Pump and valve system

Abstract

A pneumatic pump includes a housing including a plurality of outlet ports. The pneumatic pump may include a motor extending along a longitudinal axis. The pneumatic pump may include a pneumatic pump driven by the motor. The pneumatic pump may include a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct airflow generated by the pneumatic pump to the plurality of outlet ports. The pneumatic pump may include a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, where the printed circuit board extends parallel to the longitudinal axis.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 673,001, filed July 18, 2024, and U.S. Provisional Patent Application No. 63 / 718,378, filed November 8, 2024, the entire contents of both of which are incorporated herein by reference. TECHNICAL FIELD

[0003] The present disclosure relates to pump and valve systems for use within vehicle seating systems (aircraft, automobiles, etc.). BACKGROUND

[0004] Vehicle seating systems can include pneumatic bladders to provide adjustable lumbar support, seat firmness, pillow spacing, etc. The pneumatic bladders can also be inflated and deflated in specific patterns to create a massaging effect. Such systems require a source of pressurized air (typically in the form of a motor-driven air pump) and a valve system to direct the pressurized air from the source to the various bladders, thereby controlling inflation and deflation of the bladders.

[0005] Both the source of pressurized air and the valve system require electrical power and electronics to control and operate. These components must all be installed within the relatively limited space available within a vehicle seating system. Additionally, the source of pressurized air and the valve system typically generate noise, for example, by operating the motor and pump, actuating the valve system, and expelling air from the bladders to the environment. As vehicles become quieter, particularly electric vehicles, this noise becomes more noticeable. However, to provide more feature-rich seating systems (including, for example, more levels of adjustment and more pronounced massaging effects), more airflow is required. More airflow typically means larger and noisier pumps and valves. Thus, airflow, noise, and size / complexity are competing factors in the design of vehicle seating systems with pneumatic bladders. SUMMARY

[0006] Accordingly, there is a need for more compact pump and valve systems for use within vehicle seating systems to consolidate or reduce the overall footprint of the inflation devices for inflating various seat bladders. There is a further need for such pump and valve systems with low noise output and high air volume output.

[0007] In some aspects, the present disclosure provides a configuration for a pump and a method of pumping air from the pump into a valve assembly. As described in greater detail below, the pump and valve assembly are coupled together to form a compact design. The resulting pump assembly can be advantageously used in applications of pneumatic bladder systems where a compact design is desired (e.g., in vehicle seating, massage chairs, etc.).

[0008] For example, in some aspects, the technology described herein relates to a pump assembly comprising: a housing comprising a plurality of outlet ports; a motor extending along a longitudinal axis; a pneumatic pump driven by the motor; a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct airflow generated by the pneumatic pump to the plurality of outlet ports; a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, wherein the printed circuit board extends parallel to the longitudinal axis.

[0009] In some aspects, the technology described herein relates to a pump assembly comprising: a housing comprising a plurality of outlet ports; a motor extending along a longitudinal axis; a pneumatic pump driven by the motor; a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct airflow generated by the pneumatic pump to the plurality of outlet ports; a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, wherein the pump assembly is configured to output airflow at a free flow between 3 and 6 liters per minute, and wherein the pump assembly is operable at a maximum loudness between 1.1 sone and 1.2 sone.

[0010] In some aspects, the technology described herein relates to a pump assembly comprising: a housing comprising a plurality of outlet ports; a motor extending along a longitudinal axis; a pneumatic pump driven by the motor; a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct airflow generated by the pneumatic pump to the plurality of outlet ports; and a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, wherein the valve assembly comprises: a first control valve; a second control valve arranged in series with the first control valve; a third control valve arranged in parallel with the first control valve and the second control valve; and a fourth control valve arranged in series with the third control valve. Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0011] Figure 1 is a perspective view of an embodiment of a pump assembly according to embodiments of the disclosure.

[0012] Figure 2 is a schematic view of a pneumatic system according to the disclosure, the pneumatic system comprising Figure 1 the pump assembly of

[0013] Figure 3 is an exploded view of the pump assembly of Figure 1 , showing the pneumatic pump and valve assembly.

[0014] Figure 4 is a cross-sectional view along the centerline of the pump assembly of Figure 1 , showing air flow generated by the pneumatic pump and directed by the valve assembly.

[0015] Figure 5 is an enlarged cross-sectional view of the pump assembly of Figure 4 , showing the solenoid valve of the valve assembly in an open position.

[0016] Figure 6 is another cross-sectional view along the centerline of the pump assembly of Figure 1 , showing the pneumatic pump driven by the motor.

[0017] Figure 7 is a perspective view of a pump assembly according to another embodiment of the disclosure.

[0018] Figure 8 is an exploded view of the pump assembly of Figure 7 , showing the pneumatic pump and valve assembly.

[0019] Figure 9 is a schematic view of the pump assembly of Figure 7 , showing air flow directed to a plurality of air bladders.

[0020] Figure 10 is a cross-sectional view along the centerline of the pump assembly of Figure 7 , showing air flow generated by the pneumatic pump and directed by the valve assembly to some of the plurality of air bladders.

[0021] Figure 11 is a cross-sectional view along the centerline of the pump assembly of Figure 7 , showing air flow generated by the pneumatic pump and directed by the valve assembly to some other of the plurality of air bladders.

[0022] Figure 12 is an enlarged cross-sectional view of the pump assembly of Figure 7 , showing the solenoid valve of the valve assembly in an open position.

[0023] Figure 13 is an enlarged cross-sectional view of the pump assembly of Figure 7 , showing another solenoid valve of the valve assembly in an open position.

[0024] Figure 14 is a perspective view of a pump assembly according to another embodiment of the disclosure.

[0025] Figure 15 is a table reflecting data obtained during testing of the pump assembly of Figure 1 , Figure 7 and Figure 14 .

[0026] Figure 16 is a plot reflecting data obtained during testing of the pump assembly of Figure 1 , Figure 7 and Figure 14 .

[0027] Figure 17 is another plot reflecting data obtained during testing of the pump assembly of Figure 1 , Figure 7 and Figure 14 during various stages of operation.

[0028] Figure 18 is a perspective view of a pump assembly according to another embodiment of the present disclosure.

[0029] Figure 19 is an exploded view of the pump assembly of Figure 18 .

[0030] Figure 20 is a schematic view of a pneumatic system including the pump assembly of Figure 18 .

[0031] Figure 21 is an enlarged cross-sectional view of the pump assembly of Figure 18 with the solenoid valve of the pump assembly in a first inflation configuration.

[0032] Figure 22 is an enlarged cross-sectional view of the pump assembly of Figure 18 with the solenoid valve in a second inflation configuration.

[0033] Figure 23 is an enlarged cross-sectional view of the pump assembly of Figure 18 with the solenoid valve in a first deflation configuration.

