PAP System Blower

Abstract

To provide a blower that is very small in size, low in cost, and / or easy to assemble. [Solution] The blower includes a housing including an intake port and an exhaust port, a bearing-housing structure provided in the housing to rotatably support a rotor, a motor provided in the bearing-housing structure to drive the rotor, and an impeller provided on the rotor. The bearing-housing structure includes a bearing shaft having a bearing surface for rotatably supporting the rotor. The bearing shaft forms only a single non-ball bearing type bearing for the rotor.

Description

[Technical Field]

[0001] [Cross-reference of related applications] This application claims the benefits of U.S. Provisional Application No. 61 / 457,526, filed on 18 April 2011, and U.S. Provisional Application No. 61 / 630,920, filed on 22 December 2011, each of which is incorporated herein by reference in its entirety.

[0002] Furthermore, the entirety of PCT application PCT / AU2010 / 001106, filed on 27 August 2010, is incorporated herein by reference.

[0003] This technique relates, for example, to positive airway pressure (PAP) systems and / or methods used to treat sleep-disordered breathing (SDB) with continuous positive airway pressure (CPAP) or non-invasive positive airway pressure (NIPPV). More specifically, this technique relates to the blower of a PAP system. [Background technology]

[0004] Examples of head-mounted blowers, wearable CPAP machines, or portable CPAP machines are known in the art. See, for example, Patent Documents 1 and 2, which are incorporated herein by reference as a whole, and the BreatheX® system. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] U.S. Patent Application Publication No. 2006 / 0237013 [Patent Document 2] U.S. Patent Application Publication No. 2009 / 0320842 [Overview of the project] [Means for solving the problem]

[0006] One example of this technique relates to minimal CPAP systems, usage, and devices configured to minimize or reduce the impact on patients.

[0007] One example of this technique relates to a patient interface incorporating a relatively small or miniature blower.

[0008] One example of this technique relates to a blower that is very small in size, low in cost, and / or easy to assemble.

[0009] One aspect of this technique relates to a novel miniature blower used in a PAP distribution unit designed to provide pressure assistance to a user. For example, the PAP distribution unit can provide low-level pressure assistance of about 1 cmH2O to 8 cmH2O, performed at a speed of about 15,000 rpm and / or a flow rate of about 70 L / min. However, higher levels of pressure assistance, such as 1 cmH2O to 25 cmH2O, may also be provided.

[0010] One example of this technique relates to a blower in which the intake and exhaust ports are aligned with the blower's axis and in the axial direction.

[0011] One example of this technique relates to a blower whose housing includes an intake port and an exhaust port located tangentially to the intake port, both aligned in the axial direction.

[0012] Another aspect of this technique relates to a blower that does not use or does not require ball bearings. Instead, the blower may include a central bearing structure formed at least in part from, for example, sintered bronze, industrial plastic materials, low-friction lubricating materials such as polyamide-imide resins such as Torlon®, and / or other very low-friction materials and / or other materials coated with low-friction materials. This bearing may have a large bearing surface surrounding a rotor or shaft, for example, a highly polished shaft. The central bearing structure may include a radial sleeve bearing section and a thrust bearing section. The thrust bearing section may utilize, for example, a low-friction material as described above.

[0013] Another aspect of this technique relates to a blower that includes or requires only a single bearing structure, including a radial bearing section and a thrust bearing section, which can help reduce the height of the blower. A thrust load may be applied to the top surface of the bearing. The radial bearing section may be configured as a sleeve bearing along the surface of the shaft. Since there is only one bearing, the motor only needs to be balanced in one plane rather than two.

[0014] Another aspect of this technique relates to a disc-shaped bearing-housing structure that supports a rotor or shaft. The disc portion of the bearing-housing structure may provide a shielding function to prevent noise from being generated as the impeller rotates, passing from the non-swiveling vanes through the blades. The top surface of the bearing-housing structure surrounding the shaft and adjacent to the rotor cap may provide bearing functionality by forming a radial surface along the shaft and a thrust surface to allow each part to rotate. Stator components of the motor may be mounted on the bearing-housing structure.

[0015] Another aspect of this technique relates to a rotor holding configuration that prevents the rotor and / or rotor assembly from lifting or separating from the blower housing.

[0016] Another aspect of this technique relates to a bearing grease retention structure within a bearing - housing structure that forms a groove for grease supplied to the thrust surface.

[0017] Another aspect of this technique relates to an insert configuration in which at least a part of a motor (stator component, stationary magnet, and / or rotor cap) is nested within an impeller to reduce the size of the blower. The impeller may be directly molded or overmolded onto the rotor cap.

[0018] Another aspect of this technique relates to an impeller incorporating a rotor portion. The combined impeller and rotor may form a path for magnetic flux of one or more permanent magnets to pass through and interact with the magnetic flux of a stator, such as a commutator motor stator, to rotate the impeller, and may include at least some iron material such as magnetic steel.

[0019] Another aspect of this technique relates to an impeller that can be held on a rotor or shaft by magnetic retention between a magnet coupled to the inner surface of a rotor cap and a stator component. There is no need to fix the impeller to the rotor or shaft.

[0020] Another aspect of this technique relates to the blades of an impeller that curve towards a hub having a slightly S - shaped form. This shape may be designed to reduce over - excitation.

[0021] Another aspect of this technique relates to an impeller. The impeller may be a double - shrouded or alternate - shroud impeller since the shroud need not completely cover the top and / or bottom surfaces of the impeller blades. Alternatively, use an impeller with a bottom that is substantially completely covered to help address the problem of the rotor or shaft lifting during use.

[0022] One example of this technique relates to a CPAP system, method of use, and device configured to achieve at least a reduction in size and volume, reduction in vibration, reduction in generated noise, or a combination thereof.

[0023] One example of the technique relates to a small CPAP device configured to supply a breathable gas (e.g., air) pressurized in a manner suitable for the treatment of sleep apnea and / or snoring.

[0024] One example of the technique relates to a PAP system that includes a patient interface configured to form a seal against the patient's nose and / or mouth, and a headgear that supports the seal configuration in a predetermined position on the patient's head. The blower is configured to generate and supply pressurized air. The blower is supported by a patient interface on the patient's head (e.g., disposed inside the headgear or cushion or formed as part of the headgear or cushion (e.g., integrated with one or more nozzles)) and is in communication with the patient interface. The headgear may form one or more ducts that send pressurized air from the blower to a breathing cavity formed by the seal configuration. Alternatively, a separate tube for sending pressurized air from the blower to the seal configuration may be provided.

[0025] In one example, a PAP system is disclosed that can be configured to minimize the visual footprint during use. The flow generating device of such a PAP system includes at least one blower and / or at least one blower housing and is in air communication with the patient interface. Further, these PAP systems include other structural elements (e.g., but not limited to, headgear, shoulder harness, pendant configuration, clothing, strap or band configuration, or combinations thereof) that enable portability, patient carriage, use during travel, attachment to a mask, attachment to the head, placement inside or near a pillow, attachment to a bed, attachment to a headboard, attachment to a chair or wheelchair, or combinations thereof.

[0026] In one example, a PAP system may be used in a sanitary device for filtering air. The sanitary device may supply clean air or purified and filtered air to the user. The filtered air may be pressurized. The sanitary device includes a filter designed to remove particulate matter from the air and supply purified air to the user.

[0027] In one example, the blower may be approximately 60mm to 65mm wide, for example 62.8mm, and approximately 20mm to 25mm high, for example 23.2mm.

[0028] Another aspect of this technique relates to a blower comprising a housing including an intake and exhaust port, a bearing-housing structure provided in the housing to rotatably support a rotor, a motor provided in the bearing-housing structure to drive the rotor, and an impeller provided on the rotor. The bearing-housing structure includes a bearing shaft having a bearing surface for rotatably supporting the rotor. The bearing shaft forms only a single non-ball bearing type bearing structure for the rotor.

[0029] Another aspect of this technique relates to a blower comprising a housing including an intake port and an exhaust port; a bearing-housing structure provided in the housing to rotatably support a rotor; a motor provided in the bearing-housing structure to drive the rotor; and an impeller provided on the rotor, wherein at least a portion of the motor is nested within the impeller.

[0030] Another aspect of this technique relates to a blower comprising a housing including an intake port and an exhaust port; a bearing-housing structure provided in the housing to rotatably support a rotor; a motor provided in the bearing-housing structure to drive the rotor; and an impeller provided on the rotor, wherein the impeller is held on the rotor by magnetic retention.

