a center density in a central region of the grill portion and
an adjacent density in regions surrounding the central region,
where the center density is higher than the adjacent density when
measured using a total length of the connection structure per unit
area of each region; (4) at least one first generally centrally
disposed through hole opening having a first area, and a plurality
of radially adjoining through hole openings each having a second
area that are each different than the first area; or (5) any
combination of (1) through (4).
[0006] The present teachings surprisingly solve one of more of
these problems by providing an air mover that includes an air mover
interface that reduces the overall noise of the blower without
unduly impeding the flow of air into the air mover. The present
teachings provide an air mover interface that directs air to the
impeller so that aerodynamic noise created by the air mover is
reduced. The present teachings provide a cover that reduces noise
of the blower without unduly impeding air movement into the blower.
The present teachings provide a cover that increases the amount of
available area to feed the air mover inlet while maintaining an
overall height of the air mover within a predetermined packaging
space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a perspective view of an air mover;
[0008] FIG. 2 illustrates an exploded view of an air mover;
[0009] FIG. 3 illustrates a perspective cross-sectional view of the
air mover of FIG. 1;
[0010] FIG. 4 illustrates cross-sectional view of the air mover of
FIG. 1;
[0011] FIG. 5 illustrates a close-up view of the cross-section of
the air mover of FIG. 4;
[0012] FIG. 6A illustrates an example of an air mover inlet
interface having a rounded curvature;
[0013] FIG. 6B illustrates an example of an air mover inlet
interface having a curvature with one flat portion;
[0014] FIG. 6C illustrates an example of an air mover inlet
interface having an elliptical curvature;
[0015] FIG. 7 illustrates the increase in sound as flow is
increased;
[0016] FIG. 8 illustrates a perspective view of an air mover
including a cover;
[0017] FIG. 9 illustrates a top view of an air mover including a
cover;
[0018] FIG. 10A illustrates a cross-sectional view of the air mover
and cover of FIG. 8;
[0019] FIG. 10B illustrates a cross-sectional view of the air mover
and cover when the cover is flat;
[0020] FIG. 11 illustrates geometries of the cover;
[0021] FIG. 12 illustrates a top view of the cover and the various
through hole areas of the cover;
[0022] FIG. 13A illustrates a side view of a cover with a
substantially flat profile dome;
[0023] FIG, 13B illustrates a side view of a cover with a low
profile dome;
[0024] FIG. 13C illustrates a side view of a cover with a medium
profile dome;
[0025] FIG. 13D illustrates a side view of a cover with a high
profile;
[0026] FIG. 13E illustrates a side view of a flat cover that is
integrally connected to the air air mover inlet interface;
[0027] FIG. 13F illustrates a side view of a flat cover only;
[0028] FIG. 13G illustrates a side view of a flat cover with
connection structures having a circular-cross section and the flat
cover being integrally connected to the air mover inlet
interface;
[0029] FIG. 13H illustrates a side view of a flat cover only with
connection structures having a circular cross-section; and
[0030] FIG. 14 illustrates a device for testing the sound created
by the air mover.
DETAILED DESCRIPTION
[0031] The explanations and illustrations presented herein are
intended to acquaint others skilled in the art with the invention,
its principles, and its practical application. Those skilled in the
art may adapt and apply the invention in its numerous forms, as may
be best suited to the requirements of a particular use.
Accordingly, the specific embodiments of the present invention as
set forth are not intended as being exhaustive or limiting of the
teachings. The scope of the teachings should, therefore, be
determined not with reference to the above description, but should
instead be determined with reference to the appended claims, along
with the full scope of equivalents to which such claims are
entitled. The disclosures of all articles and references, including
patent applications and publications, are incorporated by reference
for all purposes. Other combinations are also possible as will be
gleaned from the following claims, which are also hereby
incorporated by reference into this written description.
[0032] The present teachings claim priority to U.S. Provisional
Patent Application No. 62/031,271, the contents of which are
incorporated by reference herein in their entirety for all
purposes. The present teachings may be used with any fan, blower,
air mover, similar device that moves air, or a combination thereof.
As discussed herein fan, blower, and air mover are used
interchangeably and the use of the term fan is intended to
encompass a blower, air mover, or any other device that moves a
fluid such as air, or a combination thereof. The fan may function
to move air from a first location to a second location to provide
heat, remove heat, provide cooling, or a combination thereof. The
fan may be a radial fan, an axial fan, or both. The fan may move
air within a component. For example, the fan may move air into a
cooling cabinet or a housing that includes equipment, electrical
components, or both. The fan may be located in a vehicle.
