Air pulse airflow device

Abstract

This invention discloses an air pulse airflow device, specifically relating to the technical field of airflow generation devices. It includes a base mechanism and a plastic top shell. The base mechanism comprises an aluminum base, which, together with the plastic top shell, forms a cylindrical structure. An airflow chamber is formed inside this cylindrical structure. The aluminum base houses a motor housing, within which a brushless motor is installed. The output shaft of the brushless motor is connected to an eccentric drive assembly. T-shaped crank arms are connected to both sides of the eccentric drive assembly, and a piston disc is connected to the other end of each T-shaped crank arm. This air pulse airflow device utilizes a 4-pole brushless motor, resulting in high output torque and low speed fluctuation. Combined with vibration damping pads, it significantly improves drive stability. Compared to existing brushed motors or low-pole brushless motors, it avoids brush wear and speed instability, ensuring sufficient pulse airflow intensity and stable frequency, meeting the requirements of high-precision pulse applications.

Description

Technical Field

[0001] This invention relates to the field of airflow generating devices, and particularly to an air pulse airflow device. Background Technology

[0002] Air pulse airflow devices are widely used in medical care, rehabilitation therapy, laboratory fluid control, and precision cleaning equipment. Their core function is to generate periodically changing pulsed airflow through mechanical transmission to achieve precise control of airflow intensity and frequency. In existing technologies, common air pulse airflow devices mainly consist of a drive motor, an eccentric transmission mechanism, an airflow chamber, and a housing. A typical structure uses a brushed motor or a low-pole brushless motor as the power source to drive a standard eccentric wheel to rotate. This rotational motion is converted into reciprocating linear motion via a universal connecting rod or transmission arm, which in turn drives the piston within the airflow chamber to generate pulsed airflow. However, existing air pulse airflow devices still have the following technical problems in practical applications: First, the drive system has poor stability. Existing devices mostly use brushed motors or two-pole brushless motors. Brushed motors suffer from problems such as rapid brush wear, commutation sparks, and short lifespan, while low-pole brushless motors have insufficient output torque and large speed fluctuations, making it difficult to provide continuous and stable power output. This results in insufficient pulse airflow intensity and significant frequency fluctuations, which cannot meet the needs of high-precision pulse airflow application scenarios.

[0003] Secondly, the transmission structure is inefficient and noisy. The eccentric wheel and transmission arm in the existing device are mostly standard general-purpose parts, which are not customized for the output characteristics of pulsed airflow. The eccentricity is unreasonable and the transmission fit clearance is large, which leads to high power loss and low transmission efficiency when the rotary motion is converted into reciprocating linear motion, and generates obvious mechanical vibration. The operating noise generally exceeds 70dB, which seriously affects the user experience. At the same time, the vibration will also accelerate the wear of core components.

[0004] Third, the design of the support and heat dissipation structure is inadequate. The base of the existing device is mostly made of ordinary plastic material, which has low strength and poor vibration resistance. It cannot provide stable installation support for the drive and transmission components, and the equipment is prone to shaking during operation, which leads to increased concentricity deviation of the components and increased friction. In addition, the base lacks a dedicated heat dissipation structure, and the heat generated by the motor is difficult to dissipate quickly. Long-term use can easily lead to overheating of the motor, reducing operational stability and service life.

[0005] Fourth, the protection and maintenance performance is poor. Existing shells mostly use general-purpose plastic shells, which have poor sealing performance, are prone to dust and water ingress, and cannot effectively protect the internal core components. They also do not reduce noise. At the same time, most of the components are general-purpose standard parts with fixed connection methods, making assembly and disassembly difficult and subsequent maintenance costs high. Summary of the Invention