[0031] Another aspect of this technique relates to a blower comprising a housing including an intake and exhaust port, a bearing-housing structure provided in the housing to rotatably support a rotor, a motor provided in the bearing-housing structure to drive the rotor, and an impeller provided on the rotor, wherein the bearing-housing structure is constructed of or coated with a low-friction or lubricating material. The lubricating material includes sintered bronze, industrial plastic materials, polyamide-imide resins such as Torlon®, and / or very low-friction materials. The bearing-housing structure may consist of a combination of materials including a lubricating material or a material with a very low coefficient of friction. For example, a first material such as aluminum, steel, brass, bronze, or other metal or plastic may be coated with a lubricating material or a material with a very low coefficient of friction, such as a ceramic-based or nickel-based coating material. In some examples, the coating may be applied only to critical wear surfaces of the bearing-housing, such as the shaft bearing surface. Alternatively or in addition, a material that reduces friction may be applied to the shaft.

[0032] Another aspect of the present technique relates to a blower comprising a housing including an intake and exhaust port; a bearing-housing structure provided in the housing to rotatably support a rotor; a motor provided in the bearing-housing structure to drive the rotor; and an impeller provided on the rotor, wherein the bearing-housing structure includes a bearing shaft for rotatably supporting the rotor and an annular disc substantially aligned with or extending radially beyond the outer edge of the impeller to provide a shielding function.

[0033] Another aspect of this technique relates to a blower comprising a housing including an intake and exhaust port; a bearing-housing structure provided in the housing to rotatably support a rotor; a motor provided in the bearing-housing structure to drive the rotor; and an impeller provided on the rotor. The bearing-housing structure includes a bearing shaft having a bearing surface for rotatably supporting the rotor. The motor includes a stator assembly, a magnet, and a rotor cap. The rotor cap includes an inner surface for supporting the magnet and an outer surface for supporting the impeller. The rotor cap engages with the rotor, thereby, in use, the stator assembly acts on the magnet to rotate the rotor cap, and therefore rotate the impeller.

[0034] In one example, multiple pre-swirl intake vanes may be provided on the top cover of the housing to direct the airflow towards the intake port. A pre-swirl cover may also be provided to cover the pre-swirl vanes.

[0035] In one example, the bearing-housing structure may be coupled to the bottom cover of the housing via a snap mechanism or a screw configuration.

[0036] In one example, the bearing-housing structure includes an annular disc that substantially aligns with or extends radially beyond the outer edge of the impeller to provide shielding. In another example, the bearing shaft and disc include a split configuration in which the bearing shaft and disc are separate components.

[0037] Another aspect of this technique relates to a blower comprising a housing including an intake and exhaust port, a bearing-housing structure provided in the housing to rotatably support a rotor, a motor provided in the bearing-housing structure to drive the rotor, and an impeller provided on the rotor. The bearing-housing structure comprises a housing section and a bearing cartridge provided in the housing section. The bearing cartridge comprises a tubular sleeve and two spaced bearings supported within the sleeve to support the rotor.

[0038] Another aspect of this technique relates to a blower comprising a housing including an air intake and an exhaust port, a motor provided in the housing to drive a rotor, an impeller provided on the rotor, and an air intake cap provided on the air intake of the housing. The air intake cap is configured to close or block at least the central portion of the air intake.

[0039] Other examples, aspects, features, and / or advantages of this technique will become apparent when the following detailed description is considered in relation to the accompanying drawings, which are part of this disclosure and illustrate the principles of the disclosed technique as an example.

[0040] The attached diagrams facilitate understanding of various examples of this technique. [Brief explanation of the drawing]