Preferably, the fan may be connected to a vehicle seat. The fan may
be attached to, located under, or both the bun or cushion of a
seat, in the back of a seat, or both. The fan may extend into a
cushion of a vehicle seat so that the fan is located within the
vehicle seat. The fan may be suspended during use (e.g., from an
insert, from a seat cushion, from a seat frame, or a combination
thereof). Preferably, the fan may be connected to a vehicle
battery. The fan may be used in a vehicle to move a fluid through a
vehicle seat. More preferably, the fan may be a low profile
fan.
[0033] The present teachings are predicated upon providing a fan
(i.e., a blower) that includes a housing, an impeller, a motor, and
control instrumentation (e.g., circuitry). The housing may function
to partially and/or fully enclose components of the fan to generate
a pressure differential so that air is moved. The housing may
enclose all of the functional components of the fan. The housing
may connect the fan to channels, an air source, a thermoelectric
device, may include a thermoelectric device, an insert, a hood,
tubing, an open space, or a combination thereof. The housing may
connect the fan to one or more devices so that the fan is retained
within a device and/or system. For example, the fan may connect to
a seat by the housing so that the fan may move air through the
seat. The housing may include one or more inlets, one or more
outlets, or both. For example, the housing may include two opposing
outlets. The housing may be a one piece design. Preferably, the
housing is a multi-piece design. For example, the housing may
include a left piece and a right piece. The inlets, the outlets, or
both may be partially or entirely formed in a left piece, a right
piece, or both pieces. The inlets, outlets, or both may only be
entirely formed when the left piece and right piece are connected
together. For example, the left and right piece when combined may
form a complete inlet. The multi-piece design may include an upper
piece and a lower piece. The inlet, the outlets, or both may be
partially or entirely located within one of the upper piece, the
lower piece, or both. The multi-piece design may be connected
around an impeller, a motor, or both so that all or a portion of
the motor, the impeller, or both are located within the
housing.
[0034] A motor may be connected within the system by a stator that
may be connected to the housing so that the stator supports a
rotor. The motor may function to rotate an impeller, move air,
rotate a rotor, or both. The motor may function to rotate a rotor
that moves an impeller. The motor may include a stator.
[0035] The stator may function to connect the rotor to the housing,
to rotate the rotor, or both. The stator may rotate the rotor, the
impeller, or both substantially about their axes. The stator may
have one or more windings that move the rotor via the magnets of
the rotor. The one or more windings when powered may create an
electric field that moves the rotor and impeller so that air is
moved.
[0036] The stator may be at least partially covered by a rotor. The
rotor may function to rotate and move air, move an impeller, or
both. The rotor may rotate about an axis (i.e., a rotational axis).
The rotor may be located within and/or include one or more bearings
so that the rotor has low friction rotation. The rotor may include
an impeller that functions to move air. The rotor may include a cup
and/or be connected to a cup so that a connection is formed with an
Impeller.
[0037] The cup may function to substantially surround the stator,
house a rotor, house one or more magnets, connect to a shaft, or a
combination thereof. The cup may form a connection with the
impeller so that the impeller is balanced, the impeller is
positioned relative to the shaft, or both. The cup may be fixedly
connected to a shaft. The cup may be permanently connected to the
shaft. The cup may fixedly connect to one or more magnets so that
the magnets are not directly connected to the impeller, the magnets
may move the impeller around the stator, or both. The cup may be at
least partially molded into the impeller, press fit into the
impeller, or both.
[0038] The one or more magnets may function to move the rotor
during operation of the fan. The one or more magnets may rotate
about the stator when the windings are activated. The rotor may
include a sufficient amount of magnets so that the rotor rotates,
air is moved, or both. The one or more magnets may be positioned
relative to the stator by the position of the cup, by the
connection of the magnets to the cup, or both.
[0039] The impeller may receive all or a portion of a rotor. The
impeller may include a hub. The hub may be wholly located within
the housing. The hub may be sufficiently tall to house the motor
within the housing. The hub may extend past the housing, out of the
housing, or both. The hub may be free of a portion that extends out
of the inlet. The hub may be about two-thirds the total height of
the impeller or more, about three-quarters the total height of the
impeller or more, or even the same height as the total height of
the impeller or more. The hub may be about two-thirds the total
height of the impeller or less, about half the total height of the
impeller or less, or a quarter the total height of the impeller or
less. The impeller may push air, pull air, or both. The impeller
may be made of any material so that the impeller moves air.
Preferably, the impeller is made of plastic or a light-weight
material. The impeller may be made of a molded material, an
injection molded material, or both. The impeller may be made of
metal. The impeller may be large enough so that the impeller moves
a sufficient amount of air to heat and/or cool an occupant, a user,
a location of interest, or a combination thereof. The impeller may
be sufficiently small so that the rotor fits within a component and
preferably a vehicle component. Preferably, the impeller may be
formed by injection molding and/or overmolding. The impeller may be
molded around a cup, a shaft, or both of the rotor. For example,
the hub of the impeller may be molded around a cup so that the hub
houses at least a portion of the rotor. The hub may be part of a
base of the impeller.