[0006] The main objective of this invention is to provide an air pulse airflow device that can effectively solve the problems of poor driving stability, insufficient pulse airflow intensity and uneven output, high operating noise, poor heat dissipation, weak protection performance, inconvenient assembly and disassembly, and easy wear and short service life of core components in existing air pulse airflow devices.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An air pulse flow device includes a base mechanism and a plastic top shell. The base mechanism includes an aluminum base, which, together with the plastic top shell, forms a cylindrical structure, the interior of which forms an airflow chamber. The aluminum base houses a motor housing, within which a brushless motor is installed. The output shaft of the brushless motor is connected to an eccentric drive assembly. T-shaped crank arms are driven to both sides of the eccentric drive assembly, and a piston disc is connected to the other end of each T-shaped crank arm. A sealing assembly is installed on the outer ring of the piston disc. The T-shaped crank arms seal both sides of the cylindrical structure using the sealing assembly. Through this integrated base and top shell structure, and by using a brushless motor to drive the eccentric assembly and achieve reciprocating motion of the T-shaped crank arms, the transmission chain is effectively simplified, and the stability and sealing of the pulse airflow generation are improved.

[0008] Preferably, the aluminum base is a one-piece molded aluminum alloy base with anti-slip pads and heat dissipation ribs on the bottom, and the motor box is integrally molded with the aluminum base. This one-piece aluminum alloy base not only provides stable installation support for each component and reduces shaking during equipment operation, but also significantly enhances heat dissipation capacity through the heat dissipation ribs, preventing the motor from overheating.

[0009] Preferably, the brushless motor is a four-pole brushless motor, which is mounted in the motor housing with fixing bolts, and a shock-absorbing pad is provided between the bottom of the brushless motor and the motor housing. The four-pole brushless motor has a large output torque and small speed fluctuation. With the shock-absorbing pad, the operating vibration and noise can be significantly reduced, ensuring precise control of the pulse airflow intensity and frequency.

[0010] Preferably, the eccentric drive assembly includes a turntable, with an eccentric pin fixedly mounted at the eccentric top of the turntable. An eccentric wheel is connected to the top of the eccentric pin, and a second eccentric pin is fixedly connected to the top of the eccentric wheel. The turntable has a shaft hole matching the output shaft of the brushless motor, and a keyway is provided within the shaft hole, which is then fixedly connected to the output shaft of the brushless motor via a flat key. This multi-stage eccentric structure allows for customized eccentricity according to pulsed airflow requirements, resulting in smooth power transmission and reduced transmission backlash and friction loss.

[0011] Preferably, two T-shaped crank arm discs are used, each with a through-hole pin hole. Each T-shaped crank arm disc is mounted on the outer wall of the corresponding eccentric shaft pin through the pin hole. The T-shaped crank arm discs are made of high-strength aluminum alloy and are T-shaped overall, with a limiting protrusion in the middle. A limiting groove is formed on the aluminum base, and the limiting protrusion slides into the limiting groove. This sliding engagement between the T-shaped crank arm disc and the limiting groove precisely converts the rotational motion of the eccentric wheel into the reciprocating linear motion of the piston disc, resulting in high transmission efficiency, smooth operation, and effective suppression of mechanical vibration.

[0012] Preferably, the sealing assembly includes a sealing sleeve, the inner ring of which is fitted onto the outer ring of the piston disc at one end of the T-shaped crankshaft disc, and the outer ring of which is fitted onto the outer ring of the cylindrical structure composed of an aluminum base and a plastic top shell. Both the inner and outer rings of the sealing sleeve are fitted with clamps. The double-layer clamp-fixed sealing sleeve ensures good airtightness of the airflow chamber, prevents air leakage, and prevents external dust and moisture from entering.

[0013] Preferably, the plastic top shell is made of ABS engineering plastic and has a semi-enclosed structure. It is sealed to the aluminum base with fixing bolts, and a sealing gasket is provided at the connection. The interior of the plastic top shell is equipped with noise-reducing cotton and heat dissipation channels. The noise-reducing cotton can effectively absorb the noise generated by the motor and transmission components, significantly reducing the operating noise of the device; the heat dissipation channels, together with the heat dissipation fins of the aluminum base, form convection, further improving the overall heat dissipation effect.

[0014] Preferably, the top of the plastic top shell has an air inlet and an air outlet that extend through its internal cavity. This design facilitates the intake and exhaust of pulsed airflow, has a simple structure, and is easy to connect to external devices.