[0041] [Figure 1] This is a perspective view of a head-mounted PAP system, an example of this technique, on the head of a model user. [Figure 2] This is an exploded view of a blower using an example of this technique. [Figure 3] Figure 2 is a cross-sectional view of the blower. [Figure 4] Figure 2 is an isometric cross-sectional view of the blower. [Figure 5] This is an isometric cross-sectional view similar to Figure 4, but without the top cover. [Figure 6] Figure 2 is a perspective view of the top cover of the blower. [Figure 7] This is a perspective view of the top cover in Figure 6, seen from the opposite direction. [Figure 8] Figure 2 is a perspective view of the bottom cover of the blower. [Figure 9] This is a perspective view of the bottom cover in Figure 8, seen from the opposite direction. [Figure 10] Figure 2 is a perspective view of the blower's bearing-housing structure. [Figure 11] Figure 10 is a perspective view of the bearing-housing structure, seen from the reverse direction. [Figure 12]Figure 2 is a perspective view of the blower rotor cup. [Figure 13] Figure 12 is a cross-sectional view of the rotor cup. [Figure 14] Figure 2 is a perspective view of the blower impeller. [Figure 15] This is a perspective view of the impeller in Figure 14, seen from the opposite direction. [Figure 16] Figure 2 is a side view of a blower, illustrating the dimensions of an example using this technique. [Figure 17] This is a perspective view of a stator core and slot liner using an example of this technique. [Figure 18] Figure 17 is a cross-sectional view of the stator core and slot liner. [Figure 19] This is a perspective view of a blower, including an overhead holding arm, as an example of this technique. [Figure 20] This is an exploded view of a rotor cup and bearing-housing structure, including the fitting mechanism, as an example of this technique. [Figure 21] Figure 20 is a cross-sectional view of the rotor cup and bearing-housing structure. [Figure 22] This is an exploded view of a rotor cap and bearing-housing structure, including a fitting mechanism, as another example of this technique. [Figure 23] This is an exploded view of a rotor cap and bearing-housing structure, including a fitting mechanism, as another example of this technique. [Figure 24] This is an exploded view of a rotor cap and bearing-housing structure, including a fitting mechanism, as another example of this technique. [Figure 25] This is an exploded view of a rotor cap and bearing-housing structure, including a fitting mechanism, as another example of this technique. [Figure 26] This is an exploded view of a rotor cap and bearing-housing structure, including a fitting mechanism, as another example of this technique. [Figure 27] Figure 26 is a plan view of the rotor cap. [Figure 28] This is a cross-sectional view of a blower including a rotor with a retaining flange, as an example of this technique. [Figure 29] This is a cross-sectional view of a blower, including a pre-swivel cover, as an example of this technique. [Figure 30] This is a cross-sectional view showing a screw configuration for connecting the rotor cap to the bearing-housing structure, as an example of this technique. [Figure 31] This is a cross-sectional view showing a screw configuration for connecting the rotor cap to the bearing-housing structure, as an example of this technique. [Figure 32] This is a cross-sectional view showing a screw configuration for connecting the rotor cap to the bearing-housing structure, as an example of this technique. [Figure 33] This is a diagram of a bottom cover including a non-rotating vane, as an example of this technique. [Figure 34] This is a diagram of a bottom cover including a non-rotating vane, as an example of this technique. [Figure 35] This is a diagram of a bottom cover including a non-rotating vane, as an example of this technique. [Figure 36] This is a diagram of a blower including a pre-swirl intake vane and pre-swirl cover, as an example of this technique. [Figure 37] This is a diagram of a blower including a pre-swirl intake vane and pre-swirl cover, as an example of this technique. [Figure 38] This is a diagram of a blower including a pre-swirl intake vane and pre-swirl cover, as an example of this technique. [Figure 39] This is a cross-sectional view showing a bearing-housing structure with a segmented configuration, based on an example of this technique. [Figure 40] This is a cross-sectional view showing a bearing-housing structure with a segmented configuration, according to another example of this technique. [Figure 41] This is a cross-sectional view showing a bearing-housing structure with a segmented configuration, according to another example of this technique. [Figure 42] This is a cross-sectional view showing a bearing-housing structure with a segmented configuration, according to another example of this technique. [Figure 43] This is a cross-sectional view showing a bearing-housing structure with a segmented configuration, according to another example of this technique. [Figure 44]This is a cross-sectional view of a blower showing the motor wiring configuration and PCB mounting configuration as an example of this technique. [Figure 45] This is a cross-sectional view showing a bearing-housing structure with a segmented configuration, according to another example of this technique. [Figure 46] This is a cross-sectional view showing a bearing-housing structure coupled to the vanes of the bottom cover, as an example of this technique. [Figure 47] This is a cross-sectional view showing a bearing-housing structure coupled to the vanes of the bottom cover, representing another example of this technique. [Figure 48] This is a cross-sectional view of a blower having an elastomer material between the bearing-housing structure and the bottom cover, as an example of this technique. [Figure 49] This is a cross-sectional view showing a bearing-housing structure connected to the bottom cover by a fastener, as an example of this technique. [Figure 50] This is a cross-sectional view showing a bearing-housing structure connected to the bottom cover by a fastener, as an example of this technique. [Figure 51] Figures 49 and 50 show the fastening hardware. [Figure 52] Figures 49 and 50 show the fastening hardware. [Figure 53] This is a cross-sectional view showing a bearing-housing structure coupled to a bottom cover, representing another example of this technique. [Figure 54] This is a cross-sectional view showing a bearing-housing structure coupled to a bottom cover, another example of this technique. [Figure 55] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 56] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 57] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 58]This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 59] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 60] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 61] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 62] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 63] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 64] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 65] This is a cross-sectional view showing a snap mechanism for attaching a bearing-housing structure to a bottom cover, using an alternative example of this technique. [Figure 66] This is a cross-sectional view showing a bearing-housing structure connected to the bottom cover by a screw configuration, as an example of this technique. [Figure 67] This is a cross-sectional view showing a bearing-housing structure connected to the bottom cover by a screw configuration, representing another example of this technique. [Figure 68] This is a cross-sectional view showing a bearing-housing structure connected to the bottom cover by an integrated screw configuration, as an example of this technique. [Figure 69] This figure shows a bearing-housing structure, including a tank and flow path for holding lubricating oil, according to an example of this technique. [Figure 70] This figure shows a bearing-housing structure, including a tank and flow path for holding lubricating oil, according to an example of this technique. [Figure 71] This is a diagram of a bearing-housing structure including a lubricating oil tank, as an example of this technique. [Figure 72] This is a diagram of a bearing-housing structure including a lubricating oil tank, as an example of this technique. [Figure 73] This is a diagram of a bearing-housing structure including a lubricating oil tank, as an example of this technique. [Figure 74] This is a diagram of a bearing-housing structure including a lubricating oil tank, as an example of this technique. [Figure 75] This is a diagram of a bearing-housing structure including a recessed channel for lubricating oil, as an example of this technique. [Figure 76] This is a diagram of a bearing-housing structure including a recessed channel for lubricating oil, as an example of this technique. [Figure 77] This is a diagram of a bearing-housing structure including a recessed channel for lubricating oil, as an example of this technique. [Figure 78] This is a diagram of a bearing-housing structure including a recessed channel for lubricating oil, as an example of this technique. [Figure 79] This is a diagram of a bearing-housing structure including a recessed channel for lubricating oil, as an example of this technique. [Figure 80] This is a plan view of a concave channel for a bearing-housing structure, using an alternative example of this technique. [Figure 81] This is a plan view of a concave channel for a bearing-housing structure, using an alternative example of this technique. [Figure 82] This figure shows a hydrodynamic pressure concentration achieved by a concave channel for a bearing-housing structure, as an example of this technique. [Figure 83] This figure shows a hydrodynamic pressure concentration achieved by a concave channel for a bearing-housing structure, as an example of this technique. [Figure 84] This is a diagram of a bearing-housing structure including an annular concave channel for lubricating oil, as an example of this technique. [Figure 85] This is a diagram of a bearing-housing structure including an annular concave channel for lubricating oil, as an example of this technique. [Figure 86]This is a diagram of a bearing-housing structure including an annular concave channel for lubricating oil, as an example of this technique. [Figure 87] This is a diagram of a bearing-housing structure including an annular concave channel for lubricating oil, as an example of this technique. [Figure 88] This is a diagram of a bearing-housing structure including an annular concave channel for lubricating oil, as an example of this technique. [Figure 89] This is a diagram of a bearing-housing structure including an annular concave channel for lubricating oil, as an example of this technique. [Figure 90] This is a schematic diagram of a bearing shaft with a three-lobe configuration, based on an example of this technique. [Figure 91] This is a cross-sectional view of a blower, including a retaining ring for holding lubricating oil, as an example of this technique. [Figure 92] This is a cross-sectional view of a blower including a bearing-housing structure having a structure for retaining lubricating oil, as an example of this technique. [Figure 93] This diagram shows an impeller and impeller blade as an example of this technique. [Figure 94] This diagram shows an impeller and impeller blade as an example of this technique. [Figure 95] This figure shows an impeller and impeller blade in another example of this technique. [Figure 96] This figure shows an impeller and impeller blade in another example of this technique. [Figure 97] This figure shows an impeller and impeller blade in another example of this technique. [Figure 98] This figure shows an impeller and impeller blade in another example of this technique. [Figure 99] This is a cross-sectional view of a blower, including the internal rotor configuration, based on an example of this technique. [Figure 100] This is a cross-sectional view of a blower, including an axial configuration, as an example of this technique. [Figure 101] This is a diagram of a bottom cover including a non-rotating vane, as an example of this technique. [Figure 102]This is a diagram of a bottom cover including a non-rotating vane, as an example of this technique. [Figure 103] This is a diagram of a top cover including pre-rotating vanes, as an example of this technique. [Figure 104] This is a diagram of a top cover including pre-rotating vanes, as an example of this technique. [Figure 105] This is a diagram of a top cover having pre-rotating vanes and a pre-rotating cover, as an example of this technique. [Figure 106] This is a diagram of a top cover having pre-rotating vanes and a pre-rotating cover, as an example of this technique. [Figure 107] This is a diagram of a top cover having pre-rotating vanes and a pre-rotating cover, as an example of this technique. [Figure 108] This is a cross-sectional view of a rotor cap and impeller formed as a single, integrated structure using an example of this technique. [Figure 109] This is a cross-sectional view of a blower, another example of this technique. [Figure 110] Figure 109 is an enlarged cross-sectional view of a portion of the blower. [Figure 111] This is a cross-sectional view of a part of a blower, another example of this technique. [Figure 112] This is a cross-sectional view of a bearing cartridge using an example of this technique. [Figure 113] This figure shows a paddle wheel as another example of this technique. [Figure 114] This figure shows a paddle wheel as another example of this technique. [Figure 115] This figure shows a paddle wheel as another example of this technique. [Figure 116] This is a diagram of a blower including an air intake cap, as an example of this technique. [Figure 117] This is a diagram of a blower including an air intake cap, as an example of this technique. [Figure 118] This is a diagram of a blower including an air intake cap, as an example of this technique. [Figure 119] This is a diagram of a blower including an air intake cap, as an example of this technique. [Figure 120]This is a perspective view of a top cover for a blower, including an air intake cap, as an example of this technique. [Figure 121] This is a perspective view of a top cover for a blower, including an air intake cap, as another example of this technique. [Figure 122] This is a perspective view of a top cover for a blower, including an air intake cap, as another example of this technique. [Figure 123] This is a perspective view of a top cover for a blower, including an air intake cap, as another example of this technique. [Figure 124] Figures 116 to 119 show other cross-sectional views of the blower. [Figure 125] This is an alternative diagram of the blower shown in Figure 109. [Figure 126] This is an alternative diagram of the blower shown in Figure 109. [Figure 127] This is an alternative diagram of the blower shown in Figure 109. [Figure 128] This is a diagram of a blower, another example of this technique. [Figure 129] This is a diagram of a blower, another example of this technique. [Figure 130] This is a diagram of a blower, another example of this technique. [Figure 131] This is a diagram of a blower, another example of this technique. [Figure 132] This is a diagram of a blower, another example of this technique. [Figure 133] This is a diagram of a blower, another example of this technique. [Figure 134] This is a diagram of a blower, another example of this technique. [Figure 135] This is a diagram of a blower, another example of this technique. [Figure 136] This is a diagram of a blower, another example of this technique. [Figure 137] This is a diagram of a blower, another example of this technique. [Figure 138] This is a diagram of a blower, another example of this technique. [Figure 139] This is a diagram of a blower, another example of this technique. [Figure 140] This is a diagram of a blower, another example of this technique. [Figure 141] This is a diagram of a blower, another example of this technique. [Figure 142] This is a diagram of a blower, another example of this technique. [Figure 143] This is a cross-sectional view of a blower, another example of this technique. [Figure 144] This is a cross-sectional view of a blower, another example of this technique. [Figure 145] This is a cross-sectional view of a blower, another example of this technique. [Figure 146] This is a cross-sectional view of a blower, another example of this technique. [Figure 147] This is a cross-sectional view of a blower, another example of this technique. [Figure 148] This is a cross-sectional view of a blower, another example of this technique. [Figure 149] This figure shows a blower installed inside the casing of a PAP device, as an example of this technique. [Figure 150] This figure shows a blower installed inside the casing of a PAP device, as an example of this technique. [Figure 151] This is a cross-sectional view of a blower, another example of this technique. [Modes for carrying out the invention]

[0042] The following explanations relate to several examples (mostly illustrated, but some not) that may share common characteristics and features. It should be understood that one or more features from any one example may be combined with one or more features from other examples. Furthermore, any single feature in any one or more examples may constitute patentable subject matter, or any combination of features may constitute patentable subject matter.

[0043] In this specification, the word "comprising" should be understood in its "open" sense, that is, in the sense of "including," and therefore not limited to its "closed" sense, that is, in the sense of "consisting of only." The corresponding meanings are derived from the corresponding words "comprise" and "comprises" and "comprised" when they appear.

[0044] The word "air" is considered to include breathable gases, such as air containing supplemental oxygen.

[0045] The headings used in the detailed descriptions are included solely for the purpose of facilitating reader reference and should not be used to limit the subject matter found throughout this disclosure and the claims. The headings should not be used in interpreting the claims or any limitation of the claims.