[0040] The base of the impeller may function to provide a support
surface for vanes, provide a connection point for vanes, radially
extend from a hub, or a combination thereof. The base may form a
bottom most wall of the impeller. The impeller, the base of the
impeller, or both include a diameter and the diameter of the
impeller, the base, or both may be equal. The base may support one
or more and preferably a plurality of vanes. The base may form an
outer most diameter. The base may be made of molded plastic, metal,
a polymer, a flowable material, or a combination thereof. The base
may be integrally formed, integrally connected, or both to a
plurality of vanes.
[0041] The vanes may function to move air when the impeller rotates
about a rotational axis. The vanes may move air in one or more
directions. The vanes may be unidirectional vanes so that air is
moved in a single direction. Preferably, the vanes pull air in
through an inlet and radially move the air out through an outlet.
However, the vanes may axially move air from an inlet to an outlet.
The vanes may be located about a circumference of the impeller.
Each of the vanes may be parallel to the adjacent vanes. The one or
more vanes include an upper edge, a lower edge, an outer edge, and
an inner edge (i.e., edges). The edges may include one or more
linear segments, one or more curved segments, one or more parallel
edges, one or more edges that extend at an angle relative to
another edge. The edges may be such that the vanes are generally
square, generally rectangular, generally a rhombus, generally a
trapezium, have an angled portion that slopes away from an opposing
edge, or a combination thereof. The upper edges of the plurality of
vanes may generally terminate along a plane so that the upper edges
are all generally the same height. The lower edges may all
generally terminate at the base. The outer edge may be located at
an outside of the diameter of the impeller. The inner edge may be
located towards a center of the impeller relative to the outer
edge. The inner edge, the upper edge, or both may have a sloped
portion. The vanes may include a contoured surface. The contoured
surface may function to move air in a primary direction. The
contoured surface of the vanes may radially move air. The contoured
surface may extend in a direction of rotation or opposite a
direction of rotation. The vanes, the impeller, or both may include
an outer diameter (e.g., a largest diameter of the impeller). The
outer diameter may be varied depending upon a predetermined amount
of fluid to be moved. The outer diameter may be increased to
increase a volume of fluid to be moved. The outer diameter may be
located at the outer edge of the vanes, the outer edge of the base,
or both. The outer diameter may extend substantially to the walls
of the housing. The outer diameter of the impeller may be larger
than the largest dimension of the inlet of the housing (e.g.,
diameter).
[0042] The inlet may function to allow air to enter the housing,
the air mover assembly, or both when the impeller rotates. The
inlet may function to provide direct access to the impeller and
vanes during operation. The inlet may be located above the
impeller, above the motor, along an axis of rotation, or a
combination thereof. The inlet may include an air mover inlet
interface.
[0043] The air mover inlet interface may be a surface that directs
air into the inlet. The air mover inlet interface may function to
reduce the speed of fluids (e.g., air) extending into the inlet.
The air mover inlet interface may function to reduce the turbulence
of fluids entering the inlet. The air mover inlet interface may
project outward from the housing. The air mover inlet interface may
project axially away from the housing. The air mover inlet
interface may gradually open as the air mover inlet interface
axially extends into the housing, towards the impeller, or both.
The air mover inlet interface may include an inner circumferential
edge, an outer circumferential edge, or both.
[0044] The inner circumferential edge may function to guide air
into the air mover inlet interface, form a low friction entry point
for fluids (e.g., air), or both. The inner circumferential edge may
be an outermost edge of the air mover inlet interface. The inner
circumferential edge may be a terminal edge of the air mover inlet
interface. The inner circumferential edge may form an inner inlet
diameter, have an inner inlet diameter, or both. The inner inlet
diameter may be the smallest diameter of the inlet. The inner
circumferential edge may be connected to a radiused surface, a
curvature, or both.
[0045] The radiused surface, curvature, or both may function to
gradually open up so that space within the inlet gradually
increases. The radiused surface may function to connect an inner
circumferential edge to an outer circumferential edge. The radiused
surface may include a single curve, a constant curvature, an arc,
one or more arcuate sections, one or more curves, one or more
linear segments, one or more curves with a radial curve, one or
more curves with an oval curve, or a combination thereof. The
radiused surface may extend outward and reduce the size of the
inlet opening. The radiused surface may bell out so that a volume
within the air mover inlet interface increases as the radiused
surface extends axially towards the impeller. The radiused surface
includes a height. The height of the radiused surface may be
sufficiently large so that fluid is channeled towards the impeller,
the fluid is all moved substantially along the rotational axis as
the fluid contacts the impeller, or a combination of both. The
height of the radiused surface may be 2 mm or more, 3 mm or more, 4
mm or more, 5 mm or more, 6 mm or more, or even 10 mm or more. The
height of the radiused surface may be about 30 mm or less, 25 mm or
less, 20 mm or less, or even about 15 mm or less. The radiused
surface may extend at a radius that is sufficiently large that the
radius reduces the aerodynamic noise generated by the flow of a
fluid into the inlet of the air mover. The radiused surface may
have a radius of about 2 mm or more, 3 mm or more, 4 mm or more, 5
mm or more, 6 mm or more (e.g., R6), or even 7 mm or more. The
radiused surface may have a radius of about 30 mm or less, about 25
mm or less, about 20 mm or less, or about 15 mm or less. The height
of the radiused surface may be inversely proportional to the volume
of sound created by the air mover. For example, the longer the
radiused surface the less sound the air mover may create (however,
the diameter of the inlet may directly affect the volume of sound
created by the air mover). The radiused surface may extend inward
and terminate at an outer circumferential edge.