[0015] Preferably, a terminal block is installed at the wiring hole of the plastic top shell, and the terminal block is connected to the wiring terminal of the brushless motor. The terminal block facilitates the access of power and control signals, improving the reliability of the electrical connection and the ease of maintenance.

[0016] Preferably, the eccentric drive assembly is made of high-strength alloy structural steel, the T-shaped crank arm is made of aluminum alloy, and the cylindrical structure formed by the aluminum base and the plastic top shell is cylindrical. The high-strength alloy structural steel ensures the wear resistance and fatigue resistance of the eccentric drive assembly during long-term reciprocating motion, while the aluminum alloy T-shaped crank arm balances lightweight and strength. The cylindrical structure ensures uniform internal airflow chamber volume, which is beneficial for generating stable pulse waveforms.

[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention provides an air pulse flow device that employs a 4-pole brushless motor, which has high output torque and low speed fluctuation. Combined with vibration damping pads, it significantly improves drive stability. Compared to existing brushed motors or low-pole brushless motors, it avoids brush wear and speed instability problems, ensuring sufficient pulse airflow intensity and stable frequency to meet the requirements of high-precision pulse applications.

[0018] 2. This invention provides an air pulse flow device that, through a customized eccentric drive component precisely matched with a T-shaped crank arm disk and a limiting groove sliding constraint, effectively reduces transmission clearance and friction loss. Compared with general standard transmission structures, it significantly reduces mechanical vibration and operating noise, thereby lowering the device's operating noise and improving the user experience.

[0019] 3. This invention provides an air pulse airflow device, which adopts an integrated molded aluminum base with heat dissipation ribs and anti-slip pads on the bottom to provide stable support for the motor and transmission components and prevent shaking during operation. At the same time, the heat dissipation ribs, together with the heat dissipation channels inside the plastic top shell, form convection to quickly dissipate heat from the motor, prevent overheating, and extend the service life of the device.

[0020] 4. This invention provides an air pulse airflow device, in which a double-layered clamp-fixed sealing sleeve is installed between the piston disc and the cylindrical structure to ensure the airtightness of the airflow chamber and prevent air leakage. At the same time, a sealing gasket is provided at the connection between the plastic top shell and the aluminum base to effectively prevent dust and moisture from entering, achieving IP54 level or higher protection and protecting the internal core components.

[0021] 5. This invention provides an air pulse airflow device. Noise-reducing cotton is installed inside the plastic top shell to effectively absorb operating noise from the motor and transmission components, improving user comfort. Simultaneously, wiring terminals are installed on the top shell for convenient power and control signal connection. All components are fixed with bolts, making disassembly and assembly convenient, reducing subsequent maintenance costs and improving the maintainability of the device. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the base mechanism of the present invention; Figure 3 This is a schematic diagram of the eccentric drive component structure of the present invention; Figure 4 This is a schematic diagram of the sealing assembly structure of the present invention; Figure 5 This is a schematic diagram of the cross-sectional structure of the plastic top shell of the present invention.

[0023] In the diagram: 1. Base mechanism; 11. Aluminum base; 12. Motor box; 121. Brushless motor; 13. Eccentric drive assembly; 131. Turntable; 132. Eccentric shaft pin one; 133. Eccentric wheel; 134. Eccentric shaft pin two; 14. T-shaped crank arm disc; 141. Pin hole; 15. Sealing assembly; 151. Sealing sleeve; 152. Clamp; 2. Plastic top shell; 21. Air inlet; 22. Air outlet. Detailed Implementation

[0024] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0025] like Figures 1 to 5 As shown, an air pulse flow device includes a base mechanism 1, with a plastic top shell 2 on the top of the base mechanism 1. The base mechanism 1 includes an aluminum base 11, and a motor box 12 is integrally formed on the aluminum base 11. A brushless motor 121 is installed in the inner cavity of the motor box 12. The aluminum base 11 and the plastic top shell 2 form a cylindrical structure, and an airflow chamber is formed inside the cylindrical structure. The output shaft of the brushless motor 121 passes through the inner cavity of the aluminum base 11 and is connected to an eccentric drive assembly 13. T-shaped crank arm disks 14 are respectively driven to both sides of the eccentric drive assembly 13. A piston disk is connected to the other end of the T-shaped crank arm disk 14. A sealing assembly 15 is provided on the outer ring of the piston disk. The T-shaped crank arm disk 14 seals both sides of the cylindrical structure with the help of the sealing assembly 15.

