Blower and method for manufacturing motor assembly for blower

Abstract

A blower and a method of manufacturing a motor assembly for a blower are provided. A blower includes: a main body; an air duct extending between the air inlet and the air outlet, the air duct including an air duct body; the motor is arranged in the air pipeline body; and a fan disposed in the air duct body. The fan and the motor are arranged in the fan assembly shell. The blower further includes at least one noise vibration intensity (NVH) material within the air duct, the NVH material configured to isolate mechanical vibrations of the housing from the air duct.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 648,684, filed May 17, 2025, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure relates generally to blowers, and more particularly to a blower and a method of manufacturing an electric motor assembly for the blower. Background Technology

[0004] Blowers are typically used to generate and output airflow that is directed by the user. Blowers are frequently used in outdoor applications, such as for blowing away leaves and other debris. Homeowners often use these blowers to clean their yards and outdoor spaces. Blower types can vary between backpack and handheld blowers, and between gas-powered and electric blowers. Electric blowers can be corded and plugged into a power outlet, or they can be wireless and battery-powered.

[0005] One problem with many power tools, including those with blowers, is the vibration and noise generated during operation. This vibration and noise can originate from the power tool's engine, fan blades, and other moving and stationary parts. The vibration generated during operation can be transmitted to the user via the blower or the tool's user interface. While quieter power tools can be produced simply by reducing their power and performance levels, the resulting product lacks the performance the customer expects.

[0006] Therefore, an improved blower that incorporates vibration and noise reduction features without compromising performance is desired. In particular, a blower that combines both reduced noise generation and improved performance characteristics would be advantageous. Summary of the Invention

[0007] Various aspects and advantages of this disclosure will be set forth in part in the description which follows, or may be apparent from the description or may be learned by practice of the art.

[0008] According to one embodiment, a blower is provided. The blower includes: a main body; an air duct extending between an air inlet and an air outlet opposite to the air inlet, the air duct including an air duct body; a motor disposed in the air duct body between the air inlet and the air outlet; and a fan disposed in the air duct body between the air inlet and the air outlet. The fan is configured to rotate about a fan axis and includes a fan hub and a plurality of fan blades extending radially outward from the fan hub to include fan blade tips. The fan and the motor are disposed within a fan assembly housing. The blower further includes at least one noise and vibration intensity (NVH) material within the air duct. The NVH material is configured to isolate mechanical vibrations of the housing from the air duct.

[0009] According to another embodiment, a method for manufacturing a motor assembly for a blower is provided. The method includes the steps of: forming a cylindrical motor housing; forming a plurality of stator blades; and forming a cylindrical shroud. The method further includes the steps of: joining the plurality of stator blades to an outer surface of the motor housing; and joining the plurality of stator blades to an inner surface of the shroud. At least one of the plurality of stator blades is joined to the motor housing and / or the shroud by vibration welding.

[0010] These and other features, aspects, and advantages of this disclosure will be better understood by referring to the following description and the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the technology and, together with this description, serve to explain the principles of the technology. Attached Figure Description

[0011] This description sets forth the complete and implementable disclosure of this application to those skilled in the art, including the best mode of making and using the systems and methods of the invention, with reference to the accompanying drawings, in which:

[0012] Figure 1 This is a perspective view of a blower according to an embodiment of the present disclosure;

[0013] Figure 2 This is a partial cross-sectional view of a blower assembly according to an embodiment of the present disclosure;

[0014] Figure 3 This is a partial cross-sectional view of a blower assembly and air duct according to an embodiment of the present disclosure;

[0015] Figure 4 This is a partial cross-sectional view of a motor assembly according to an embodiment of the present disclosure; and

[0016] Figure 5 This is a partial front view of a blower according to an embodiment of the present disclosure. Detailed Implementation

[0017] Reference will now be made in detail to embodiments of the present disclosure, with one or more examples of said embodiments illustrated in the accompanying drawings. The term “exemplary” is used herein to mean “serving as an example, instance, or demonstration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, each example is provided by way of explanation rather than limitation of the art. Indeed, those skilled in the art will appreciate that modifications and variations can be made to the art without departing from the scope or spirit of the claimed art. For example, a feature shown or described as part of one embodiment may be used with another embodiment to produce yet another embodiment. Therefore, this disclosure is intended to cover such modifications and variations as fall within the scope of the appended claims and their equivalents. Detailed description uses numerical and alphabetic names to refer to features in the drawings. Similar or analogous names in the drawings and description have been used to refer to similar or analogous parts of this disclosure.