[0046] The outer circumferential edge may function to create an
outer diameter of the air mover inlet interface. The outer
circumferential edge may function to create a connection surface,
connection point, or both with the housing. The outer
circumferential edge may be a location on the air mover inlet
interface where the radiused surface terminates. The outer
circumferential edge may include an inlet outer diameter. The inlet
outer diameter may have a size that is less than the size of the
impeller (e.g., the diameter of the inlet outer diameter may be
less than the outer diameter of the impeller). The outer
circumferential edge may extend into the inlet of the housing. The
outer circumferential edge may terminate at a top of the housing.
The outer circumferential edge may guide fluid toward the impeller,
into the housing, or both. The outer circumferential edge may be
substantially free of contact with the fluid as the fluid moves
into the housing.
[0047] The fluid as it enters the inlet through the air mover inlet
interface may be directed towards the impeller. The fluid as it
moves may function to create a constant flow, a laminar flow, a
flow that is free of turbulence, or a combination thereof so that
the aerodynamic noise is not created by the flow of the fluid. The
movement of the fluid may be generally along the axial direction of
the impeller as the fluid travels within the air mover inlet
interface and then the fluid movement may extend radially outward
into contact with the impeller. Movement of the fluid may be varied
based upon use of a cover over the inlet.
[0048] The cover may function to prevent foreign objects from
entering the blower, from user limbs and/or digits from entering
the blower, or both. The cover may function to provide screening of
fluids entering the blower. The cover may function to limit
interference with fluid flow while preventing access to the
impeller. The cover may be dome shaped, hemispherical, rounded,
arcuate, flat, have a flat portion, have a rounded portion, have an
elevated portion that gradually raises above the rest of the cover,
or a combination thereof. Preferably, the cover is of a flat
profile (e.g., 80 percent or more of the cover extends within a
single plane). A highest point on the cover (e.g., a peak) may be
located substantially in the center of the cover or may be offset
from center. The height of the cover may be equal throughout the
entire area of the cover. The height of the cover may be
substantially equal to the thickness of the connecting structures.
The height of the cover at the center may be substantially equal to
the height of the cover at an outer radius, an outermost edge, or
both. The height (i.e., tallest point) of the cover may have a
ratio relative to the cross-sectional length (e.g., diameter) of
the cover. The ratio of height to cross-sectional length may be
about 1:2 or more, 1:4 or more, or about 1:6 or more (i.e., about
1:6.6). The ratio of height to cross-sectional length may be about
1:100 or less, 1:50 or less, 1:30 or less, about 1:15 or less, or
about 1:10 or less. The cover may be free of a domed shape. The
cover, the grill portion of the cover, or both may be configured to
allow for a constant stream of fluid into the air mover, to be
non-restrictive to air flow, minimize restriction, or a combination
thereof. The cover may include a series of through holes located
between a series of connection structures. The through holes may be
randomly disposed within the area of the cover (e.g., the grill
portion). The through holes may be uniformly disposed within the
area of the cover (e.g., grill portion). The through holes may
connect together to form a grill portion that air travels through
to reach the impeller. The grill portion may include one or more
groups of holes, one or more series of holes, one or more radially
extending holes, or a combination thereof. Preferably, the grill
portion includes at least one first generally centrally disposed
through hole opening (i.e., one or more first through holes).
[0049] The one or more first through holes may function to create a
structure in a central portion of the grill portion. The one or
more first through holes may function to provide structure to an
outermost portion of the grill portion, to provide strength to the
grill portion, restrict entry of foreign objects, or a combination
thereof. The one or more first though holes may have a plurality of
connection structures that have a density. The one or more first
through holes may be located in a central region, along the axis of
rotation, or a combination of both. The one or more first through
holes may be any shape so that one or more adjoining through holes
may be radially disposed about the one or more first through holes.