[0026] Specifically, the piston disc is a cylindrical aluminum alloy disc with a single-sided gap of 0.1mm to 0.3mm between its outer diameter and the inner diameter of the cylindrical structure to ensure the effective compression of the sealing assembly 15. The piston disc and the T-shaped crank arm disc 14 are fixedly connected by a threaded pin, and the surface of the pin is nitrided to improve wear resistance.

[0027] The brushless motor 121, as the core drive of the entire device, adopts a 4-pole design and features high torque, low speed fluctuation, no brush wear, and high energy efficiency. The aluminum base 11 is custom-made from aluminum alloy and has anti-slip pads and heat dissipation fins on its bottom to fix and support all core components, and to achieve heat dissipation and stable support. The eccentric drive assembly 13 includes a turntable 131, with an eccentric shaft pin 132 fixedly installed at the eccentric position of the top of the turntable 131. An eccentric wheel 133 is connected to the top of the eccentric shaft pin 132. An eccentric shaft pin 134 is fixedly connected to the top eccentric part of the 33. Both T-shaped crank arm disks 14 are provided with pin holes 141 that pass through the top and bottom. Each T-shaped crank arm disk 14 is installed on the outer wall of the corresponding eccentric shaft pin 134 through the pin hole 141. The eccentric drive assembly 13 is made of high-strength alloy structural steel. Its eccentricity is designed according to the pulse airflow intensity requirements. The turntable 131 is provided with a shaft hole that matches the output shaft of the brushless motor 121. A keyway is provided in the shaft hole, and it is fixedly connected to the output shaft of the brushless motor 121 through a flat key.

[0028] Specifically, the eccentricity of eccentric pin 132 is 5mm to 10mm, and the eccentricity of eccentric pin 134 is 6mm to 12mm. The phase angle difference between the two is 180° to ensure the symmetry of the movement of the piston discs on both sides, thereby outputting a stable symmetrical pulse airflow. The flat key is a national standard type A flat key, made of 45# steel, to withstand periodic torque impact.

[0029] The sealing assembly 15 includes a sealing sleeve 151. The inner ring of the sealing sleeve 151 is fitted onto the outer ring of the piston disc at one end of the T-shaped crankshaft disc 14. The outer ring of the sealing sleeve 151 is fitted onto the outer ring of the cylindrical structure formed by the aluminum base 11 and the plastic top shell 2. Both the inner and outer rings of the sealing sleeve 151 are fitted with clamps 152 for fixing and sealing. The T-shaped crankshaft disc 14 is made of high-strength aluminum alloy and is T-shaped. A limiting protrusion is provided in the middle part, which slides and engages with the limiting groove on the aluminum base 11 to convert the rotational motion of the eccentric wheel 133 into reciprocating linear motion. The plastic top shell 2 is made of ABS engineering plastic and is semi-enclosed. The structure is sealed to the aluminum base 11 by fixing bolts, and a sealing gasket is provided at the connection. The sealing gasket is a silicone foam sealing ring, and the thickness after compression is 70% to 80% of the original thickness to achieve IP54 protection. The top of the plastic top shell 2 has an air inlet 21 and an air outlet 22 that penetrate its internal cavity. The interior is designed with noise reduction cotton and heat dissipation channels. The brushless motor 121 is installed in the motor box 12 of the aluminum base 11 by four fixing bolts. A shock-absorbing pad is provided between the bottom of the brushless motor 121 and the motor box 12. A wiring terminal is installed at the wiring hole of the plastic top shell 2, which is connected to the wiring terminal of the brushless motor 121 for power supply and control signal access.