[0018] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of individual components. The singular forms “a,” “an,” and “described” include plural references unless the context clearly indicates otherwise. The terms “connected,” “fixed,” “attached to,” etc., refer both to a direct connection, fixation, or attachment and to an indirect connection, fixation, or attachment via one or more intermediate components or features, unless otherwise specified herein. As used herein, the terms “comprising,” “including,” “having,” or any other variation thereof are intended to cover non-exclusive inclusion. For example, a process, method, object, or apparatus that includes a list of features is not necessarily limited to those features but may include other features not expressly listed or inherent to such a process, method, object, or apparatus. Furthermore, unless the contrary is expressly stated, “or” means inclusive or, not exclusive or. For example, condition A or B is satisfied by any of the following: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0019] For example, approximate terms such as "approximately," "generally," "roughly," or "substantially" include values ​​that are no more than 10 percent larger or smaller than the stated value. When used in the context of angles or directions, such terms include values ​​that are no more than 10 degrees larger or smaller than the stated angle or direction. For example, "generally vertical" includes directions that differ from a vertical line by no more than 10 degrees in any direction (e.g., clockwise or counterclockwise).

[0020] "Noise and Vibration Intensity ("NVH") Material" should mean any material designed to reduce noise and / or vibration, for example, by absorbing noise and vibration, including but not limited to rubber, cork, foam, foam / film laminates such as polyurethane foam, polyurethane elastomers, polyolefin elastomers and resins, acrylic liquid-coated sound-absorbing materials, polyester and / or polypropylene fibers. NVH materials may be in the form of foam, resin, liquid-coated coating materials, flexible acoustic materials, flexible damping materials, or any other suitable form.

[0021] Benefits, other advantages, and solutions to problems are described below with respect to specific embodiments. However, benefits, advantages, solutions to problems, and any features(s) that may make any benefit, advantage, or solution occur or become more apparent should not be construed as key, essential, or fundamental features of any or all claims.

[0022] Generally, the present invention relates to a blower having an isolated motor and fan assembly. The blower includes a fan assembly and a motor disposed within an air duct of the blower, and the motor and fan assembly are isolated from the air duct body by at least one damping material, such as an NVH material. The inlet end of the blower air duct upstream of the motor and fan assembly may further include at least one damping material, such as an NVH material, surrounding the air duct body. In this way, during operation of the blower, mechanical vibrations generated by the operation of the motor and fan can be isolated from the air duct body and the blower housing, thereby reducing noise generated by mechanical vibrations compared to conventional blowers.

[0023] Now refer to the attached diagram, Figure 1 A blower tool 10 with a main body 12 and a blower unit 14 is shown. Although Figure 1 The blower 10 shown is a backpack blower configured to be carried on the back of a user, for example, using a backpack support 16, but the features of the invention can be implemented for handheld blowers (not shown), such as handheld axial fan blowers or centrifugal fan blowers.

[0024] The blower unit 14 includes an air duct 20 extending from an air inlet 22 to an air outlet 24. The air duct 20 may be formed by an air duct body 26 and a blower pipe 28. For example, the air duct body 26 may define the air inlet 22 at one end. The air duct body 26 may be directly or indirectly connected to the blower pipe 28 at the opposite end relative to the air inlet 22. For example, an elbow 30 may be provided between the air duct body 26 and the blower pipe 28, such as... Figure 1As shown. Alternatively, for example, in a handheld blower (not shown), the air duct body 26 may be directly connected to the blower pipe 28. In some arrangements, a bellows 32 may be provided between the air duct body 26 and the blower pipe 28, for example, to allow the blower pipe 28 to pivotally move and / or rotate relative to the air duct body 26.