[0046] PAP system A PAP system (e.g., a CPAP system) typically includes a PAP device (including a blower for generating air at positive pressure), an air supply conduit (also called a tube or tubing), and a patient interface. When in use, the PAP device generates and supplies pressurized air (e.g., 2 cmH2O to 30 cmH2O) which is delivered to the patient interface via the air supply conduit. The patient interface or mask may have a suitable configuration as known in the art, such as a full-face mask, nasal mask, mouth-nasal mask, mouth mask, nasal prongs, or nasal cannula. Furthermore, a headgear may be used to comfortably support the patient interface in a desired position on the patient's face.

[0047] One example relates to a PAP system in which a PAP device or blower can be attached to a patient's head, or built into or incorporated into a patient interface or mask, making it wearable or transportable by the patient, portable, reduced in size, or a combination thereof. In one example, the blower may be of the type described in international application PCT / AU2010 / 001031, filed on 11 August 2010 and titled “Single Stage, Axial Symmetric Blower and Portable Ventilator”, and / or international application PCT / AU2010 / 001106, filed on 27 August 2010 and titled “PAP system”, each application of which is incorporated herein by reference in whole.

[0048] For example, Figure 1 shows a head-mounted PAP system 10 including a PAP device or blower 20, a patient interface or mask 30 (e.g., a nasal mask), and an exhaust tube 40 connecting the patient interface and the blower. The headgear 50 secures the blower and patient interface in place on the patient's head when in use. However, the PAP system may be configured, for example, in or near a pillow, within a scarf-like configuration, incorporated into clothing, or attached to a bed or bed head, or within a more conventional PAP device configured to be positioned on a surface near the bedside, similar to the ResMed® S9® CPAP system.

[0049] In one example, a PAP system may be used as a sanitary device to purify incoming air. A filter may be present at the air intake of the device to filter out particulate matter or impurities from the incoming air and deliver purified or filtered air to the user.

[0050] Blower Figures 2 to 16 show a single-stage blower 100 according to an example of this technique (for example, blower 100 may be provided as blower 20 in the PAP system in Figure 1). The blower is very small in size, low in cost, compact, and lightweight, forming a configuration that is easy to assemble, for example, when used in a small, wearable PAP system. In one example, the blower may be suitable for the treatment of mild sleep-disordered breathing or snoring and may be configured to supply pressurized air at a speed of about 15,000 rpm and a flow rate of about 60 L / min to 70 L / min, up to about 8 cmH2O (for example, up to about 4 cmH2O to 8 cmH2O, e.g., 4 cmH2O, 5 cmH2O, 6 cmH2O, 7 cmH2O, or 8 cmH2O). In another example, the blower may be configured to supply pressurized air at a higher pressure, such as about 1 cmH2O to 25 cmH2O, and a higher flow rate exceeding 70 L / min, such as up to about 90 L / min to 120 L / min. In yet another example, the blower may include a multi-stage configuration, for example, two or more impellers. In such a multi-stage configuration, the blower may be able to achieve higher levels of pressurized air, such as about 1 cmH2O to 30 cmH2O, and a higher flow rate, such as up to about 140 L / min. However, those skilled in the art will understand that other motor speeds, pressures, and flow rates may be used.

[0051] As shown in the figure, the blower 100 includes a housing or cover 120 having a top housing or top cover 122 and a bottom housing or bottom cover 124, a bearing-housing structure 130 (also called a central bearing structure), a motor 140 (including a stator assembly or stator components 145, magnets 150, and a rotor cup or cap 160) provided in the bearing-housing structure to drive a rotatable shaft or rotor 170, and an impeller 180 coupled to the rotor cap 160. The rotor cap 160 is coupled to the end of the rotor 170 and together with the magnets 150 may be called a rotor assembly. In this configuration, the motor has an outer rotor configuration that rotates the impeller 180. This configuration allows at least some of the motor components to be nested inside the impeller, thus forming a low-profile blower.

[0052] In alternative configurations not shown, the motor may include an internal rotor configuration in which the magnets 150 are coupled to the rotor 170 and the impeller 180 is coupled to the shaft or the end of the rotor 170. In such a configuration, the impeller may be positioned above or around the motor components. Figure 99 shows an internal rotor configuration in which the rotor cap 160 includes an inner wall 160-1 for supporting the magnets 150 within a stator component 145 supported by a bearing-housing structure 130. The impeller 180 is coupled to the rotor cap 160 and thus extends above or around the motor components. In further alternative configurations, as shown in Figure 100, the motor may include an axial gap motor in which the stator component 145 (including the stator and windings), the magnets 150, and the rotor cap 160 have a stacked or pancake configuration. However, it should be understood that the motor may have any configuration suitable for rotational driving using electromagnetic interaction.

[0053] Motor assembly Figures 3–5 show the assembled motor 140 within the blower 100. The motor is configured such that the bearing-housing structure 130 supports other components of the motor and provides a bearing function that facilitates the rotation of the rotor assembly. In the illustrated example, one end 170(1) of the rotor 170 (e.g., metal or plastic) is rotatably supported within the bearing shaft 136 of the bearing-housing structure 130, and the other end 170(2) of the rotor 170 is freely inserted into the rotor cap 160, i.e., the rotor is not fixed to the motor. The rotor cap 160 includes an opening 162 to receive the rotor 170 (see, for example, Figures 12 and 13). However, in some examples, a rotor retaining configuration may be incorporated to hold the rotor and / or rotor assembly within the motor, particularly when the motor is not in use, as will be described in detail below.

[0054] The hub 185 of the impeller 180 is provided along the outer surface 163 of the rotor cap 160, and the magnet 150 is provided along the inner surface 165 of the rotor cap 160, for example by using friction engagement or adhesive. The inner surface 165 may form a recess or groove 165(1) for receiving the magnet 150 (see, for example, Figure 13).

[0055] In an alternative example, as shown in Figure 108, the rotor cap and impeller may be integrally formed as a single structure, for example, from a plastic material, e.g., Lexan®, polycarbonate (e.g., glass-reinforced polycarbonate), polyetheretherketone (PEEK), or other suitable material. As shown, this integral structure includes a rotor cap 360 and an impeller 380. A metal sleeve 351 and a magnet 350 are provided along the inner surface of the rotor cap 360. The sleeve 351 forms a magnetic return path or magnetic flux path between the poles of the magnet 350. Another example of an integrated rotor cap impeller is described in U.S. Patent No. 7804213, which is incorporated herein by reference in whole.

[0056] In a further alternative (not shown), the impeller may be overmolded onto the rotor cap. The surface of the rotor cap may be given a diamond-neutral surface finish or other surface finish to facilitate the fastening or mounting of the overmolded impeller.

[0057] The magnet 150 is coupled to the inner surface of the rotor cap 160 and positioned to drive the motor by promoting magnetic interaction with the stator assembly. The magnet may be made from any permanent magnet material such as bonded NdFeB ring, ferrite material, samarium cobalt, or other such magnetic material. In one example, the magnet may be centered on the stator assembly. In another example, the magnet 150 may be offset from the stator assembly to apply magnetic preload to the thrust bearing portion of the bearing-housing structure 130. In this configuration, a preload spring for the bearing may not be necessary. Offsetting the magnet 150 may also help to hold the rotor assembly within the motor.

[0058] The stator assembly 145 is coupled to the bearing-housing structure 130, which holds the stator assembly 145 in place. The stator assembly 145 may be coupled to the bearing-housing structure 130 by snap fitting, overmolding, adhesive, or other fastening means. The stator assembly or stator component 145 is mounted along the outer surface 136(3) of the bearing shaft 136 of the bearing-housing structure 130. During use, the stator assembly 145 acts on the magnet 150, thereby causing the rotor cap 160, and thus the impeller 180, to rotate. This configuration reduces the size of the blower by nesting at least part of the motor (stator assembly, fixed magnet, and rotor cap) inside the impeller. In one example, at least part of the motor components are located in a common (horizontal) plane.

[0059] As shown in Figures 17 and 18, the stator assembly 145 includes a stator core 146 having a plurality of stator teeth 147 around which stator coils or windings are wound, for example, six stator teeth. In the illustrated example, the stator core 146 includes a plurality of laminations stacked on top of each other, for example, two to more than 100 laminations. Each lamination may be fixed to each other using adhesive or other techniques. The number of laminations may depend on the motor's power requirements. Alternatively, the stator core may have a different configuration, such as a solid member instead of a stack of laminations.

[0060] The stator assembly 145 may include a pair of slot liners configured to insulate the stator core 146 from the stator coils or windings, for example, first and second slot liners 148-1 and 148-2 as shown in Figures 17 and 18. The first and second slot liners 148-1 and 148-2 may be provided on both sides of the stator core before the stator coils are wound onto the stator core. The thickness of the slot liners may be adjusted to facilitate filling the stator with more stator coils or windings. However, in an alternative configuration, the material on the stator core may be applied, for example, by powder coating the stator core. In one example, the slot liners may include the slot liner described in concurrently pending U.S. Patent Application Publication No. 2009-0324435, published on December 31, 2009, titled “Insulator for Stator Assembly of Brushless DC Motor,” which is incorporated herein in its entirety by reference.