[0030] Specifically, the sealing sleeve 151 has a double-layer structure, with the inner layer being made of fluororubber and the outer layer being coated with polytetrafluoroethylene. The clamp 152 is a stainless steel worm gear clamp with a tightening torque of 3 N·m to 5 N·m to ensure no leakage under ±0.05 MPa air pressure. The fit clearance between the limiting protrusion and the limiting groove is 0.02 mm to 0.05 mm. The sliding surface is coated with a molybdenum disulfide solid lubricating film to reduce the coefficient of friction to below 0.1, thereby reducing wear and noise.

[0031] Furthermore, the noise-reducing cotton is polyurethane open-cell sponge, covering the entire inner wall of the plastic top shell 2 except for the air inlet and outlet. The heat dissipation channel consists of multiple arc-shaped guide grooves arranged circumferentially along the inner wall of the plastic top shell 2, forming a convection circulation with the heat dissipation fins on the aluminum base 11. The shock-absorbing pad is made of nitrile rubber. The wiring terminals are waterproof RJ45 or M12 aviation plugs with a rated current ≥5A and a protection level of IP67. They are connected to the wiring terminals of the brushless motor 121 by a shielded cable, and the shielding layer is grounded to resist electromagnetic interference.

[0032] The working principle of this air pulse airflow device will be explained in detail below.

[0033] like Figure 1-5 As shown, during the startup phase: power and control signals are connected to the brushless motor 121 via the terminal blocks. The brushless motor 121 starts and rotates at a set speed. The speed is adjusted according to the pulse airflow frequency requirements, typically from 0-150 rpm. Due to its 4-pole design, the brushless motor 121 has high output torque and low speed fluctuation, avoiding the problems of brush wear in brushed motors and insufficient torque in low-pole motors, thus providing stable power for subsequent pulse airflow output.

[0034] Power transmission stage: The output shaft of the brushless motor 121 drives the eccentric drive assembly 13 to rotate at a constant speed around the output shaft. Specifically, the turntable 131 is movably connected to the T-shaped crank arm disk 14 through eccentric shaft pins 132 and 134 on the upper and lower sides. Because the eccentric wheel 133 adopts a customized eccentricity design and is precisely matched with the T-shaped crank arm disk 14, the rotational motion is transmitted to the T-shaped crank arm disk 14 through eccentric shaft pins 132 and 134, allowing the T-shaped crank arm disk 14 to perform smooth reciprocating linear motion under the constraint of the limiting groove of the aluminum base 11. During this process, the adaptive design of the eccentric wheel 133 and the T-shaped crank arm disk 14 reduces transmission backlash and lowers friction and vibration.

[0035] Pulse airflow generation stage: When the T-shaped crank arm disk 14 reciprocates, it drives the piston disk connected to one end in the airflow chamber to reciprocate synchronously. When the piston disk moves forward, it compresses the air in the airflow chamber, increasing the air pressure in the chamber, and the air is ejected in pulse form through the air outlet 22; when the piston disk moves backward, a negative pressure is formed in the airflow chamber, and outside air enters the chamber through the air inlet 21 to replenish it. This cycle generates a stable and uniform pulse airflow. Because the brushless motor 121 has a stable speed, the eccentric wheel 133 and the T-shaped crank arm disk 14 drive smoothly, and the intensity and frequency of the pulse airflow are highly consistent.

[0036] Support, heat dissipation, and protection phase: The aluminum base 11, made of high-strength aluminum alloy and featuring an integrated design, provides stable support for components such as the brushless motor 121, eccentric drive assembly 13, and T-shaped articulated arm 14, preventing shaking during equipment operation. The heat dissipation fins on the aluminum base 11 quickly dissipate the heat generated by the brushless motor 121, and combined with the brushless motor 121's built-in heat dissipation structure, ensure that the brushless motor 121 does not overheat during long-term operation. The plastic top shell 2 achieves a sealed connection with the aluminum base 11 through the sealing assembly 15, preventing dust and moisture from entering the device. The noise-reducing cotton on the inner wall of the plastic top shell 2 absorbs the noise generated by the motor and transmission components, reducing the overall operating noise of the device.