[0034] Figure 24 is another enlarged cross-sectional view of the pump assembly of Figure 18 with the solenoid valve in a second inflation configuration.

[0035] Before any embodiments of the present disclosure are explained in detail, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The present disclosure is capable of supporting other embodiments and being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. In addition, as used herein, the terms “upper,” “lower,” and other directional terms are not intended to require any particular orientation, but are used for descriptive purposes only. DETAILED DESCRIPTION

[0036] Figure 1 A pump assembly 100 according to embodiments of the present disclosure is shown. In one embodiment, the pump assembly 100 is configured for providing air for use in an application, such as for use in an automotive application. Such air is provided from the pump assembly 100 through one or more of a plurality of outlet ports 103. The pump assembly 100 can include a pump configured to operate (i.e., pump air through the plurality of outlet ports 103) using an electrical connection 105, which can supply power to the pump assembly 100. The electrical connection 105 can be connected to a power source through the use of a connector 104.

[0037] Figure 2 An embodiment of a pneumatic system 200 including the pump assembly 100 is shown. The pneumatic system 200 can be part of an automobile. For example, in the illustrated embodiment, the pneumatic system 200 is part of an automotive seat assembly. However, other applications of the pneumatic system 200 are contemplated, such as aerospace applications, office / desk chair applications, etc.

[0038] In the illustrated embodiment, the pneumatic system 200 includes a power source 201, which can be part of the electrical power system of the automobile. The connector 104 is configured to connect to the power source 201. In this way, the power source 201 can supply power 201a (e.g., at 12 volts or 24 volts in some embodiments) via the electrical connection 105 and to the pump assembly 100 through the connector 104.

[0039] When the pump assembly 100 is powered, the pump assembly 100 can operate to pump an air flow AF through the plurality of outlet ports 103. The air flow AF can travel from one or more of the outlet ports 103 through a respective pneumatic line 206a, 206b. The pump assembly 100 also includes a valve assembly 106 Figure 4), the valve assembly 106 can be used to: (i) direct air from the pump assembly 100 along the pneumatic lines 206a, 206b; (ii) interrupt the flow of air from the pump assembly 100 along the pneumatic lines 206a, 206b; (iii) regulate the pressure of the flow of air through the pneumatic lines 206a, 206b; and / or (iv) regulate the flow rate of the flow of air through the pneumatic lines 206a, 206b. The pump assembly 100 and the valve assembly 106 thus define an integrated pump and valve system.

[0040] The pneumatic lines 206a, 206b can be connected to respective bladders 205a, 205b. The bladders 205a, 205b can be configured to inflate or deflate as air flow AF from the pneumatic lines 206a, 206b flows into or out of the bladders 205a, 205b. In one embodiment, the bladders 205a, 205b can be supported in a bladder support device 204. In some embodiments, the bladder support device 204 is a seat configured to be positioned within an automobile. For example, the bladder 205b is positioned within the bladder support device 204 to provide lumbar support when a user is seated in the seat with the bladder support device 204 against the user's back. In such embodiments, the user can request increased or decreased lumbar support (e.g., the user can press a button 208), in which case the pump assembly 100 needs to be activated to provide air flow AF from the pump assembly 100 through the pneumatic line 206b into the bladder 205b (the lumbar bladder) to inflate the bladder 205b and provide the requested lumbar support. Similarly, the user can increase or decrease thoracic support by inflating or deflating the bladder 205a by the user pressing the same or a different button (or other suitable actuator).

[0041] Figure 3 An exploded view of the pump assembly 100 is shown. The pump assembly 100 extends along a longitudinal axis 408, and includes an upper housing 101, a lower housing 102, and a pump enclosure 107 between the upper housing 101 and the lower housing 102. The upper housing 101 includes the plurality of outlet ports 103 in the illustrated embodiment, and also includes a coupling structure 300 configured to engage the lower housing 102 and couple the upper housing 101 and the lower housing 102 together. In the illustrated embodiment, the coupling structure 300 includes four fingers 301 positioned equidistantly around a perimeter of the upper housing 101. Each finger 301 engages a corresponding receiving portion, such as the receiving portions 601 (there are four receiving portions 601 in total, but only two are shown in the illustrated embodiment). The lower housing 102 includes a corresponding coupling structure 302 configured to engage the coupling structure 300 of the upper housing 101. In the illustrated embodiment, the coupling structure 302 includes four receiving portions 601 positioned equidistantly around a perimeter of the lower housing 102. Each receiving portion 601 is configured to receive a corresponding finger 301 of the coupling structure 300 of the upper housing 101. Figure 3Only three of the receiving portions 601 are shown. In this way, to connect the upper housing 101 to the lower housing 102, the fingers 301 can engage (e.g., by snapping in) the receiving portions 601. In the illustrated embodiment, a plurality of screws 404 extend through the upper housing 101 in a direction parallel to the longitudinal axis 408 and are screwed into the lower housing 102 to secure the housings 101, 102 together and to clamp the pump enclosure 107 between the upper housing 101 and the lower housing 102. In the illustrated embodiment, the fingers 301 and the screws 404 are positioned in an alternating fashion around the perimeter of the upper housing 101. In other embodiments, the upper housing 101 and the lower housing 102 can be coupled together in other ways, or can be formed as a single unitary housing.

[0042] Referring to Figure 3 and Figure 4 , the illustrated pump assembly 100 includes a head plate 309 and a valve plate 310 located between the upper housing 101 and the lower housing 102 and more specifically between the pump enclosure 107 and the upper housing 101. A diaphragm assembly 417 forming part of a pneumatic pump 410 described in more detail below is clamped between the head plate 309 and the pump enclosure 107. The valve plate 310 includes a plurality of intake valves 414 and a plurality of exhaust valves 415 to control the flow of air AF into and out of the diaphragm assembly 417 as the diaphragm assembly 417 is sequentially compressed and expanded during operation of the pneumatic pump 410. One intake valve 414 and one exhaust valve 415 are aligned with each respective diaphragm cup 412 of the diaphragm assembly 417. The intake valves 414 and the exhaust valves 415 can be one-way reed valves formed integrally with the valve plate 310. The valve plate 310 can be constructed of rubber or other suitable resilient elastomeric material. In other embodiments, the valve plate 310 can include other types of one-way valves.

[0043] The upper housing 101 includes an outlet plate 307 positioned adjacent the valve plate 310 Figure 4 . The outlet plate 307 includes passages for each intake valve 414 to communicate with an intake port of the pneumatic pump 410 (e.g., a passageway through the upper housing 101 that communicates with the external environment) and passages for each exhaust valve 415 to communicate with a pair of outlet ports 407 (one of which is shown in Figure 4 . In the illustrated embodiment, each outlet port 407 leads to a respective check valve chamber 500. As described in more detail below, the air flow generated by the pump assembly 100 is discharged through the outlet ports 407 before being ultimately directed to one or more of the plurality of outlet ports 103.