[0025] Figure 2 A partial cross-sectional view of the air duct body 26 is shown with a portion of it removed. An air inlet 22 is formed at the upstream end of the air duct body 26. In some aspects, the upstream end of the air duct body may include a bell-shaped section 34. The bell-shaped section 34 may include a maximum bell diameter D1 and smoothly and continuously transitions to match the smaller diameter D2 of the cylindrical section 36 (described below). In some embodiments, the bell-shaped section 34 may assist in forming beneficial airflow properties through the air duct 20.

[0026] The bell-shaped section 34 may include a grooved portion 40 disposed at the air inlet 22 and formed from the air duct body 26. Downstream of the grooved portion 40, the air duct body 26 may include a flange or lip 42 at which the air duct body 26 forms an inner diameter larger than the inner diameter D3 of the grooved portion adjacent to the flange 42. The flange 42 may be formed such that damping material 76 (described in further detail below) can be disposed around the inner circumference of the air duct body 26 in the bell-shaped section 34. In this way, the inner surface of the grooved portion 40 and the inner surface of the damping material 76 within the bell-shaped section 34 can have a generally smooth transition zone therebetween. In other words, as Figure 2 As shown, the inner diameter D3 of the grooved portion 40 adjacent to the flange 42 and the inner diameter of the damping material 76 adjacent to the flange 42 are substantially the same. The inventors have discovered that the substantially smooth and continuous transition zone from the bell-shaped section 34 to the cylindrical section 36 (including the damping material 76 within the air duct body 26) can help create beneficial airflow properties through the air duct 20.

[0027] Downstream of the bell-shaped section 34 of the air duct 20 and the air duct body 26 is a generally cylindrical section 36. Downstream of the generally cylindrical section 36, the air duct body 26 may include a connecting section 38 configured for connection to the blower pipe 28, elbow 30, bellows 32, or other connecting sections of the blower unit 14.

[0028] A fan assembly 50 is disposed within an air duct body 26 and includes a fan 52 and a motor 54 configured to drive the fan 52. The fan assembly 50 may further include a motor housing 56 configured to receive and support the motor 54. The motor housing 56 and the motor 54 may be coaxially aligned with the fan 52. The motor housing 56 may be disposed within a shroud 60 and may be coupled to the shroud 60 via, for example, a plurality of stator blades 58. The shroud 60, also referred to as the fan assembly housing, may circumferentially surround the motor housing 56. In some aspects, the shroud 60 may have a generally cylindrical shape. The shroud 60 may at least partially surround the fan 52. For example, at least a portion of the fan hub 62 of the fan 52 and the fan blades 64 may be disposed within the shroud 60.

[0029] In some aspects of the invention, the motor housing 54, stator blades 58, and shroud 60 can be permanently joined together. For example, the motor housing 54, stator blades 58, and shroud 60 can be formed of the same material, such as a thermoplastic material. In particular, the motor housing 54, stator blades 58, and shroud 60 can be joined together by vibration welding along a vibration weld joint 65. Vibration welding (also known as linear or friction welding) is a process in which two workpieces are brought into contact under pressure and subjected to reciprocating motion (vibration) along a common interface to generate heat. The resulting heat melts the workpieces, and the workpieces are welded when the vibration stops and the interface cools. The inventors have found that, at least because the stator blades 58 can be formed independently, joining the motor housing 54, stator blades 58, and shroud 60 by vibration welding provides specific advantages in the design of the fan assembly 50 of the blower 10. In this invention, the stator blades 58 can be formed independently, thereby achieving a variablely reduced diameter within the stator geometry, which is not possible when the stator blades are injection molded together with the motor housing and shroud. In contrast, in some conventional blowers, the motor housing, stator blades, and shroud can be integrally formed as a single part via injection molding, which leads to limitations in the design and tolerances of the stator blade angles.