[0037] Stopping phase: Power is cut off, brushless motor 121 stops rotating, eccentric wheel 133 and T-shaped crank arm disc 14 stop moving, piston disc stops reciprocating, and air pulse airflow output stops. Due to the customized adaptation design of each component, wear is small, stability is high, and it can be repeatedly started and stopped over a long period of time.

[0038] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. An air pulse airflow device, characterized in that: It includes a base mechanism (1) and a plastic top shell (2). The base mechanism (1) includes an aluminum base (11). The aluminum base (11) and the plastic top shell (2) form a cylindrical structure, and an airflow chamber is formed inside the cylindrical structure. The aluminum base (11) is provided with a motor box (12), and a brushless motor (121) is provided inside the motor box (12). The output shaft of the brushless motor (121) is connected to an eccentric drive assembly (13). The eccentric drive assembly (13) is connected to a T-shaped crank arm disk (14) on both sides, and a piston disk is connected to the other end of the T-shaped crank arm disk (14). A sealing assembly (15) is provided on the outer ring of the piston disk. The T-shaped crank plate (14) seals both sides of the cylindrical structure with the help of the sealing assembly (15).

2. The air pulse airflow device according to claim 1, characterized in that: The aluminum base (11) is an integrally formed aluminum alloy base with anti-slip pads and heat dissipation ribs at the bottom. The motor box (12) is integrally formed with the aluminum base (11).

3. The air pulse airflow device according to claim 1, characterized in that: The brushless motor (121) is a 4-pole brushless motor, which is installed in the motor box (12) by fixing bolts, and a shock-absorbing pad is provided between the bottom of the brushless motor (121) and the motor box (12).

4. The air pulse airflow device according to claim 1, characterized in that: The eccentric drive assembly (13) includes a turntable (131), an eccentric pin one (132) is fixedly installed at the top eccentric part of the turntable (131), an eccentric wheel (133) is connected to the top of the eccentric pin one (132), an eccentric pin two (134) is fixedly connected to the top eccentric part of the eccentric wheel (133), the turntable (131) has a shaft hole that matches the output shaft of the brushless motor (121), a keyway is provided in the shaft hole, and it is fixedly connected to the output shaft of the brushless motor (121) by a flat key.

5. An air pulse airflow device according to claim 4, characterized in that: There are two T-shaped crank arm discs (14). Each T-shaped crank arm disc (14) has a through pin hole (141) that runs vertically through it. Each T-shaped crank arm disc (14) is installed on the outer wall of the corresponding eccentric shaft pin (134) through the pin hole (141). The T-shaped crank arm disc (14) is made of high-strength aluminum alloy and is T-shaped. A limiting protrusion is provided in the middle part of the disc. A limiting groove is provided on the aluminum base (11). The limiting protrusion and the limiting groove slide together.

6. An air pulse airflow device according to claim 1, characterized in that: The sealing assembly (15) includes a sealing sleeve (151), the inner ring of which is fitted around the outer ring of the piston disc at one end of the T-shaped crank arm disc (14), and the outer ring of which is fitted around the outer ring of the cylindrical structure formed by the aluminum base (11) and the plastic top shell (2). Both the inner and outer rings of the sealing sleeve (151) are fitted with clamps (152).

7. An air pulse airflow device according to claim 1, characterized in that: The plastic top shell (2) is made of ABS engineering plastic and has a semi-closed structure. It is sealed to the aluminum base (11) by fixing bolts, and a sealing gasket is provided at the connection. The interior of the plastic top shell (2) is provided with noise reduction cotton and heat dissipation channels.

8. An air pulse airflow device according to claim 1, characterized in that: The top of the plastic top shell (2) is provided with an air inlet (21) and an air outlet (22) that penetrate its inner cavity.

9. An air pulse airflow device according to claim 1, characterized in that: The plastic top shell (2) has a wiring terminal installed at the wiring hole, and the wiring terminal is connected to the wiring terminal of the brushless motor (121).

10. An air pulse airflow device according to claim 1, characterized in that: The eccentric drive assembly (13) is made of high-strength alloy structural steel, the T-shaped crank arm disk (14) is made of aluminum alloy, and the cylindrical structure composed of the aluminum base (11) and the plastic top shell (2) is cylindrical.

Images