[0044] With continuing reference to Figures 3-4 , the illustrated pump assembly 100 also includes a lower pump assembly 305 connected to the upper pump assembly 306. The drive interface 406 (Figure 6 ) can provide electrical and / or mechanical communication between the lower pump assembly 305 and the upper pump assembly 306. For example, the illustrated lower pump assembly 305 includes an electric motor 315 driving the drive interface 406 about the longitudinal axis 408, which extends along the axis 408, and the upper pump assembly 306 includes a pneumatic pump 410 coupled to the drive interface 406. In such embodiments, the drive interface 406 provides rotational energy (e.g., via a drive shaft) to the upper pump assembly 306 to drive the pneumatic pump 410 contained therein.

[0045] More particularly, in the illustrated embodiment, the drive interface 406 includes a drive shaft coupled to an eccentric crank, which in turn is coupled to a wobble plate 411 that sequentially actuates a plurality of chambers or diaphragm cups 412 one after another as the wobble plate 411 oscillates about the longitudinal axis 408. The wobble plate 411 has a plurality of arms 413, with each arm 413 coupled to a respective diaphragm cup 412 Figure 4 、 Figure 6 ) As a result of the oscillating nature of the wobble plate 411, each arm 413 of the wobble plate 411 continuously and sequentially pushes and pulls the respective diaphragm cup 412 to draw and expel a flow of air AF into and out of the diaphragm cup 412 Figure 4 ) When a diaphragm cup 412 is pulled by the respective arm 413, a flow of air AF is drawn in and into the diaphragm cup 412 through a corresponding one of the plurality of intake valves 414 Figure 3 ) Subsequently, when the diaphragm cup 412 is pushed by the respective arm 413, the compressed flow of air AF is expelled from the diaphragm cup 412 through a corresponding one of the outlet valves 415 Figure 3 ) The flow of air AF expelled from each diaphragm cup 412 ultimately exits the upper pump assembly 306 via the outlet 407 in the outlet plate 307. In the illustrated embodiment, the wobble plate 411 includes five arms 413 connected to five chambers or diaphragm cups 412. This arrangement provides efficient packing and greater volume in the diaphragm cups 412 compared to other arrangements (e.g., diaphragm assemblies having 2, 3, or 4 diaphragm cups), enabling higher flow rates for the pneumatic pump 410 compared to such other arrangements for a given operating speed of the motor 315. When lower amounts of air flow are needed, the motor 315 can be driven more slowly compared to pumps having other diaphragm arrangements, which in some embodiments can result in power savings, reduced noise, and increased longevity. In other embodiments, the wobble plate 411 can include a greater number of arms and diaphragm cups.

[0046] Figure 6A pressure relief valve 416 is shown disposed within the upper pump assembly 306 for relieving excess pressure delivered from the air pump 410 to the valve assembly 106, thereby reducing potential wear on the air pump 410. The pressure relief valve 416 is in fluid communication with both upper assembly outlets 407 on the discharge side of the air pump 410. The illustrated pressure relief valve 416 includes a seal head 418 and a head spring 420 biasing the seal head 418 toward a closed position. When the seal head 418 is in the closed position (as shown in Figure 6 any air flow AF generated by the air pump 410 passes through both upper assembly outlets 407 in the outlet plate 307 and toward the check valve 501 associated with the respective outlet 407. However, if excess pressure builds downstream of the air pump 410 (e.g., due to the check valve 501 being stuck, due to increased pressure downstream of the check valve 501 due to compression of the bladder 205a, 205b by weight, etc.), the pressure exerts a force on the seal head 418 that overcomes the bias of the head spring 420 to move the seal head 418 to an open position. When the seal head 418 moves to the open position, air can vent past the seal head 418 into the lower housing 102 (which is in communication with the ambient atmosphere), thereby reducing the pressure downstream of the air pump 410. When the excess pressure is relieved, the seal head 418 is urged back to the closed position via the head spring 420. In other embodiments, the pressure relief valve 416 can have other configurations (e.g., a reed valve or a flapper valve, etc.). In still other embodiments, the pressure relief valve 416 can be omitted.

[0047] As previously described, the air pump 410 pumps a compressed air flow AF through both upper assembly outlets 407 in the outlet plate 307 and toward the check valves 501a, 501b Figure 3 ). The two check valves 501a, 501b are essentially identical— one for each upper assembly outlet 407 downstream— but for the sake of brevity and clarity, only one check valve will be described in further detail below.

[0048] With continued reference to Figure 4 , the check valve 501 is aligned with the upper assembly outlet 407 and oriented parallel to the longitudinal axis 408. The check valve 501 includes a valve body 502 and a spring 503 biasing the valve body 502 to a closed position. When the check valve 501 is in the closed position (as shown in Figure 4When the motor 315 is activated, the air flow AF expelled from the diaphragm cup 412 creates enough pressure to overcome the bias of the spring 503, causing the check valve 501 to move to an open position. When the check valve 501 is in the open position, the valve body 502 is pushed upward against the bias of the spring 503 to enable the air flow AF to pass over the check valve 501 and through toward the control valve 505. The air flow AF travels through the air passageway 409 disposed between the check valve 501 and the control valve 505.

[0049] There are two control valves 505a, 505b - one downstream of each check valve 501a, 501b in the illustrated embodiment. The two check valves 501a, 501b and the two control valves 505a, 505b are arranged in parallel (not in series) relative to each other, such that air created by the displacement of the diaphragm cup 412 can pass through both check valves 501a, 501b and both control valves 505a, 505b simultaneously and independently. For the sake of brevity and clarity, only one control valve 505 will be described.

[0050] The illustrated control valve 505 is a 3 / 2-way solenoid actuated directional control valve, and is oriented parallel to the longitudinal axis 408. The control valve 505 is also located downstream of the check valve 501. The control valve 505 includes a housing 506 and a plunger 507. When the control valve 505 is not energized, the plunger 507 is biased toward a charging position ( Figure 4 ) via a spring 508, allowing the air flow AF to pass through the control valve 505. As such, the air flow AF from the check valve 501 flows through the control valve 505 and is directed to the associated one outlet port 103 (e.g., to inflate the connected bladder 205a, 205b). Conversely, when the control valve 505 is energized, the plunger 507 moves against the bias of the spring 508 to a deflating position ( Figure 5 ), preventing the air flow AF from passing through the control valve 505. At the same time, the air flow AF (if any) from the bladder 205a, 205b associated with the outlet port 103 is allowed to exit to the environment through a vent port 509 of the control valve 505. In the illustrated embodiment, the vent port 509 is oriented perpendicular to the longitudinal axis 408. Figure 5 In the illustrated embodiment, a filter (e.g., open cell foam) is positioned between the vent port 509 and the environment to reduce noise created by the outflowing air.