[0030] like Figures 2 to 3 As shown, the outer surface 66 of the shield 60 may be provided with one or more ribs 68 extending therefrom. The ribs 68 may be configured to form one or more channels 70 therebetween. As will be discussed in more detail below, the channels 70 may be configured to receive damping material 76 therein, such that the damping material 76 extends around the outer surface 66 of the shield 60.

[0031] In some aspects of the invention, a shield 60 is disposed within and spaced apart from the air duct body 26 such that the shield 60 does not directly contact the air duct body 26. For example, a damping material 76 may be disposed between the shield 60 and the air duct body 26. The air duct body 26 may have one or more receiving sections 74 configured to hold the shield 60 in place relative to the air duct 20 and the air duct body 26. The receiving sections 74 may be aligned with a channel 70 on the outer surface 66 of the shield 60. In this way, when the damping material 76 is disposed in the channel 70, the ring 72 of the damping material 76 can indirectly connect the shield 60 to the air duct body 26. In some aspects of the invention, the ring 72 of the damping material 76 may have a thickness in the range of about 1 mm to about 8 mm, such as about 2 mm to about 5 mm, within the channel 70 surrounding the shield 60. The ring 72 of the damping material 76 may have a length L2 ranging from approximately 4 mm to approximately 50 mm along the axial direction of the air duct. With this arrangement, the mechanical vibrations of the motor 54 and fan 52 during the operation of the blower 10 can be isolated, and the audible noise generated by such vibrations can be reduced, thereby reducing the noise generated by the operation of the blower 10.

[0032] Returning to the bell-shaped section 34, in some aspects of the invention, damping material 76 may be disposed around the air duct 20 on the inner surface of the bell-shaped section 34. For example, damping material 76 may be disposed along the length L1 of the air duct body 26 from the flange 42 to the cylindrical section 36. In some aspects of the invention, damping material 76 may have a thickness within the bell-shaped section 34 in the range of approximately 4 mm to approximately 30 mm. In some aspects, damping material 76 within the bell-shaped section 34 may at least partially surround the shroud 60 of the fan assembly 50. For example, damping material 76 within the bell-shaped section 34 may overlap with an upstream portion of the shroud 60. Length L1 may extend to or terminate upstream of the upstream channel 70 surrounding the shroud 60. In some aspects, damping material 76 may be disposed on the inner surface of the bell-shaped section 34 in the form of one or more damping material pads 76, such as two, three, four, or more damping material pads 76. For example, damping material 76 may be disposed on multiple sides or around at least a portion of the air duct 20 circumferentially around the bell-shaped section 34. By providing damping material 76 within the bell-shaped section 34 of the air duct body 22, the inventors have discovered that superior noise reduction can be achieved compared to conventional blower tools.

[0033] The damping material 76 can be a material referred to as "noise and vibration intensity" ("NVH") material. As previously defined in this disclosure, NVH material can be a material designed to reduce noise and / or vibration, for example, by absorbing noise and vibration, including but not limited to rubber, cork, foam, foam / film laminates, such as polyurethane foam, polyurethane elastomers, polyolefin elastomers and resins, acrylic liquid-coated anechoic materials, polyester and / or polypropylene fibers. NVH material can be in the form of foam, resin, liquid-coated coating material, flexible acoustic material, flexible damping material, or any other suitable form. The NVH materials used in the blower 10 can include, but are not limited to, rubber, foam, and / or plastics with noise, vibration, and intensity reduction properties. For example, NVH material can be applied directly to the air duct body 26, for example, by spraying or foaming, or NVH material can be formed separately and then positioned together with the air duct body 26 and / or the shroud 60.