The one or more first through holes may have an area of about 25
mm.sup.2 or more, preferably about 35 mm.sup.2 or more, or more
preferably about 45 mm.sup.2 or more (e.g., about 51 mm.sup.2). The
one or more first through holes may be about 110 mm.sup.2 or less,
about 100 mm.sup.2 or less, about 75 mm.sup.2 or less, or about 60
mm.sup.2 or less. The one or more first through holes may be a
round, oval, square, rectangle, diamond, pentagon, hexagon,
octagon, heptagon, or a combination thereof. Preferably, the one or
more first through holes is a single pentagonal through hole
located in the center of the grill portion. The one or more first
through holes may all be the same size. The one or more first
though holes may be different sizes. The one or more first through
holes may be the same size as the through holes that are radially
disposed about the first through holes.
[0050] One or more and preferably a plurality of radially adjoining
through hole openings (i.e., second through holes) may be radially
disposed about the first through hole. The second through holes may
function to provide structure to the grill portion, form a curve,
form a dome, provide strength to the grill, or a combination
thereof. The second through holes may function to increase in
cross-sectional length, area, or both relative to the
cross-sectional length, area, or both of the first through hole
openings so that air may pass through the through hole openings.
The second through holes may have a plurality of connection
structures. The connection structures of the second through holes
may have a density that is less than that of the first though
holes. The density as discussed herein is the density of the
connection structures per unity area unless otherwise stated. The
second through holes may include more open area then the first
though holes so that the density of the second through holes is
less than the first though holes. The density of the connection
structures of the second through holes may be decrease as the
second through holes extend radially outward. The density may be
measured by measuring the total length of the connection structures
per unit area. For example, the total length of the connection
structures may be 50 mm and the area of all of the second through
holes may be 625 mm.sup.2 (e.g., 1 mm/12.5 mm.sup.2) and the total
length of the connection structures of the first through holes may
be about 15 mm and the area of all of the first though holes may be
about 80 mm.sup.2 (e.g., 1 mm/5 mm.sup.2). The second through hole
openings may be larger than the first through hole openings but
smaller than the third through hole openings. The one or more
second through holes may have an area of about 70 mm.sup.2 or more,
preferably about 90 mm.sup.2 or more, or more preferably about 110
mm.sup.2 or more (e.g., about 115 mm.sup.2). The one or more second
through holes may be about 200 mm.sup.2 or less, about 175 mm.sup.2
or less, about 150 mm.sup.2 or less, or about 130 mm.sup.2 or less.
The second through hole openings may all be the same size, may all
be different sizes, may be a combination of two or more sizes, or a
combination thereof. The one or more second through hole openings
may be any of the shapes discussed herein for the first through
hole openings. Preferably, the second through hole openings are
smaller than third through hole openings.
[0051] The one or more and preferably a plurality of radially
adjoining through hole openings (i.e., third through holes) may be
radially disposed about the plurality of second through holes. The
one or more third through holes may perform any of the functions of
the second through holes, the first through holes, or both and vice
versa as discussed herein. The third through holes may function to
create a dome shape, to prevent foreign objects from entering the
blower, or both. The one or more third through hole openings may be
any of the shapes discussed herein for the first through hole
openings, the second through hole openings, or both. The third
through holes may have a density. The density of the third through
holes may be the length of the connection structures per unit area.
The density of the through holes may be less than that of the
second through holes. The density of each of the third through
holes may be less than each of the second through holes, each of
the first through holes, or both. Similarly, the density of the
total group of third through holes may be less than that of the
total group of the second through holes and the first through
holes. The density of the group of through holes may be solely
based upon the amount of connection structures forming each through
hole. Preferably, however, the density is based upon the amount of
connection structures per unit area. The one or more third through
holes may have an area of about 100 mm.sup.2 or more, preferably
about 125 mm.sup.2 or more, or more preferably about 140 mm.sup.2
or more (e.g., about 155 mm.sup.2). The one or more third through
holes may be about 300 mm.sup.2 or less, about 250 mm.sup.2 or
less, about 200 mm.sup.2 or less, or about 175 mm.sup.2 or less.
The one or more third through holes may be a partial hexagonal
shape and thus the area may be less than a full hexagonal shape.
The area of the partial third through holes may have an alternating
area. For example, one third through hole opening may be a partial
so that the area is close to a complete area and an adjoining third
through hole opening may be about half of a total through hole
opening. The third through hole openings may have a partial area of
about 175 mm.sup.2 or less, about 150 mm.sup.2 or less, about 120
mm.sup.2 or less, about 100 mm.sup.2 or less, or even about 75
mm.sup.2 or less. The third through hole openings may have a
partial area of about 40 mm.sup.2 or more, 50 mm.sup.2 or more, or
60 mm.sup.2 or more.
[0052] The grill portion may include two groups of radially
disposed through holes or more, three groups of radially disposed
through holes or more, four groups of radially disposed through
holes or more, or even five groups of radially disposed through
holes or more. The teachings of the second and third through holes
are incorporated herein for the fourth, fifth, sixth, or more
groups of through holes. Each of groups two, three, four, or more
may decrease in density, increase in area, or both so that fluid
flow is not unduly impeded by the connection structures.