[0051] Although the illustrated control valve 505 is a solenoid valve, it should be understood that other control valves 505 can be used, including valves having other types of actuators. For example, the control valve 505 can include a shape memory alloy actuator configured to expand or contract to move the plunger 507.

[0052] With reference toFigure 3 and Figure 4 Pump assembly 100 also includes a printed circuit board (or PCB) 701. PCB 701 is coupled alongside upper housing 101 and lower housing 102, and more particularly, to the outer periphery of upper housing 101 via a pair of fasteners 702. In the illustrated embodiment, PCB 701 is mounted to housings 101, 102 in an orientation parallel to longitudinal axis 408. That is, PCB 701 includes a longitudinal axis 703 that extends along the length of PCB 701, and this longitudinal axis 703 is parallel to longitudinal axis 408. A PCB enclosure 704 is coupled to housings 101, 102 via a plurality of quick connect tabs 705. PCB enclosure 704 encloses PCB 701 to prevent unwanted debris from invading and to protect PCB 701 from inadvertent damage. Upper housing 101, lower housing 102, pump enclosure 107, and PCB enclosure 704 can collectively define an enclosure of pump assembly 100, and can be referred to herein as portions of the enclosure of pump assembly 100. In some embodiments, one or more of upper housing 101, lower housing 102, pump enclosure 107, and PCB enclosure 704 can be integrally formed together, and the enclosure of pump assembly 100 can otherwise be configured in various ways.

[0053] PCB 701 is adjacent to motor 315 at a bottom end 706 and adjacent to upper housing outlet port 103 at a top end 707, such that PCB 701 extends between motor 315 and upper housing outlet port 103. Motor pins 708 extend from motor 315 and engage PCB 701 at bottom end 706. Similarly, power pins 709 extend from connector 104 and engage PCB 701 at top end 707. Also, valve pins 710 extend from enclosure 506 of control valve 505 and engage PCB 701 between top end 707 and bottom end 706. Pins 708, 709, 710 enable PCB 701 to communicate with various components of pump assembly 100 (e.g., motor 315, solenoid valve 505, etc.). PCB 701 can also include one or more heat-generating electronic components 711 (e.g., MOSFETs, resistors, transistors, capacitors, inductors, sensors) that can be aligned with exhaust port 509 to dissipate heat from heat-generating electronic components 711. PCB 701 can also include a microcontroller or microprocessor configured to monitor various characteristics of pneumatic system 200 (e.g., the state of solenoid valve, etc.).

[0054] In operation, an occupant of the seat can request an increase or decrease in, for example, lumbar support (e.g., the user can press button 208), in the case of an increase in lumbar support, this will require the pump assembly 100 to be activated to provide air from the pump assembly 100 through the pneumatic line 206b into the bladder 205b (lumbar bladder) positioned within the bladder support device 204, thereby inflating the bladder 205b and providing the requested lumbar support. Specifically, the motor 315 is activated to begin filling the air bladder 205b by supplying air from the pump assembly 100 and through the pneumatic line 206b. As shown in FIG. 3, the motor 315 is activated to drive the pneumatic pump 410, which draws air through the plurality of intake valves 414 and expels the air flow AF through the upper assembly outlet 407. By default, the check valve 501 and the pressure relief valve 416 are in the closed position, but the air flow AF exiting the upper assembly outlet 407 provides enough force to overcome the biasing force of the spring 503, thereby moving the valve body 502 away from the outlet 407. In this way, the check valve 501 moves to the open position and the air flow AF passes through the air passageway 409 toward the control valve 505. Subsequently, the air flow AF bypasses the unenergized control valve 505b (i.e., in the deflated position), exits the upper assembly outlet port 103, passes through the pneumatic line 206b, and enters into the air bladder 205b. Figure 4

[0055] For example, if the air flow AF is unable to pass the check valve 501 due to the air bladder 205b being fully inflated, excess pressure can build up in the valve assembly 106 and the air flow AF can be expelled through the pressure relief valve 416. Once the air bladder 205b is properly inflated, the motor 315 is deactivated and, in response, the check valve 501b moves to the closed position via the biasing of the spring 503. As a result, the air bladder 205b is prohibited from deflating because the check valve 501b is in the closed position. To deflate the bladder 205b, the PCB 701 sends an electrical signal to the control valve 505b via the valve pin 710, thereby causing the plunger 507 to move to the deflation position (FIG. 4B). With the solenoid valve 505b in the deflation position, air exits the air bladder 205b along the pneumatic line 206b and out of the exhaust port 509 to the environment. Figure 5

[0056] If another air bladder 205a is to be supplied with the air flow AF, the control valve 505a is in the closed position such that the air flow AF passes the control valve 505a and along the pneumatic line 206a toward the air bladder 205a to be filled. To avoid filling, for example, the air bladder 205b, the associated solenoid valve, such as the solenoid valve 505b, remains in the deflation position such that the air flow AF is prevented from reaching the bladder 205b and the air currently present in the bladder 205b is expelled through the outlet port 103 and the exhaust port 509.

[0057] ​​Figure 7 and Figure 8 A pump assembly 1100 according to another embodiment is shown. Pump assembly 1100 is similar to pump assembly 100 described above with reference to Figures 1-6 and pump assembly 1100 is given the same reference numerals plus 1000 corresponding to features and elements of pump assembly 100. In addition, the following description focuses primarily on the differences between pump assembly 1100 and pump assembly 100.

[0058] With reference to Figure 7 and Figure 8 , pump assembly 1100 is shown to include two pairs of control valves 1505a, 1505b, 1505c, 1505d for a total of four control valves, rather than two control valves 505a, 505b. As described in greater detail below, control valves 1505a, 1505c provide inflation and deflation control, and control valves 1505b, 1505d provide port selection (direction) control. That is, control valves 1505b, 1505d select which of bladders 1205a-1205d are fluidly connected to pump assembly 1100, and control valves 1505a, 1505c control whether the selected bladders 1205a-1205d are inflated or deflated.

[0059] In the illustrated embodiment, one pair of control valves 1505a, 1505b is arranged in parallel (not in series) relative to the other pair of control valves 1505c, 1505d. That is, the individual control valves comprising each pair of valves are arranged in series such that control valves 1505a, 1505b are arranged in series with each other, and control valves 1505c, 1505d are arranged in series with each other Figures 8-10 . In this way, air generated from diaphragm cup 1412 is able to pass through each pair of control valves simultaneously and independently after passing through respective check valves 1501a, 1501b. That is, check valve 1501a is upstream of one pair of control valves 1505a, 1505b, and check valve 1501b is upstream of the other pair of control valves 1505c, 1505d Figure 10 .