[0061] The stator coil or winding comprises magnet wire or motor wiring, such as copper wire. In one example, the stator assembly may have three motor wires in the case of a three-phase motor, for example, with two coils per phase and 45 turns per coil, although other coil configurations are also possible. Each of the different wires for each phase may be identified by using a different color for each motor wire. The motor wiring may be directly interconnected with a PCB coupled to a blower for ease of assembly. Furthermore, center taps and lead wires may be coupled to the housing to minimize loose motor wiring entering the airflow path. In the exemplary configuration, the motor wiring may be routed through the stator vanes to the PCB assembly or driver as described later. The motor wiring may be twisted together and routed to facilitate insertion and removal. However, the motor wiring may also be routed separately. The motor wiring is wound on the stator core.

[0062] Rotor holding In some examples, one or more rotor retaining configurations or structures may be included to help hold the rotor and / or rotor assembly within the motor, particularly when the motor is not in use. For example, one or more over-top rotor retaining arms may be attached to the top cover and mounted on the rotor assembly to prevent vertical movement of the rotor assembly. Figure 19 shows an example of an over-top retaining arm 202, with one end 202(1) attached, for example, by a fastener to the top cover 122 of the cover 120, and the other end 202(2) positioned on the rotor assembly (i.e., the rotor cap 160, the magnet 150, and the rotor 170).

[0063] In another example of rotor retention, the bearing-housing structure 130 may be coupled or connected to a fitting mechanism of the rotor cap 160. For example, as shown in Figures 20 and 21, the bearing-housing structure 130 may have an elongated hole or groove 131 on the thrust bearing surface 136(2) configured to receive a lip or ridge 161 present on the fitting mechanism of the rotor cap 160. The lip or ridge 161 on the rotor cap 160 may snap into the elongated hole or groove 131 on the thrust bearing surface 136(2). The fitting mechanism may be incorporated into the underside surrounding the opening 162 of the rotor cap 160. This snap-fit ​​configuration may include radial portions, fillets, and / or chamfers to assist in the connection. The ridge or lip may be provided around the entire circumference of the fitting mechanism of the rotor cap 160, or may be limited to a number of individual snaps, beads, or protrusions at positions around the fitting surface, such as two to ten or more snaps or protrusions.

[0064] Figures 22–27 show alternative examples of fitting mechanisms for coupling the rotor cap to the bearing-housing structure. Figure 22 is similar to the configurations in Figures 20 and 21, in which the rotor cap 160 includes a lip or ridge 161 that engages with an elongated hole or groove 131 provided in the bearing-housing structure 130. In Figure 23, the rotor cap includes a bead 161-1 that engages with a groove 131-1 provided in the bearing-housing structure 130. In Figures 22 and 23, the fitting mechanism engages along the inward-facing surface of the bearing-housing structure, i.e., the surface facing the rotor. Figures 24 and 25 show configurations in which the fitting mechanism engages along the outward-facing surface of the bearing-housing structure, i.e., the surface facing away from the rotor. For example, Figure 24 shows a rotor cap including a bead 161-2 that engages into a groove 131-2 provided in the bearing-housing structure 130, and Figure 25 shows a rotor cap including a recess 161-3 that engages into a bead 131-3 provided in the bearing-housing structure 130. Figures 26 and 27 show a configuration in which the rotor cap 160 includes a plurality of individual beads 161-4 (for example, four beads) that engage into grooves 131-4 provided in the bearing-housing structure 130.

[0065] Figure 28 shows another rotor retaining example in which a lower flange, ridge, or projection 171 (for example, made of stainless steel and press-fitted onto the rotor) located below the bearing-housing structure 130 is coupled to the bottom of the rotor or shaft 170. The lower flange 171 prevents the rotor 170 from lifting vertically away from the motor assembly. The lower flange may form an additional or alternative surface of rotation for the rotor 170.

[0066] In one example including a pre-swivel cover as shown in Figure 29, the pre-swivel cover 205 may further include an axial impact bumper or fastener 205-1 to prevent the rotor assembly (i.e., rotor cap 160, magnet 150, and rotor 170) or rotor 170 from separating from the motor assembly in the event of impact, as will be described in more detail below. For example, the bumper or fastener 205-1 may prevent the rotor assembly from lifting off the thrust bearing surface of the bearing-housing structure in the event that the blower is dropped or struck, particularly when not in use. The bumper or fastener is positioned above the rotor 170 to prevent the rotor and / or rotor assembly from lifting and detaching from the motor assembly. The bumper or fastener may include balls such as steel balls, flat surfaces, or any other means for maintaining the rotor and rotor assembly in the correct position within the motor.

[0067] In another example of rotor retention, auxiliary screws 161-5 and 131-5 may be incorporated on the rotor cap 160 and on the thrust bearing surface 136(2) of the bearing-housing structure 130, as shown in Figures 30 to 32. In such a configuration, the rotor assembly (i.e., the rotor cap 160, magnet 150, and rotor 170) must be screwed into the auxiliary screws and fully engaged with the thrust bearing surface 136(2) of the bearing-housing structure 130 so that the rotor assembly can rotate freely. The auxiliary screws are configured in the same direction as the rotor rotates to prevent the rotor assembly from coming loose or falling out during use. The rotor assembly may be removed by rotating or disengaging the rotor assembly in the opposite direction to its normal rotation. Figure 30 shows the rotor assembly and bearing-housing structure before engagement, Figure 31 shows the rotor assembly and bearing-housing structure partially engaged, and Figure 32 shows the rotor assembly and bearing-housing structure fully engaged.

[0068] Blower Housing The top cover 122 forms an intake port 123 at one end of the blower, and the bottom cover 124 forms an exhaust port 125 at the other end of the blower. The blower is operable to draw gas into the housing through the intake port and to form a pressurized flow of gas at the exhaust port. The blower has axial symmetry with respect to both the intake port and the exhaust port, which are aligned with the blower's axis. During use, gas enters the blower axially at one end and exits the blower axially at the other end.

[0069] In another example, the blower may include an intake port and an exhaust port located tangentially to the intake port, both aligned axially.

[0070] The top and bottom covers (composed of, for example, plastic material) may be attached to each other by fasteners, for example, by a number of openings 126 provided along the flanged periphery of covers 122, 124 to allow fasteners to pass through. Furthermore, the top and bottom covers may form joints 128 (for example, tongue and groove configurations shown in Figures 3 and 4) along their periphery to facilitate alignment and connection. However, it should be noted that the covers may be attached to each other by other suitable methods, such as ultrasonic welding.

[0071] As shown in Figures 8 and 9, the bottom cover 124 includes a number of stator vanes or non-swirl vanes 129, for example, between about 2 and 50 stator vanes, or between about 15 and 30 or 5 and 15 stator vanes, for directing the airflow toward the exhaust port 125, also known as a flow straightener. In the illustrated example, the bottom cover has six stator vanes. Each vane is substantially identical and generally helical. In the illustrated example, the leading edge of each vane extends roughly tangentially to the flow, collecting the air leaving the impeller and directing it roughly tangentially and then roughly radially. In the illustrated example, the stator vanes support a bearing-housing structure 130 within the cover.

[0072] In some examples, one or more non-swivel vanes 129 may be configured as dual vanes that form a passage allowing motor wiring to be routed through the vanes to the PCB or driver. For example, Figures 33–35 show exemplary non-swivel vanes 129, each including spaced-apart side walls or dual vanes 129-1, 129-2 that form a space 129-3 between them. A cylindrical guide 129-4 is provided that allows motor wiring 203 (see, for example, Figure 35) to be routed through the vanes. Figure 33 shows an example of a dual-vane configuration compared to a single-vane configuration. Figure 34 shows an example including a dual-vane configuration in which three non-swivel vanes 129 form a passage for motor wiring. In other examples, a dual-vane structure may include only one or two non-swivel vanes for routing all of the motor wiring.

[0073] Figures 101 and 102 show another example of a non-swivel vane configuration for a bottom cover. In this example, the vanes include different thicknesses. For example, one vane 129.1 is relatively thick, while the remaining vanes 129.2 (for example, the remaining five vanes) are relatively thin compared to vane 129.1. However, it should be noted that this thickness configuration may have other suitable configurations, for example, the number of thick vanes and thin vanes may be the same, the number of thin vanes may be greater than the number of thick vanes, the number of thick vanes may be greater than the number of thin vanes, or all the vanes may have different thicknesses.