[0053] The one or more and preferably a plurality of connection
structures may function to protect the impeller, prevent foreign
objects from entering the impeller, or both. The one or more
connection structures may resist pressure, force, or both from
damaging the blower, the impeller, or both. The one or more
connection structures may be the material that forms the grill
portion. The one or more connection structures may be features that
are interconnected to form the grill, each of the series of through
holes, or both. The one or more connection structures may be ribs
that radially extend outward and interconnect with adjacent
connection structures. The one or more connection structures may be
generally arcuate, have linear segments, connected to adjacent
linear segments and form an angle between the adjacent linear
segments, or a combination thereof. The one or more connection
structures may have any cross-sectional shape that prevents foreign
objects from entering the inlet, resists crushing of the cover, or
both. The one or more connection structures may have a
cross-sectional shape that is hexagonal, circular, square,
pentagonal, triangular, oval, diamond, symmetrical,
non-symmetrical, or a combination thereof. The length of the
connection structure in each of the first through hole opening,
second through hole opening, third through hole opening, etc. . . .
may increase in length as the through hole openings are measured
radially outward. The connection structures of the first through
hole openings may have a length of about 3 mm or more, 4 mm or
more, 5 mm or more. The connection structures of the first through
hole openings may have a length of about 7 mm or less, about 6 mm
or less. The connection structures of the second through hole
openings may have a length of about 4 mm or more, about 5 mm or
more, about 6 mm or more (i.e., 6.6 mm). The connection structures
of the second through hole openings may have a length of about 9 mm
or less, about 8 mm or less, or about 7 mm or less. The connection
structures of the third through hole openings may have a length of
about 5 mm or more, about 6 mm or more, about 7 mm or more (i.e.,
7.6 mm). The connection structures of the third through hole
openings may have a length of about 10 mm or less, about 9 mm or
less, or about 8 mm or less.
[0054] The sound created by the air mover may be tested. The
testing assembly may be located within a structure that functions
to remove all ambient sounds. The testing assembly may include a
sound meter. The sound meter may be a digital sound meter. The air
mover outlet may be connected directly to a flow meter thus the
static pressure or system resistance may be substantially zero. The
air mover outlet may be connected to a diffuser box that may be
adjusted to create a predetermined static pressure or system
resistance. The static pressure or system resistance used during
measurement may be calculated based upon the resistance of the
system the air mover is intended to be used in conjunction with.
Preferably, the system resistance, the static pressure or both
against the outlet of the air mover assembly is about 50 percent.
The system resistance may be calculated using a system resistance
curve for each given fan as the system resistance may vary based
upon the size of the air mover assembly. A flow meter may be used
to test the volume of flow being produced by each air mover
assembly as the covers, the air mover inlet interface, or both are
varied and the sound generated by each are tested. The decibels
created by the air mover assembly of the teachings herein may be
about 67 or less, about 66.5 or less, about 66 or less, preferably
about 65.75 or less, more preferably about 66.5 or less, or even
about 66.25 or less when the sound meter is placed at a distance of
200 mm and a static pressure (system resistance) of 50 percent is
applied to the air mover.
EXAMPLES
[0055] The following test may be used to determine the amount of
sound created by the air mover. The air mover assembly is placed in
a sound proof room. A sound meter is placed 200 mm from the inlet
of the air mover. The outlets of the air mover may be restricted to
create a static pressure (e.g., system resistance) on the air mover
of 50 percent. One or both of the outlets are connected to a
diffuser box that includes a flow meter. A flow meter is in
communication with the diffuser box that measures the flow of air
exiting the air mover assembly.
[0056] FIG. 1 illustrates a perspective view of an air mover
assembly 2. The air move assembly 2 includes an inlet 4 having an
inner diameter (ID.sub.I) and a pair of opposing outlets 6.
[0057] FIG. 2 illustrates an exploded view of an air mover assembly
2. The air move assembly 2 includes a housing 40 with an upper
piece 42 and a lower piece 44. The upper piece 42 includes an inlet
4 and a pair or outlets 6 are formed between the upper piece 42 and
the lower piece 44. The impeller 8 is removed from the housing 40
and a cover 80 that extends over the inlet 4 is shown. The impeller
8 includes a total height (I.sub.H) and the hub 12 has a total
height of (H.sub.H).
[0058] FIG. 3 illustrates a cross-sectional (perspective) view of
the air mover assembly 2 of FIG. 1 cut along line 3-3. The air
mover assembly 2 includes a housing 40 that houses an impeller 8.
The impeller 8 includes a base 28 with a hub 12 and a plurality of
vanes 14 extending therefrom. Each of the vanes 14 include an upper
edge 16, a lower edge 18, an outer edge 20, and an inner edge 22.