[0060] The control valves 1505a, 1505b, 1505c, 1505d are oriented parallel to the longitudinal axis 1408. Similarly, the PCB 1701 defines a longitudinal axis 1702 that is oriented parallel to the longitudinal axis 1408. In the illustrated embodiment, each control valve 1505a-1505d is a 3 / 2 pneumatic directional control valve. Downstream of each pair of control valves 1505a, 1505b, 1505c, 1505d is a plurality of air bladders, for a total of four air bladders 1205a, 1205b, 1205c, 1205d. The pump assembly 1100 can also include a pressure relief valve 416 that allows air flow AF to exit the pump assembly 1100 if excess pressure is present.

[0061] In operation, an occupant of the seat can desire to inflate or deflate (i.e., increase or decrease air pressure) air bladders 1 and 2, 1205a, 1205c, for example. To obtain additional support from air bladders 1 and 2, the motor 1315 of the pump assembly 1100 is activated to provide air flow AF from the pump assembly 1100 through pneumatic lines 1206a, 1206c into air bladders 1205a, 1205c (i.e., air bladders 1 and 2) to inflate them. Prior to activation of the motor 1315, the check valves 1501a, 1501b are in the closed position by default. However, when the motor 1315 is activated, the air flow AF exiting the upper assembly outlet 1407 provides sufficient force to overcome the biasing force of the spring 1503, moving the valve body 1502 away from the outlet 1407 and opening the outlet 1407 Figure 10 ). Thus, the check valves 1501a, 1501b are in the open position, allowing air flow AF to pass through the respective air passages 1409 toward the control valves 1505a, 1505c. Subsequently, with continued reference to Figure 9 and Figure 10 , the air flow AF passes through the unenergized control valves 1505a, 1505c (i.e., in the inflate position), through the unenergized control valves 1505b, 1505d, exits the two upper assembly outlet ports 1103, passes through pneumatic lines 1206a, 1206c, and into air bladders 1205a, 1205c. If the air flow AF is unable to pass the check valves 1501a, 1501b due to air bladders 1205a, 1205c being fully inflated, for example, excess pressure can build and the air flow AF can be expelled through the pressure relief valve 416.

[0062] To inflate only one of the airbags (e.g., airbag 1205a), control valve 1505c is energized, thereby preventing airflow AF from entering airbag 1205c, and simultaneously allowing air present in airbag 1205c to exit through exhaust port 1509c. As demonstrated, control valves 1505a, 1505c are responsible for inflating or deflating airbags, while control valves 1505b, 1505d are responsible for directing airflow AF toward a particular airbag (e.g., airbags 1 and 2 or headrests R, L).

[0063] To inflate headrests 1205b, 1205d, Figure 9 and Figure 11 ), direction control valves 1505b, 1505d are energized. Air exits the other two upper assembly outlet ports 1103, passes through pneumatic lines 1206b, 1206d, and enters airbags 1205b, 1205d, by bypassing the energized control valves 1505b, 1505d, through the unenergized "inflate / deflate" control valves 1505a, 1505c.

[0064] Once airbags 1205a, 1205b, 1205c, 1205d are inflated, motor 1315 is deactivated, and in response, check valves 1501a, 1501b move to the closed position via the bias of springs 1503. As a result, airbags 1205a, 1205c are prohibited from deflating because check valves 1501a, 1501b and control valves 1505a and 1505c are in the closed position. Also, airbags 1205b, 1205d are prohibited from deflating by the unenergized state of control valves 1505a, 1505c.

[0065] As shown in Figure 12 and Figure 13 , to deflate any of airbags 1205a, 1205b, 1205c, 1205d, motor 1315 remains deactivated and PCB 1701 sends an electrical signal to "inflate / deflate" control valves 1505a, 1505c via valve pins 1710, causing control valves 1505a, 1505c to move to the open or deflation position. Specifically, with control valves 1505a, 1505c in the open position and control valves 1505b, 1505d in the closed position, airflow AF exits airbags 1205a, 1205c through flow around unenergized control valves 1505b and 1505d and through energized (i.e., open) control valves 1505a and 1505c to exhaust port 1509 and the environment.

[0066] Alternatively, in a similar manner, in the case where the control valves 1505a, 1505c are still in the open position and the control valves 1505b, 1505d are energized to the open position, the airflow AF exits from the bladders 1205b, 1205d through the open control valves and to the exhaust port 1509 and the environment.

[0067] Figure 14 A pump assembly 2100 according to another embodiment is shown. The pump assembly 2100 is similar to the pump assembly 100 described above with reference to FIGS. 1A-1C, and features and elements of the pump assembly 2100 that correspond to features and elements of the pump assembly 100 are given the same reference numbers plus 2000. The main difference between the pump assembly 2100 and the pump assembly 100 is the configuration of the control valves 2505 and the outlet ports 1103. Specifically, there are three outlets 1407 fluidly connected to three control valves (not shown, but which can be similar to the control valves 1505a-1505c, for example) and downstream thereof. Figures 1-6

[0068] Each of the control valves can be an inflation / deflation control valve associated with a respective one of the outlet ports 1103 to individually control inflation or deflation of the connected bladder. In such an embodiment, pressure is maintained in the bladder by a check valve (not shown, but which can be similar to the check valves 1501a, 1501b, for example) until it is desired to deflate the bladder, at which time the control valve associated with the bladder is moved to the deflation position.

[0069] In another embodiment, one of the control valves can be an inflation / deflation control valve, a second one of the control valves can be a directional valve in series with the inflation / deflation control valve and coupled to two of the outlet ports 2103, and a third one of the control valves can be an on / off valve in series with the inflation / deflation control valve and coupled to the remaining one of the outlet ports 2103. In such an embodiment, the two bladders coupled to the directional valve can be inflated and deflated without inflating or deflating the third bladder coupled to the on / off valve. This can be advantageous, for example, if one of the bladders is configured as a lumbar support bladder and the two bladders are arranged in a seat back or seat cushion to provide an alternating massage effect.

[0070] It should be appreciated that other arrangements of control valves can also be incorporated into any of the assemblies described and shown herein to provide the desired functionality.

[0071] ​The various features of the pump assemblies 100, 1100, 2100 described and shown herein advantageously contribute to quieter operation than known pump assemblies. For example, the five diaphragm cup configuration (i.e., cups 412, 1412, 2412) allows the motor 315, 1315, 2315 to operate at a lower rotational speed while pumping similar volumes of air compared to pump assemblies having fewer diaphragm cups. Each pump assembly 100, 1100, 2100 can be configured to pump air at a free flow (without connected bladder) of 3 to 6 liters per minute in some embodiments, or at least 4 liters per minute in some embodiments. The five diaphragm cup configuration also decouples harmonic modes and reduces resonance overlap between the motor 315, 1315, 2315 and the cups 412, 1412, 2412 relative to a four diaphragm cup configuration. Finally, the check valve 501, 1501, 2501 tends to remain open during pumping due to the more frequent air pulses per revolution provided by the five diaphragm cup configuration, thereby reducing valve noise.