[0034] As described above, the air duct body 26 can be rigidly connected to the main body 12 of the blower 10. For example, a plurality of fastener receivers 80 can extend from the outer surface of the air duct body 26, for example, along the bell-shaped section 34, and a plurality of fasteners (not shown) can be fastened to the main body 12. As previously described, the air duct body 26 can be vibrationally isolated from the fan assembly 50 at least by a damping material 76 in the channel 70 between the shroud 60 and the air duct body 26. Furthermore, the bell-shaped section 34 can be provided with the damping material 76 as described above. In this way, even when the air duct body 26 is rigidly connected to the main body 12 as described, the mechanical vibration of the fan assembly 50 during operation of the blower can be isolated from the main body 12.

[0035] Further aspects of this disclosure are provided through one or more of the following embodiments:

[0036] A blower includes: a main body; an air duct extending between an air inlet and an air outlet opposite to the air inlet, the air duct including an air duct body; a motor disposed within the air duct body between the air inlet and the air outlet; and a fan disposed within the air duct body between the air inlet and the air outlet. The fan is configured to rotate about a fan axis and includes a fan hub and a plurality of fan blades extending radially outward from the fan hub to include fan blade tips. The fan and the motor are disposed within a fan assembly housing. The blower further includes at least one noise and vibration intensity (NVH) material within the air duct, the NVH material being configured to isolate mechanical vibrations of the housing from the air duct.

[0037] The blower as described in any one or more of the embodiments, wherein the air duct body is rigidly connected to the main body.

[0038] The blower as described in any one or more of the embodiments, wherein the rigid connection between the air duct body and the main body is upstream of the fan assembly housing.

[0039] The blower as described in any one or more of the embodiments, wherein the main body includes a backpack support configured to be carried on the back of a user.

[0040] The blower as described in any one or more of the embodiments, wherein the blower outlet pipe is connected to the downstream end of the air duct body, and the air outlet is located at the downstream end of the blower outlet pipe.

[0041] As described in any one or more of the embodiments, the downstream end of the air duct body is configured to be nested inside the upstream end of the blower outlet pipe.

[0042] The blower as described in any one or more of the embodiments, wherein the at least one NVH material is disposed within the air duct body.

[0043] The blower as described in any one or more of the embodiments, wherein at least a portion of the fan assembly housing is surrounded by the at least one NVH material.

[0044] As described in any one or more of the embodiments, the blower wherein at least a portion of the fan assembly housing is circumferentially surrounded by the at least one NVH material.

[0045] The blower as described in any one or more of the embodiments, wherein the at least one NVH material surrounds the inner surface of the air inlet.

[0046] The blower as described in any one or more of the embodiments, wherein the at least one NVH material extends along the air duct from the air inlet to the fan assembly housing.

[0047] The blower as described in any one or more of the embodiments, wherein the at least one NVH material comprises one or more vibration isolation rings surrounding the circumference of the fan assembly housing.

[0048] The blower as described in any one or more of the embodiments, wherein each of the one or more vibration isolation rings is spaced apart from both the upstream and downstream ends of the fan assembly housing.

[0049] The blower as described in any one or more of the embodiments, wherein the fan assembly housing is isolated from the air duct body by at least one NVH material.

[0050] The blower as described in any one or more of the embodiments, wherein the at least one NVH material comprises at least two NVH material sections separated by a gap.

[0051] The blower as described in any one or more of the embodiments, wherein the fan assembly housing includes a motor housing surrounded by a shroud, and the fan assembly housing further includes a plurality of stator blades extending between the motor housing and the shroud, wherein the stator blades are joined to the motor housing and the shroud by vibration welding.

[0052] A method for manufacturing a motor assembly for a blower, the method comprising the steps of: forming a cylindrical motor housing; forming a plurality of stator blades; and forming a cylindrical shroud. The method further comprises the steps of: joining the plurality of stator blades to an outer surface of the motor housing; and joining the plurality of stator blades to an inner surface of the shroud. At least one of the plurality of stator blades is joined to the motor housing and / or the shroud by vibration welding.