[0074] In some examples, as shown in Figures 28, 29, and 36-38, the blower may include a plurality of pre-swirling intake vanes 206 positioned above the intake port 123 and above or on the top cover 122 of the cover 120. The plurality of intake vanes 206, for example between about 2 and 50, or about 15-30, or about 5-15, for example, 5, 6, 7, 8, 9, 10, or 11 vanes, are configured to direct the airflow toward the intake port 123. Each intake vane 206 is substantially identical and has a curved shape (see, for example, Figure 37) to direct the airflow toward the intake port 123. The intake vanes are configured to pre-swirle the incoming air to promote the reduction of impact losses at the leading edges of the impeller blades. The intake vanes can also help reduce noise radiated from the intake port 123. Furthermore, the intake vanes can help improve the efficiency of the blower. In one example, the pre-swirl vanes are bonded to the outer surface of the top cover 122. The pre-swirl vanes may be integrally molded to the top cover 122 or attached via gluing, ultrasonic welding, snap fitting, adhesive, or some other fastening means. Figures 103 and 104 show an example of pre-swirl vanes 206 integrally molded to or otherwise attached to the top cover 122.

[0075] As shown in Figures 28, 29, and 36-38, the pre-swirl vanes 206 are covered by a pre-swirl cover 205 configured to cover the pre-swirl vanes and form multiple channels that direct the airflow toward the intake port 123. The pre-swirl cover is bonded to the top edge of the pre-swirl vanes on the top cover 122 of the cover 120 by, for example, heat scribing, ultrasonic welding, gluing, bonding, or other such fastening means. Figures 105-107 show the top cover 122 and the vanes 206 of Figures 103 and 104 with the pre-swirl cover 205 bonded to the vanes. The pre-swirl cover may be made of plastic material, metal, aluminum, or other suitable material; for example, the pre-swirl cover may be molded from plastic material or formed by metal injection molding. The pre-swirl cover may be molded from or overmolded from a low indentation hardness material such as silicone or urethane to achieve a wetting function. In an alternative example, the pre-swivel vane 206 may be integrally molded with the pre-swivel cover 205, and the top cover 122 is coupled to the bottom edge of the pre-swivel vane 206. Figure 38 also shows a bumper or fastener 205-1 on the pre-swivel cover 205 as described above with respect to Figure 29.

[0076] Air intake cap In one example, an intake cap may be provided at the intake port to reduce noise. The intake cap may be formed integrally with the top cover. Alternatively, the intake cap may be formed separately from the top cover and attached to the intake port of the top cover or otherwise provided. In one example, the intake cap may be configured to support or otherwise hold a filter for filtering the incoming air.

[0077] For example, FIGS. 116 to 119 show a blower 300 including an intake port cap 310 provided at an intake port 323 of a top cover 322 according to an example of the present technique. The remaining components of the blower are the same as those shown in FIGS. 109 to 110 and will be described in more detail below. For example, the blower includes a bearing-housing structure 330 configured to support a bearing cartridge 390 that rotatably supports a rotor 370.

[0078] As shown in the drawings, the intake port cap 310 includes a generally disk-shaped inner portion 312, a generally ring-shaped outer portion 314, and radially extending spokes or connectors 316 that interconnect the inner portion 312 and the outer portion 314. The outer portion 314 of the intake port cap 310 engages an annular side wall 322(1) of the top cover 322 that forms the intake port 323, and supports the intake port cap 310 at the location of the intake port 323. The outer portion 314 projects from the side wall 322(1) to fix the intake port cap in a predetermined position and aligns the intake port cap with the axis of the intake port. In one example, the intake port cap may be engaged with the side wall by press fitting or friction fitting, but it should be understood that the intake port cap may be fixed to the side wall by other suitable methods, such as adhesion, mechanical connection (e.g., snap fitting), ultrasonic welding, etc.

[0079] In use, the inner portion 312 is positioned to close or block the central portion of the intake port 323, and gas is supplied and drawn into the housing through an annular gap 315 defined between the outer edge of the inner portion 312 and the inner edge of the outer portion 314. In one example, the cross-sectional area formed by the gap 315 (i.e., the intake port area) is greater than about 150 mm 2 more, for example about 150 mm 2 ~300 mm 2 、175 mm 2 ~225 mm 2 、200 mm 2 ~250 mm 2 、250 mm 2 ~300 mm 2Such a configuration reduces noise, for example, by reducing the noise radiated from the air intake, narrowing the effective air intake area, or lowering the Helmholtz resonance frequency.

[0080] In the illustrated example, the inner portion 312 has a diameter smaller than the diameter of the rotor cap 360, for example, the diameter of the inner portion 312 is less than approximately 20 mm, for example, 18 mm. However, it should be noted that other examples of the inner portion may have a diameter similar to or larger than the diameter of the rotor cap.

[0081] In one example, as shown in Figure 124, the gap A between the rotor cap 360 and the inner portion 312 of the intake cap 310 is substantially the same as the gap A between the impeller 380 and the top cover 322, for example, the gap A is greater than 0.1 mm, for example greater than about 0.1 mm and up to 1.0 mm, between 0.3 mm and 0.5 mm or between 0.35 mm and 0.4 mm, or greater than 0.381 mm, greater than about 0.381 mm and up to 1.0 mm. Furthermore, in one example, as shown in Figure 124, the thickness B of the inner portion 312 of the intake cap 310 is substantially the same as the thickness B of the top cover 322.

[0082] In the illustrated example, the intake cap includes three spokes or connectors 316, but please note that the number of spokes may be more or less than this, for example, two, four, five, six, or more. Furthermore, please note that the spokes or connectors may include other configurations and may be configured in other suitable ways to connect the inner portion 312 and the outer portion 314 to each other.

[0083] For example, Figures 120 to 123 show an air intake cap according to an alternative example of this technique. In Figure 120, the air intake cap 410 extends radially and includes more connectors 416 than the air intake cap 310 described above, for example, 17 connectors, which connect the inner portion 412 and the outer portion 414 to each other. However, please note that the number of connectors may be more or less than that.

[0084] In Figure 121, the intake cap 510 includes a plurality of connectors 516, for example, 10 connectors, that extend tangentially from the inner portion 512 and connect the inner portion 512 to the outer portion 514. Furthermore, the connectors may be positioned diagonally or inclined toward the horizontal to improve noise reduction, for example.

[0085] In Figure 122, the connector 616 between the inner portion 612 and the outer portion 614 of the intake cap 610, for example, seven connectors, includes an overall curved configuration.

[0086] In Figure 123, the connector 716 between the inner portion 712 and the outer portion 714 of the intake cap 710, for example, 15 connectors, are cylindrical in shape.

[0087] The number of connectors 416, 516, 616, and 716 may be changed, and the above numbers are merely examples. Therefore, please understand that the number of available connectors 416, 516, 616, and 716 may be more or less than this, such as 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, or more.

[0088] Bearing-housing structure In one example, the blower does not require, nor does it use, ball bearings to rotatably support the rotor. Instead, a bearing-housing structure 130 rotatably supports the rotor 170 together with the rotor cap 160 and holds the stator assembly 145 of the motor 140. The bearing-housing structure 130 may include a shielding disc between the impeller blades and the stator vanes. The bearing-housing structure 130 is composed of a lubricating material such as sintered bronze, industrial plastic material, polyamide-imide resin such as Torlon®, and / or other very low-friction material, or a combination of materials including a lubricating material or a material with a very low coefficient of friction. For example, a first material such as aluminum, steel, brass, bronze, or other metal or plastic may be coated with a lubricating material or a material with a very low coefficient of friction such as a ceramic-based or nickel-based coating material. In one example, the coating may be applied only to critical wear surfaces of the bearing-housing, such as the shaft bearing surface. Alternatively, or in addition to that, a material that reduces friction may be applied to the shaft.

[0089] As shown in Figures 10 and 11, the bearing-housing structure 130 includes a base 132, an annular flange or disc 134 extending from the base, and a rotor shaft or bearing shaft 136 that rotatably supports the rotor 170. The bearing shaft 136 includes a radial or sleeve bearing portion 136(1) and a thrust bearing portion 136(2). The thrust bearing portion 136(2) is located on the top surface of the bearing-housing structure 130 surrounding the rotor 170 and adjacent to the rotor cap 160. The thrust bearing portion 136(2) forms a thrust surface that allows the rotor cap to rotate. The radial bearing portion 136(1) is configured as a sleeve bearing along the surface of the rotor and forms a radial surface along the rotor to facilitate the rotation of the rotor 170. The rotor may be polished to provide a desired surface finish to the rotor cap thrust surface. Surface finishing may be performed using one or more techniques including grinding, diamond polishing, lapping, and polishing, and / or chemical barrel polishing or any other surface creation technique. Surface finishing may be performed by microfinishing between 3 microinches RMS and 40 microinches RMS, for example, 3 microinches RMS to 32 microinches RMS, or for example, 8 microinches RMS to 16 microinches RMS. In some examples, extremely high polishing may not be required as a surface finish, because extremely high polishing can introduce some friction. Alternatively, instead of polishing the surface, a lubricating material or a material with a very low coefficient of friction may be applied to the surface as described above. The bearing shaft forms a single bearing that incorporates both radial and thrust bearing characteristics, thereby helping to reduce the height of the blower. A thrust load may be applied to the thrust bearing portion 136(2) of the bearing-housing structure 130. The thrust load is applied to the top surface or thrust bearing surface 136(2) of the bearing shaft by the rotor cap 160 during use. Since there is only one bearing, the motor only needs to be balanced in one plane, and does not need to be balanced in two planes.