[0072] In addition to the advantages provided by the five diaphragm cup configuration, the wall structure of the upper housing 101, 1101, 2101 and lower housing 102, 1102, 2102 dampen the sound of the internal moving parts (e.g., motor, wobble plate, cups, solenoids, etc.). Furthermore, the passages (e.g., 407, 409, 103, etc.) along which the airflow AF travels are preferably air tight to prohibit leaks out of the pump assembly 100, 1100, 2100. As a result, the sound from the pump assembly 100, 1100, 2100 due to hissing air and moving parts is reduced.

[0073] For example, the pump assembly 100 was tested in a standard vehicle seat to inflate and deflate two bladders of a pneumatic lumbar system. The seat was located in a noise isolated room at an ambient temperature of about 23 degrees Celsius and was equipped with full trim. The pump assembly 100 was powered by a power supply having a voltage of 13.0 V ± 0.2 V. The vehicle seat was loaded with an adult male manikin weighing 75 kilograms and a microphone was placed about 600 millimeters from the head position of the manikin. The pump assembly 100 was mounted to the seat frame inside the vehicle seat.

[0074] During the test, the two lumbar bladders were fully inflated and then deflated simultaneously. Then, the bladders were inflated and deflated in an alternating manner. This inflation and deflation cycle was repeated three times for the test pump assembly 100. Then, for comparison purposes, the same test was repeated with three existing pumps. The test cycle is shown in Figure 17 .

[0075] As Figures 15-16As shown in FIG. 12, the pump assembly 100 similarly operates at a maximum sound pressure level between about 32.1 dB(A) and about 32.5 dB(A). Specifically, the pump assembly 100 similarly operates at a maximum sound pressure level of about 32.2 dB(A). In comparison, existing pumps operate at a maximum sound pressure level between about 33.2 dB(A) and about 44.8 dB(A).

[0076] As shown in FIG. 12, the pump assembly 100 similarly operates at a maximum sound pressure level between about 32.1 dB(A) and about 32.5 dB(A). Specifically, the pump assembly 100 similarly operates at a maximum sound pressure level of about 32.2 dB(A). In comparison, existing pumps operate at a maximum sound pressure level between about 33.2 dB(A) and about 44.8 dB(A). Figures 15-16 As shown in FIG. 12, the pump assembly 100 similarly operates at a maximum sound pressure level between about 32.1 dB(A) and about 32.5 dB(A). Specifically, the pump assembly 100 similarly operates at a maximum sound pressure level of about 32.2 dB(A). In comparison, existing pumps operate at a maximum sound pressure level between about 33.2 dB(A) and about 44.8 dB(A).

[0077] Figure 17 As shown in FIG. 12, the pump assembly 100 similarly operates at a maximum sound pressure level between about 32.1 dB(A) and about 32.5 dB(A). Specifically, the pump assembly 100 similarly operates at a maximum sound pressure level of about 32.2 dB(A). In comparison, existing pumps operate at a maximum sound pressure level between about 33.2 dB(A) and about 44.8 dB(A).

[0078] Figures 18-24 A pump assembly 3100 according to another embodiment is shown. The pump assembly 3100 is similar to the pump assembly 100 described above with reference to FIGS. 1-11, and features and elements of the pump assembly 3100 that correspond to features and elements of the pump assembly 100 are given the same reference numbers plus 3000. In addition, the following description focuses primarily on the differences between the pump assembly 3100 and the pump assembly 100. As shown in FIG. 13, the pump assembly 3100 is part of a pneumatic system 3200. Figures 1-6 Figure 20 Figure 2

[0079] Figure 19 ​​​​An exploded view of the pump assembly 3100 is shown. The pump assembly 3100 extends along a longitudinal axis 3408 and includes an upper housing 3101, a lower housing 3102, and a pump enclosure 3107 between the upper housing 3101 and the lower housing 3102. The upper housing 3101 includes a plurality of outlet ports (three ports 3103a-c in the illustrated embodiment). The illustrated pump assembly 3100 also includes a head plate 3309 and a valve plate 3310 between the upper housing 3101 and the lower housing 3102 and more particularly between the pump enclosure 3107 and the upper housing 3101. A diaphragm assembly 3417 forming part of a pneumatic pump 3410 is clamped between the head plate 3309 and the pump enclosure 3107.

[0080] The valve plate 3310 includes a plurality of intake valves 3414 and a plurality of exhaust valves 3415 to control the flow of air AF into and out of the diaphragm assembly 3417 as the diaphragm assembly 3417 is sequentially compressed and expanded during operation of the pneumatic pump 3410. One intake valve 3414 and one exhaust valve 3415 are aligned with each respective diaphragm cup 3412 of the diaphragm assembly 3417.

[0081] The upper housing 3101 includes an outlet plate 3307 positioned adjacent the valve plate 3310 and a valve assembly enclosure 3115 coupled to the outlet plate 3307. Figure 21 The outlet plate 3307 includes passages for each intake valve 3414 to communicate with an intake port 3419 of the pneumatic pump 3410 and passages for each exhaust valve 3415 to communicate with a pair of outlets 3407. As shown in Figure 20 The valve assembly enclosure 3115 includes a first chamber 3117 in fluid communication with the first outlet port 3103a, a second chamber 3119 in fluid communication with the second outlet port 3103b, and a third chamber 3121 in fluid communication with the third outlet port 3103c.

[0082] With continued reference to Figure 20 The pneumatic system 3200 includes two pneumatic bladders 2505a, 2505b coupled (e.g., via suitable pneumatic lines) to respective first and second outlet ports 3101a, 3103b. The pneumatic bladders 2505a, 2505b may, for example, be positioned in a lumbar or bolster region of a vehicle seat to provide adjustable firmness to the lumbar or bolster. The pneumatic system 3200 can also include a pneumatic device such as a fluid module 3206 coupled (e.g., via suitable pneumatic lines) to the third outlet port 3103c. In the illustrated embodiment, the third outlet port 3103c is disposed between the first and second outlet ports 3103a, 3103b.

[0083] The fluid module 3206 can be, for example, any of the fluid modules disclosed in U.S. Patent No. 11,883,358, assigned to Leggett & Platt Canada Co., the entirety of which is incorporated by reference herein. The fluid module 3206 can feed air to a plurality of additional pneumatic bladders and provide air switching functionality to inflate and deflate the additional pneumatic bladders in a desired order, thereby providing a massage function. The fluid module 3206 can instead include an external valve module for inflating and deflating the additional pneumatic bladders. As described in greater detail below, the valve assembly 3106 of the pneumatic pump 3410 is capable of directing two parallel air flows to the first and second outlet ports 3103a, 3103b or combining the two air flows to supply a greater volume of air to the third outlet port 3103c, which can then provide a more effective massage.