[0053] As described in any one or more of the embodiments, each of the plurality of stator blades is joined to the motor housing by vibration welding.

[0054] As described in any one or more of the embodiments, each of the plurality of stator blades is joined to the shroud by vibration welding.

[0055] This written description uses examples to disclose this application, including best practices, and also enables those skilled in the art to practice this disclosure, including making and using any device or system and performing any combined methods. The patentable scope of this disclosure is defined by the claims, but may include other examples that would occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A blower, characterized in that, include: Main body; An air duct extending between an air inlet and an air outlet opposite to the air inlet, the air duct including an air duct body; An electric motor is disposed in the air duct body between the air inlet and the air outlet; as well as A fan disposed within the air duct body between the air inlet and the air outlet, the fan being configured to rotate about a fan axis, the fan including a fan hub and a plurality of fan blades extending radially outward from the fan hub to include fan blade tips. The fan and the motor are housed within the fan assembly housing; The blower further includes at least one noise and vibration intensity (NVH) material within the air duct, the NVH material being configured to isolate the mechanical vibrations of the housing from the air duct.

2. The blower as described in claim 1, characterized in that, The air duct body is rigidly connected to the main body.

3. The blower as described in claim 2, characterized in that, The rigid connection between the air duct body and the main body is located upstream of the fan assembly housing.

4. The blower as described in claim 1, characterized in that, The main body includes a backpack support configured to be carried on the user's back.

5. The blower as described in claim 1, characterized in that, The blower outlet pipe is connected to the downstream end of the air duct body, and the air outlet is located at the downstream end of the blower outlet pipe.

6. The blower as described in claim 5, characterized in that, The downstream end of the air duct body is configured to be nested inside the upstream end of the blower outlet pipe.

7. The blower as described in claim 1, characterized in that, The at least one NVH material is disposed within the air duct body.

8. The blower as described in claim 1, characterized in that, At least a portion of the fan assembly housing is surrounded by the at least one NVH material.

9. The blower as described in claim 8, characterized in that, The at least portion of the fan assembly housing is surrounded on multiple sides by the at least one NVH material.

10. The blower as described in claim 8, characterized in that, The at least portion of the fan assembly housing is surrounded circumferentially by the at least one NVH material.

11. The blower as described in claim 1, characterized in that, The at least one NVH material surrounds the inner surface of the air inlet.

12. The blower as described in claim 10, characterized in that, The at least one NVH material extends along the air duct from the air inlet to the fan assembly housing.

13. The blower as described in claim 1, characterized in that, The at least one NVH material includes one or more vibration isolation rings surrounding the circumference of the fan assembly housing.

14. The blower as described in claim 12, characterized in that, Each of the one or more vibration isolation rings is spaced apart from both the upstream and downstream ends of the fan assembly housing.

15. The blower as described in claim 1, characterized in that, The fan assembly housing is isolated from the air duct body by the at least one NVH material.

16. The blower as described in claim 1, characterized in that, The at least one NVH material comprises at least two NVH material segments separated by a gap.

17. The blower as described in claim 1, characterized in that, The fan assembly housing includes a motor housing surrounded by a shroud, and the fan assembly housing further includes a plurality of stator blades extending between the motor housing and the shroud, wherein the stator blades are joined to the motor housing and the shroud by vibration welding.

18. A method for manufacturing a motor assembly for a blower, characterized in that, The method includes the following steps: Forming a cylindrical motor housing; Multiple stator blades are formed; Forming a cylindrical protective shield; The plurality of stator blades are joined to the outer surface of the motor housing; as well as The plurality of stator blades are joined to the inner surface of the protective cover; At least one of the plurality of stator blades is joined to the motor housing and / or the protective cover by vibration welding.

19. The method as described in claim 17, characterized in that, Each of the plurality of stator blades is joined to the motor housing by vibration welding.

20. The method as described in claim 17, characterized in that, Each of the plurality of stator blades is joined to the shroud by vibration welding.

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