As illustrated, the inner edge 22 has a sloped portion 24 and a
contoured surface 26. The housing 40 as illustrated includes an air
mover inlet interface 60. The air mover inlet interface 60 has an
inner circumferential edge 62 and an outer circumferential edge 64
connected by a radiused surface 66 (e.g., a curvature).
[0059] FIG. 4 illustrates a cross-sectional (plan) view of the air
mover assembly 2 of FIG. 1 cut along line 3-3. The housing 40
includes an impeller 8 that has a hub 12 which receives a portion
of the motor 30. An axis of rotation 10 extends through the center
of the impeller 8, motor 30, and an inlet 4 of the housing 40. The
housing 40 has an air mover inlet interface 60 that extends axially
away from the impeller 8. The air mover inlet interface 60 has a
radiused surface 66 that extends between an inlet inner diameter
(ID.sub.I) and an inlet outer diameter (ID.sub.O). The impeller 8
includes an outer diameter (D.sub.O) that is larger than the inlet
inner diameter (ID.sub.I) and an inlet outer diameter
(ID.sub.O).
[0060] FIG. 5 illustrates a close-up view of the housing 40 of FIG.
4. An impeller 8 with a plurality of vanes 18 is located within the
housing 40. The impeller 8 moves air into the inlet and the air
mover inlet interface 60 directs the flow of air in the direction
100 so that the air gradually turns as the air moves into the
housing 40. The air mover inlet interface 60 has a radiused surface
66 that extends axially away from the impeller 8 and has a height
(H).
[0061] FIGS. 6A-6C illustrates a close up example of air mover
inlet interface 60 that may be used with the housing (not shown) or
the cover (not shown). FIG. 6A illustrates the air mover inlet
interface 60 having a radiused surface 66 that gradually extends
between an inner circumferential edge 62 and an outer
circumferential edge 64. The radiused surface 66 has a generally
circular radius.
[0062] FIG. 6B illustrates the air mover inlet interface 60 having
a radiused surface 66 that includes a linear segment with multiple
curves between the inner circumferential edge 62 and an outer
circumferential edge 64.
[0063] FIG. 6C illustrates the air mover inlet interface having an
extended radiused surface 66 that extends between an inner
circumferential edge 62 and an outer circumferential edge 64. The
radiused surface 66 has an elliptical radius.
[0064] FIG. 7 chart plotting airflow versus noise. As illustrated,
for all 4 blowers as the amount of flow increases so does noise
associated with the blower. As illustrated in the legend the first
blower has a radius of 4 mm with an inner inlet diameter of 52.8
mm, the second blower has a radius of 4 mm with an inner inlet
diameter of 58.8 mm, the third blower has a radius of 6 mm with an
inner inlet diameter of 52.8 mm, and the fourth blower has a radius
of 6 mm with an inner inlet diameter of 58.8 mm. As illustrated, as
the radius size of the air mover inlet interface is increased the
noise created by the blower is decreased relative to an air mover
with an air mover inlet interface with a smaller radius. As
illustrated, as the inlet inner diameter of the fans is increased
the noise increases.
[0065] FIG. 8 illustrates a perspective view of an air mover
assembly 2. The air mover 2 includes a housing 40 having an upper
piece 42 and a lower piece 44. The upper piece 42 as illustrated
has an inlet 4 that includes a cover 80 (which may be integral with
the housing or removable). An air mover inlet interface 60 extends
between the cover 80 and the housing 40.
[0066] FIG. 9 illustrates a top view of the housing 40 with a cover
80 over the inlet 4. The cover 80 includes a first generally
centrally disposed through hole opening 82 located in a central
region of the inlet 4. The cover 80 includes a plurality of
radially adjoining through hole openings (e.g., second set of
openings) 84 radially disposed in a region radially outside of the
central region. The cover includes a second plurality of radially
adjoining through hole openings (e.g., third set of openings) 86
radially disposed in a region radially outside of the openings
adjoining the first generally centrally disposed through hole
opening 82. The cover 80 includes a diameter (D) that is generally
the same size as the inlet 4.
[0067] FIG. 10A illustrates a cross-sectional view along lines
10A-10A of FIG. 8. As the impeller 8 is turned by the motor 30 air
is moved in the direction 100 through the cover 80 and the hole
design in the domed cover 80 reduces aerodynamic noise. The domed
cover 80 has a height (H).
[0068] FIG. 10B illustrates a cross-sectional view of an air mover
assembly 2 having a flat cover 80. As impeller 8 is turned by the
motor 30 air is moved in the direction 100 through the cover 80 and
the hole design in the cover 80 reduces aerodynamic noise. The
cover 80 has a height (H').