[0090] The disc 134 of the bearing-housing structure supports the rotor. The outer edge 134(1) of the disc 134 is substantially aligned with the outer edge of the impeller 180 or extends radially beyond the outer edge, obstructing the line of sight between the impeller blades and the tips of the non-swirl vanes 129. The outer edge 134(1) of the disc 134 provides a shielding function to prevent noise from being generated from the non-swirl vanes of the bottom cover 124 through the blades when the impeller rotates during use. The disc 134 forms a narrow annular gap 135 between the outer edge of the disc 134 and the side wall of the cover 120, for example, about 0.75 mm wide, allowing sufficient gas to flow toward the exhaust port without significantly impairing pressure and motor efficiency. In some examples, this gap may be between 0.4 mm and 100 mm, for example between 0.4 mm and 2 mm, or it may be 0.5 mm, 0.75 mm, 1 mm, or 1.5 mm. Furthermore, the disk may include one or more openings for guiding motor wiring to the outside of the air passage; see Figures 28, 29, and 35, which show, for example, motor wiring 203 routed through opening 144 of disk 134.

[0091] In one example, the bearing-housing structure 130 may be assembled from a separate disc component 134 and a separate bearing component 136, and may have a split configuration further including, for example, a base 132. In this split configuration, the disc component 134 and the bearing components 132,136 may be made of different materials. For example, the bearing components 132,136 may be made of a lubricating material as described above, and the disc component 134 may be made of plastic, polycarbonate, or a similar material. The separate disc component 134 may be coupled to the bearing components 132,136 using a series of different coupling systems. The coupling system between the disc component 134 and the bearing components 132, 136 may include one or more of the following systems: a system in which one component is overmolded onto the other component, for example, the disc component 134 being overmolded onto the base 132 or the base 132 being overmolded onto the disc component 134; a system using a snap-fit ​​or clip configuration; a system using a crimp-fit ​​configuration; a system using a screw or push-in connection; a system using an elastomer component coupled between the disc component 134 and the base 132 so that the disc component does not need to be directly fixed to the base 132 and an elastomer component, such as TPE, can be overmolded onto the end of the disc component, the base 132, or both; or any other coupling system. One or more elastomer components or complaint components, such as a TPE overmolded or O-ring, may be included between the disc component 134 and the base 132 in any of the coupling systems above to reduce vibration transmission.

[0092] For example, Figure 39 shows an example of separate disc components 134 coupled to separate cylindrical bearing components 136, which are, for example, overmolded with each other. In Figure 40, for example, to enhance the connection between the components, the base 132 of the separate bearing component 136 is connected to a groove provided in the separate disc component 134. In Figures 41 and 42, an O-ring 138 is provided between the separate disc component 134 and the separate bearing components 132, 136, for example, to minimize the transmission of vibrations. Furthermore, one or more O-rings 139 may be provided between the bearing components 132, 136 and the bottom cover 124 to further minimize the transmission of vibrations. Figure 45 shows separate bearing components 132, 136 with an elastomer 137 overmolded along the edge of the base 132. The separate disc component 134 (for example, made of plastic) may be ultrasonically welded or heat-crimped to the vanes 129 of the bottom cover 124.

[0093] In such a split configuration example, the multiple stator vanes or non-swivel vanes 129 located below the disk component 134 may be arranged on the disk component or the bottom cover 124 as described above, or some stator vanes 129 may be arranged on the disk component 134 and some stator vanes 129 may be arranged on the bottom cover 124 to form a complete set of stator vanes 129, so as to be arranged on both the disk component and the bottom cover 124. The stator vanes 129 may be formed or molded integrally with the disk component 134 and / or the bottom cover 124. For example, Figure 43 shows a separate disk component 134 with stator vanes 129 integrally formed or molded and separate bearing components 132,136 with stator vanes 129 overmolded. The bottom cover 124 supports the ends of the vanes, for example, the ends of the vanes molded into the bottom cover.

[0094] Such a split configuration allows motor wiring or stator wiring to be routed from the blower assembly between the disk 134 and the base 132. See, for example, Figure 43, which shows motor wiring 203 routed from between the disk component 134 and the bearing components 132, 136 through the exit of the bottom cover 124. The motor wiring may be routed through the exit in the bottom cover and attached to the PCB assembly or driver. See, for example, Figure 44, which shows motor wiring 203 routed through the bottom cover 124 to the PCB assembly or driver 207. The motor wiring may also be routed through at least some stator vanes 129 as described above. In some examples, the PCB assembly or driver may be attached to the bottom cover outside the air passage. See, for example, Figure 44, which shows the PCB assembly or driver 207 attached outside the bottom cover 124 outside the air passage.

[0095] In another example, disk 134 may be a separate component acting as a shield as described in U.S. Patent No. 7,866,944, titled "Compact low noise efficient blower for CPAP devices," which is incorporated herein by reference in its entirety.

[0096] The bearing-housing structure may be coupled to the bottom cover 124 to facilitate the assembly of the blower. The bearing-housing structure 130 may be coupled to the bottom cover 124 in two or more positions, such as three to six or more positions. At least some stator vanes 129 on the bottom cover may be coupled to the disk 134 of the bearing-housing structure 130. However, if the stator vanes are located on the disk 134, at least some stator vanes 129 may be coupled to the bottom cover. The stator vanes 129 may be coupled to the disk 134 and / or the bottom cover by any means including one or more of the methods described below, a combination thereof, or any other coupling method.

[0097] In some examples, at least some of the stator vanes 129 may be adhesively bonded to the disk 134 and / or bottom cover 124 by means of glue or double-sided tape, for example. For example, Figure 46 shows a disk 134 bonded to the stator vanes 129 by double-sided tape 208. Figure 47 shows an example where the stator vanes 129 of the bottom cover 124 are overmolded TPE or rigid plastic that can be adhesively bonded to the disk 134. In other examples, the stator vanes 129 may be bonded to the disk 134 and / or bottom cover 124 by heat riveting or ultrasonic welding. For example, Figure 29 shows a heat-riveted bearing-housing structure 130 on the bottom cover 124. In such examples, the vanes 129 are overmolded with elastomer 129-5 to minimize vibration, for example. In other examples, the stator vanes 129 may be coupled to the disk 134 and / or bottom cover 124 using a press-fit configuration in which projections on the edge of the stator vanes are received into an auxiliary opening in the disk 134 or bottom cover 124, or the reverse press-fit configuration in which projections are on the disk 134 and / or bottom cover 124 and the auxiliary opening is on the stator vanes 129. In further examples, the stator vanes 129 may be coupled to the disk 134 and / or bottom cover 124 using snap-fit, press-fit, clip, or boss configurations.

[0098] The top or bottom edges of the stator vanes 129 may include elastomer material to minimize the transmission of vibrations from the bearing-housing structure 130 to the bottom cover 124. The elastomer material can be overmolded, attached with adhesive, or inserted into the edges of the stator vanes 129. Elastomer material, such as an O-ring, may be held between the stator vanes 129 and the disk 134 and / or bottom cover, which are coupled by coupling means. For example, Figure 48 shows an O-ring or TPE overmolded 139 positioned between the bearing-housing structure 130 and the bottom cover 124 to insulate vibrations. The bearing-housing structure may be heat-crimped onto the bottom cover to hold the O-ring in place.

[0099] In some examples, in addition to or instead of the above, the bearing-housing structure 130 may be coupled directly to the bottom cover 124, i.e., without the stator vanes 129. In examples such as those shown in Figures 49 and 50, the bearing-housing structure 130 may include a boss 130-1 that engages with a retaining clip 209 at the bottom cover 124. As best shown in Figures 50 to 52, the retaining clip 209 may include a plurality of toothed projections 209-1 that grip or bite into and hold the boss 130-1. The toothed projections may be inclined to facilitate insertion of the boss in one direction but prevent or restrict the boss from disengaging in the opposite direction. The retaining clip may be a separate component that is inserted into the bottom cover to couple the bottom cover 124 and the bearing-housing structure 130. Alternatively, the boss may be located on the bottom cover 124 and the retaining clip on the bearing-housing structure 130.

[0100] In an alternative configuration, as shown in Figure 53, the boss 130-1 may be integrated with the bearing-housing structure 130 and press-fitted into the bottom cover 124 until at least a portion of some of the stator vanes 129 contact the disc 134 of the bearing-housing structure 130. The bearing-housing structure may be secured to the bottom cover by fasteners 210 such as Tinnerman clips, pal nuts, speed nuts, push nuts, or other fasteners. Figure 54 shows another example of the bearing-housing structure 130 secured to the bottom cover 124 by fasteners 210, such as Tinnerman clips. In this example, the bearing bore or through-hole 133 of the bearing-housing structure in the area of ​​the bottom cover (i.e., the lower part of the bore 133) is slightly larger in diameter compared to the area of ​​the bearing sleeve or rotor support (i.e., the upper part of the bore 133 supporting the rotor 170), which minimizes compressive shrinkage due to the press-fitting of fasteners, such as Tinnerman clips.