[0084] Referring again to Figure 19 , the valve assembly 3106 is at least partially received within a valve assembly housing 3115, such that the pump assembly 3100 and the valve assembly 3106 define an integrated pump and valve system. The illustrated valve assembly 3106 includes a plurality (e.g., four) of control valves 3505a-d. However, unlike the valve assemblies associated with the pump assemblies 100, 1100, 2100, the valve assembly 3106 does not include check valves between the outlet 3407 and the control valves 3505a-d.

[0085] The illustrated valve assembly 3106 includes two pairs of control valves for a total of four control valves 3505a, 3505b, 3505c, 3505d. As described in greater detail below, the control valves 3505a, 3505c provide inflation and deflation control, and the control valves 3505b, 3505d provide port selection (direction) control. That is, the control valves 3505b, 3505d select which of the outlet ports 3103a-c is fluidly connected to the pump assembly 3100, and the control valves 3505a, 3505c control whether pressurized air is supplied to or exhausted from the selected outlet port 3103a-c.

[0086] In the illustrated embodiment, one pair of control valves 3505a, 3505b is arranged in parallel (not in series) relative to the other pair of control valves 3505c, 3505d. That is, the individual control valves comprising each pair of valves are arranged in series, such that the control valves 3505a, 3505b are arranged in series with one another, and the control valves 3505c, 3505d are arranged in series with one another. Thus, air generated from the diaphragm cup 3412 can be simultaneously and independently passed through each pair of control valves.

[0087] Control valves 3505a, 3505b, 3505c, and 3505d are oriented parallel to the longitudinal axis 3408 and connected to PCB 3701, which also extends parallel to the longitudinal axis 3408. Like PCB 701, PCB 3701 is also connected to the motor 3315 of the pump assembly 3100. In the illustrated embodiment, each control valve 3505a-3505d is a 3 / 2-way pneumatic directional control valve, such as a solenoid-actuated control valve. In other embodiments, other types of valves may be used.

[0088] Now refer to Figures 20-24 The operation of the pump assembly 3100 and the pneumatic system 3200 is described. In operation, to inflate the first pneumatic bladder 3205a connected to the first outlet port 3103a, a motor 3315 (e.g., via PCB 3701) is energized to sequentially compress and expand the diaphragms 3412. During expansion, each diaphragm 3412 draws air from the inlet 3419 and through a corresponding inlet valve 3414. In the illustrated embodiment, a filter 3421 (e.g., an open-cell foam filter) is disposed adjacent to the inlet 3419 to remove potential dust or debris from the incoming air and also to reduce noise associated with the flowing air. As each diaphragm 3412 is compressed, air is forced out through a corresponding outlet valve 3415 and routed to the outlet 3407 via a channel (not shown) in the outlet plate 3307. Figure 21 As shown, to inflate the first bladder 3205a, the first control valve 3505a is held in its de-energized position, allowing airflow AF to flow from outlet 3407 through the first control valve 3505a to the second control valve 3505b. The second control valve 3505b is actuated to its energized position, allowing airflow AF to enter the first chamber 3117. Airflow AF is then able to flow from the first chamber 3117 to the first outlet port 3103a and inflate the bladder 3205a. Figure 20 ).

[0089] refer to Figure 23 To deflate the first pneumatic bladder 3205a, both the first control valve 3505a and the second control valve 3505b are energized. This allows airflow AF from the bladder 3205a to flow from the first chamber 3117 through the second control valve 3505b back to the first control valve 3505a, which, when energized, opens the exhaust port 3423. The exhaust port 3423 routes the airflow AF back to the inlet 3419 for recirculation and through the filter 3421 to reduce noise. The inlet 3419 is also in communication with the surrounding environment, so any excess pressure at the inlet 3419 can be released into the environment.

[0090] Inflation and deflation of the second pneumatic bladder 3205b is performed in the same manner as the first pneumatic bladder 3205a, but using the third control valve 3505c and the fourth control valve 3505d instead of the first control valve 3505a and the second control valve 3505b.

[0091] Finally, the illustrated pump assembly 3100 can also be operated to deliver the air flow AF to the fluid module 3206 Figure 20 ) or any other bladder or device connected to the third outlet port 3103c. The volume of air flow AF delivered to the third outlet port 310c can be greater than the volume of air flow AF delivered to the first bladder port 3103a or the second bladder port 3103b. As Figure 24 illustrated in FIG. 6, in the case where all of the control valves are in their de-energized positions, the resulting air flow AF flows through each pair of control valves 3505a, 3505b, 3505c, 3505d in two parallel streams. The air flow AF then combines and flows into the third chamber 3121 Figure 20 and Figure 22 ). Thus, when all of the control valves 3505a-3505d are de-energized, the valve assembly 3106 assumes a pass-through configuration, allowing the entire output of the pump assembly 3100 to be routed to the third outlet port 3103c and providing sufficient volume of air to operate the connected fluid module 3206. In some embodiments, the pump assembly 3100 can have a free flow of 3-6 liters (without a connected bladder), or at least 4 liters per minute in some embodiments.

[0092] Representative Features

[0093] Representative features are set forth in the following clauses, which are independently

[0094] Clause 1. A pump assembly, comprising: a housing including a plurality of outlet ports; a motor extending along a longitudinal axis; a pneumatic pump driven by the motor; a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct an air flow generated by the pneumatic pump to the plurality of outlet ports; a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, wherein the printed circuit board extends parallel to the longitudinal axis.

[0095] Clause 2. The pump assembly of clause 1, wherein the plurality of outlet ports includes at least three outlet ports, and wherein the valve assembly includes at least three valves.

[0096] Clause 3. The pump assembly of clause 1, wherein the printed circuit board extends continuously from the motor to the valve assembly.

[0097] Clause 4. The pump assembly of clause 1, wherein the housing comprises a lower housing, an upper housing, and a PCB housing, the lower housing is coupled to the motor, the upper housing comprises the plurality of outlet ports, the PCB housing is coupled to the upper housing, and at least partially encloses the printed circuit board.

[0098] Clause 5. The pump assembly of clause 4, wherein the upper housing at least partially encloses the valve assembly, wherein the pneumatic pump comprises a diaphragm assembly and a valve plate, the valve plate comprises a plurality of intake valves and a plurality of outlet valves, and wherein the upper housing comprises an outlet in communication with the plurality of outlet valves and the valve assembly.

[0099] Clause 6. The pump assembly of clause 5, wherein the valve assembly comprises a check valve and a directional control valve downstream of the check valve, the check valve comprises a valve body and a spring, the spring biases the valve body to close the outlet.

[0100] Clause 7. The pump assembly of clause 6, wherein the check valve is oriented parallel to the longitudinal axis.