[0069] FIG. 11 illustrates a cover 80 configuration where the
density of connection structures 88 decreases as the connection
structures 88 are measured radially outward of the center. As
illustrated, the first generally centrally disposed through hole
opening 82 has the greatest density of connection structures 88 per
unit area. A group of radially adjoining through hole openings 84
extend around the first through hole opening 82 and have a lower
density of connection structures 88. A second group of radially
adjoining through hole openings 86 are radially outward of the
group of through hole openings 84 and have a lower density of
connection structures relative to the first through hole 82 and the
group 84. The decreases in density of the connection structures 88
is demonstrated by the increase in hole size as the holes extend
radially outward.
[0070] FIG. 12 illustrates the cover 80 with the first through hole
opening 82 having a first area (e.g., about 51 mm.sup.2) being
located in the center and be pentagonal in shape. A group of second
through hole openings 84 having a second area (e.g., about 115
mm.sup.2) extend around the first through hole opening 82 along the
first dashed circle. A third group of through hole openings 86
extend around the second group of through hole openings 84 and the
first though hole opening 82. Each of the through hole openings is
formed by a plurality of connection structures 88 which are
interconnected. The second through hole openings 84 and the third
through hole openings 86 are hexagons. The third through hole
openings 86 have a first area 86A (e.g., about 128 mm.sup.2) and a
second area 86B (e.g., about 75 mm.sup.2) that are different.
[0071] FIG. 13A illustrates a side view of a cover 80 that has a
dome height (H.sub.1). The height (H.sub.1) is substantially
flat.
[0072] FIG. 13B illustrates a side view of a cover 80 that has a
dome height (H.sub.2). The height (H.sub.2) is low profile but
extends higher than the height (H.sub.1).
[0073] FIG. 13C illustrates a side view of a cover 80 that has a
dome height (H.sub.3). The height (H.sub.3) is a medium profile but
extends higher than the height (H.sub.2).
[0074] FIG. 13D illustrates a side view of a cover 80 that has a
dome height (H.sub.4). The height (H.sub.4) is low profile but
extends higher than the height (H.sub.3).
[0075] FIG. 13E illustrates a perspective view of a flat cover 80
that has connection structures 88 with a hexagonal cross-sectional
shape and the cover 80 being integrally connected to an air mover
inlet interface 60.
[0076] FIG. 13F illustrates a perspective view of a flat cover 80
that has connection structures 88 with a hexagonal cross-sectional
shape.
[0077] FIG. 13G illustrates a perspective view of a flat cover 80
that has connection structures 88 with a circular cross-sectional
shape and the cover 80 being integrally connected to an air mover
inlet interface 60.
[0078] FIG. 13H illustrates a perspective view of a flat cover 80
that has connection structures 88 with a circular cross-sectional
shape.
[0079] FIG. 14 illustrates an example of a testing device 120. The
testing device 120 is located in a sound proof room 130. The
testing device 120 includes a digital sound meter 132 that is
located a distance (D.sub.S) above the inlet 4 of an air mover
assembly 2. An outlet of the air mover assembly 2 is connected to a
diffuser box 134. The diffuser box 134 replicated back pressure
created by connecting the air mover assembly 2 to a seating system
(not shown). The diffuser box includes a flow meter 136 that
measures the flow of air generated by the air mover assembly 2.
[0080] Any numerical values recited herein include all values from
the lower value to the upper value in increments of one unit
provided that there is a separation of at least 2 units between any
lower value and any higher value. As an example, if it is stated
that the amount of a component or a value of a process variable
such as, for example, temperature, pressure, time and the like is,
for example, from 1 to 90, preferably from 20 to 80, more
preferably from 30 to 70, it is intended that values such as 15 to
85, 22 to 68, 43 to 51, 30 to 32 etc. are expressly enumerated in
this specification. For values which are less than one, one unit is
considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These
are only examples of what is specifically intended and all possible
combinations of numerical values between the lowest value and the
highest value enumerated are to be considered to be expressly
stated in this application in a similar manner.
[0081] The disclosures of all articles and references, including
patent applications and publications, are incorporated by reference
for all purposes. The term "consisting essentially of" to describe
a combination shall include the elements, ingredients, components
or steps identified, and such other elements ingredients,
components or steps that do not materially affect the basic and
novel characteristics of the combination. The use of the terms
"comprising" or "including" to describe combinations of elements,
ingredients, components or steps herein also contemplates
embodiments that consist essentially of the elements, ingredients,
components or steps. By use of the term "may" herein, it is
intended that any described attributes that "may" be included are
optional.
[0082] Plural elements, ingredients, components or steps can be
provided by a single integrated element, ingredient, component or
step. Alternatively, a single integrated element, ingredient,
component or step might be divided into separate plural elements,
ingredients, components or steps. The disclosure of "a" or "one" to
describe an element, ingredient, component or step is not intended
to foreclose additional elements, ingredients, components or
steps.
* * * * *