[0101] Clause 8. The pump assembly of clause 7, wherein the check valve is one of a plurality of check valves.

[0102] Clause 9. The pump assembly of clause 1, wherein the valve assembly comprises a plurality of control valves oriented parallel to the longitudinal axis.

[0103] Clause 10. The pump assembly of clause 1, wherein the pneumatic pump comprises a diaphragm assembly, the diaphragm assembly has five chambers that sequentially expand and compress in response to the motor being activated.

[0104] Clause 11. The pump assembly of clause 1, wherein the pump assembly is configured to output a flow of air at a free flow between 3 and 6 liters per minute.

[0105] Clause 12. The pump assembly of clause 1, wherein the pump assembly is operable at a maximum loudness between 1.1 and 1.2 Song.

[0106] Clause 13. A pump assembly comprising: a housing comprising a plurality of outlet ports; a motor extending along a longitudinal axis; a pneumatic pump driven by the motor; a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct airflow generated by the pneumatic pump to the plurality of outlet ports; a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, wherein the pump assembly is configured to output airflow at a free flow of between 3 and 6 liters per minute, and wherein the pump assembly is operable at a maximum loudness of between 1.1 sone and 1.2 sones.

[0107] Clause 14. The pump assembly of clause 13, wherein the pneumatic pump comprises a diaphragm assembly having five diaphragm chambers.

[0108] Clause 15. A pump assembly comprising: a housing comprising a plurality of outlet ports; a motor extending along a longitudinal axis; a pneumatic pump driven by the motor; a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct airflow generated by the pneumatic pump to the plurality of outlet ports; and a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, wherein the valve assembly comprises: a first control valve; a second control valve arranged in series with the first control valve; a third control valve arranged in parallel with the first control valve and the second control valve; and a fourth control valve arranged in series with the third control valve.

[0109] Clause 16. The pump assembly of clause 15, wherein the first control valve, the second control valve, the third control valve, and the fourth control valve are all 3 / 2 way solenoid actuated valves.

[0110] Clause 17. The pump assembly of clause 15, wherein the plurality of outlet ports comprises a first outlet port, a second outlet port, and a third outlet port.

[0111] Clause 18. The pump assembly of clause 17, wherein, when the first control valve, the second control valve, the third control valve, and the fourth control valve are de-energized, airflow generated by the pneumatic pump is routed to the third outlet port by the valve assembly.

[0112] Clause 19. The pump assembly of clause 15, wherein the first control valve and the third control valve are configured to selectively connect the plurality of outlet ports to an exhaust port.

[0113] Clause 20. The pump assembly of clause 19, wherein the exhaust port is in fluid communication with an intake port of the pneumatic pump.

[0114] Various features and aspects of the present disclosure are set forth in the claims that follow.

Claims

1. A pump assembly comprising: a housing, the housing comprising a plurality of outlet ports; a motor, the motor extending along a longitudinal axis; a pneumatic pump, the pneumatic pump driven by the motor; a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct airflow generated by the pneumatic pump to the plurality of outlet ports; a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, wherein the printed circuit board extends parallel to the longitudinal axis.

2. The pump assembly of claim 1, wherein, the plurality of outlet ports comprises at least three outlet ports, and wherein the valve assembly comprises at least three valves.

3. The pump assembly of claim 1, wherein, the printed circuit board extends continuously from the motor to the valve assembly.

4. The pump assembly of claim 1, wherein, the housing comprises a lower housing coupled to the motor, an upper housing comprising the plurality of outlet ports, and a PCB housing coupled to the upper housing and at least partially encapsulating the printed circuit board.

5. The pump assembly of claim 4, wherein, the upper housing at least partially encapsulates the valve assembly, wherein the pneumatic pump comprises a diaphragm assembly and a valve plate, the valve plate comprising a plurality of intake valves and a plurality of outlet valves, and wherein the upper housing comprises an outlet in communication with the plurality of outlet valves and the valve assembly.

6. The pump assembly of claim 5, wherein, the valve assembly comprises a check valve and a direction control valve downstream of the check valve, the check valve comprising a valve body and a spring biasing the valve body to close the outlet.

7. The pump assembly of claim 6, wherein, the check valve is oriented parallel to the longitudinal axis.

8. The pump assembly of claim 7, wherein, the check valve is one of a plurality of check valves.

9. The pump assembly of claim 1, wherein, the valve assembly comprises a plurality of control valves oriented parallel to the longitudinal axis.

10. The pump assembly of claim 1, wherein, the pneumatic pump comprises a diaphragm assembly having five chambers that sequentially expand and compress in response to the motor being activated.

11. The pump assembly of claim 1, wherein, the pump assembly is configured to output airflow at a free flow rate of between 3 and 6 liters per minute.

12. The pump assembly of claim 1, wherein, the pump assembly is operable at a maximum loudness of between 1.1 sone and 1.2 sone.

13. A pump assembly comprising: a housing, the housing comprising a plurality of outlet ports; a motor, the motor extending along a longitudinal axis; a pneumatic pump, the pneumatic pump driven by the motor; a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct airflow generated by the pneumatic pump to the plurality of outlet ports; a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, wherein the pump assembly is configured to output airflow at a free flow rate of between 3 and 6 liters per minute, and wherein the pump assembly is operable at a maximum loudness of between 1.1 sone and 1.2 sone.

14. The pump assembly of claim 13, wherein, the pneumatic pump comprises a diaphragm assembly having five diaphragm chambers.

15. A pump assembly comprising: a housing, the housing comprising a plurality of outlet ports; a motor, the motor extending along a longitudinal axis; a pneumatic pump, the pneumatic pump driven by the motor; a valve assembly downstream of the pneumatic pump and in fluid communication with the plurality of outlet ports, the valve assembly configured to selectively direct airflow generated by the pneumatic pump to the plurality of outlet ports; and a printed circuit board supported by the housing and electrically connected to the motor and the valve assembly, wherein the valve assembly includes a first control valve, a second control valve arranged in series with the first control valve, a third control valve arranged in parallel with the first control valve and the second control valve, and a fourth control valve arranged in series with the third control valve.

16. The pump assembly of claim 15, wherein, The first, second, third, and fourth control valves are 3 / 2 way solenoid actuated valves.

17. The pump assembly of claim 15, wherein, The plurality of outlet ports includes a first outlet port, a second outlet port, and a third outlet port.

18. The pump assembly of claim 17, wherein, When the first, second, third, and fourth control valves are de-energized, airflow generated by the pneumatic pump is routed by the valve assembly to the third outlet port.

19. The pump assembly of claim 15, wherein, The first and third control valves are configured to selectively connect the plurality of outlet ports to an exhaust port.

20. The pump assembly of claim 19, wherein, The exhaust port is in fluid communication with an air intake of the pneumatic pump.

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