[0101] In one example, the boss of the bearing-housing structure 130 includes a projection containing one or more lips configured to engage with a fastener at the bottom cover 124. The fastener may have one or more mating grooves that receive the lips in a snap-fit ​​configuration. Alternatively, the projection may be located on the bottom cover 124 and the fastener on the bearing-housing structure 130. Other fasteners that may be used include Tinnerman clips, pal nuts, speed nuts, push nuts, and other fasteners.

[0102] In other examples, the base 132 of the bearing-housing structure 130 may be directly coupled to the bottom cover 124 via a snap mechanism that snaps into a groove. The snap mechanism may be located on the bottom cover 124 and the groove on the bearing-housing structure 130, or conversely, the snap mechanism may be located on the bearing-housing structure 130 and the groove on the bottom cover 124.

[0103] For example, Figure 55 shows a bottom cover 124 that includes a snap mechanism 211 configured to snap into a groove provided on the bearing-housing structure 130 for attaching the bearing-housing structure to the bottom cover. Figures 56 to 65 show alternative examples of the snap mechanism 211 for attaching the bottom cover 124 to the bearing-housing structure 130.

[0104] In one example, as shown in Figure 66, the bottom cover 124 may be coupled to the bearing-housing structure 130 using a screw configuration. A central screw 212 may be inserted through a portion of the bottom cover 124 via a vent 125 into a threaded anchor 213 provided on the bearing-housing structure 130 (for example, the anchor may be integrally molded or the anchor may have a bore). The screw 212 may also be inserted into an anchor portion 124-1 of the bottom cover 124, which further includes at least one arm 124-2 that extends upward toward the disk 134 of the bearing-housing structure 130 to provide support. At least one arm 124-2 may be coupled to the disk 134 and configured, for example, to interlock. This facilitates wetting the bottom cover by clamping. In some cases, the screw may be sealed after assembly to prevent it from coming loose, being removed, or being tampered with. The screw can help seal the bottom of the bearing spindle, preventing airflow from passing through and preventing the bearing grease or lubricant from drying out. The bearing grease or lubricant may be added to the bearing spindle before the screw is installed. Figure 67 shows another example of a bottom cover 124 coupled to the bearing-housing structure 130 by a central screw 212.

[0105] In some examples, the thread configuration may be integrated with the bottom cover 124 and / or the bearing-housing structure 130. For example, as shown in Figure 68, the bearing-housing structure 130 may be configured to have a threaded portion 212-1 (e.g., a male threaded portion) at the end of the bearing shaft 136 that is received in a corresponding threaded receiving portion 212-2 (e.g., a female threaded portion) of the bottom cover 124. Alternatively, the male threaded portion may be located on the bottom cover 124 and the female threaded portion on the bearing-housing structure 130. The threaded portions can be used to fasten the bearing-housing structure and the bottom cover together.

[0106] Bearing grease or lubricant is used to help stabilize the rotor assembly within the bearing-housing structure. Therefore, means for retaining the lubricant may be incorporated into the motor assembly. As shown in Figure 69, a lubricant reservoir 215 designed to supply lubricant to the thrust bearing surface 136(2) may be built into the bearing shaft 136 of the bearing-housing structure 130. The supplied lubricant may be delivered to the reservoir 215 through an opening 216 through the bearing-housing structure. The bearing shaft 136 may include one or more concave channels 217 (see, for example, Figure 70) along the thrust bearing surface 136(2) to concentrate pressure points at the top and / or bottom of the bearing shaft 136, for example, 3 to 10 channels, 4 to 8 channels, 4 to 6 channels, 4 channels, 5 channels, or 6 channels, etc. The concave channels help retain the lubricant on the rotating surface.

[0107] Figures 71 to 74 show an example of a bearing-housing structure 130 that includes a lubricating oil tank 215 within a bearing shaft 136. In one example, as shown in Figure 73, the lubricating oil tank 215 is positioned substantially in the center of the bearing shaft 136, and its depths, for example, d1 and d2 may be approximately 1.5 mm to 3.0 mm, for example, approximately 2.25 mm. In one example, as shown in Figure 73, the depth of the tank d3 may be approximately 0.05 mm to 0.1 mm, for example, approximately 0.08 mm, or approximately 0.003 inches.

[0108] Figures 75–79 show an example of a bearing-housing structure 130 that includes one or more concave channels 217 (also called lands) along the thrust bearing surface 136(2) of the bearing shaft 136 to help retain lubricating oil on the rotating surface. In one example, as shown in Figures 77 and 78, the length d1 of each channel is approximately 0.5 mm to 1.0 mm, for example 0.8 mm; the width d2 of each channel is approximately 0.2 mm to 0.6 mm, for example 0.4 mm; the radius of curvature d3 is approximately 0.2 mm; the depth d4 is approximately 0.01 mm to 0.05 mm, for example 0.025 mm (approximately 0.001 inches); and the radius of curvature d5 is approximately 0.0155 inches. However, it should be noted that other suitable dimensions for the channels are possible. For example, the dimensions may be chosen to adjust the hydrodynamic pressure realized by the flow channels, for instance, Figure 80 shows flow channels 217 with each width approximately 0.016 inches, and Figure 81 shows flow channels 217 with each width less than approximately 0.011 inches.

[0109] Figures 82 and 83 schematically show the hydrodynamic pressure concentration (roughly indicated by dashed lines) that occurs between the bearing shaft 136 and the rotor cap 160 due to the flow path 217 during use.

[0110] Figures 84 to 89 show an example of a bearing-housing structure 130 that includes an annular concave channel 217 along the thrust bearing surface 136(2) of the bearing shaft 136 to help retain lubricating oil on the rotating surface. In one example, as shown in Figure 88, the channel depth d1 is approximately 0.01 mm to 0.04 mm, for example 0.025 mm, the radius of curvature d2 is approximately 0.3 mm to 0.5 mm, for example 0.4 mm, d3 is approximately 1.5 mm to 2 mm, for example 1.9 mm, and d4 is approximately 0.25 mm to 0.5 mm, for example 0.4 mm.

[0111] The bearing shaft or sleeve is preferably a three-lobe configuration rather than a circular configuration. For example, Figure 90 shows an example of a bearing shaft with a three-lobe configuration for a rotor 170 in use. Each "lobe" increases the hydrodynamic or hydraulic pressure. In one example, the depth d1 of each leaf is approximately 0.0001 inches to 0.0005 inches.

[0112] In one example, as shown in Figure 91, a retaining ring 218, such as an acorn-shaped grooveless retaining ring, may be attached to the bottom of the bearing shaft 136 to help retain lubricating oil around the bearing-housing structure 130.

[0113] In one example, as shown in Figure 92, the bearing-housing structure 130 may be closed at one end, such as the lower end 130.1 of the radial bearing section 136(1), in order to retain lubricating oil within the bearing shaft.

[0114] The grease or lubricant may include Kyoto Ushi Multem or other such lubricants. Alternatively, the bearing may be a dry bearing, i.e., the bearing-housing components and / or rotating components may be formed in part with or coated with a low friction material, such as a low coefficient of friction material that imparts lubricity and eliminates the need for grease or lubricant, for example, a ceramic-based coating, a nickel-based coating, Teflon®, or graphite.

[0115] Bearing cartridge In an alternative example, as shown in Figures 109-110 and 125-127, the bearing shaft of the bearing-housing structure may be replaced with a bearing cartridge 390 including bearings 394, 395 that rotatably support the rotor 370.

[0116] As shown in the figure, the bearing cartridge 390 includes a tubular sleeve or cartridge 392, two bearings 394, 395 spaced apart from each other and supported within the sleeve 392, and a spacer 396 between the bearings for applying a preload (for example, the direction of the preload is indicated by arrows a1 and a2 in Figure 112) (the spacer 396 is optional). Each bearing 394, 395 includes an outer race engaged with the inner surface of the sleeve 392 and an inner race engaged with the rotor 370 and bonded, for example, using adhesive. Figure 112 shows only the bearing cartridge 390.

[0117] In this example, the bearing-housing structure 330 (for example, injection-molded from a plastic material) includes a housing portion comprising a base 332 and an annular flange or disc 334 extending from the base 332. The base 332 forms a tubular portion 333 that supports the end of the bearing cartridge 390, and the outer surface of the sleeve 392 of the bearing cartridge 390 is bonded to the tubular portion 333, for example, using an adhesive. Furthermore, a stator component 345 is provided along the outer surface of the sleeve 392 (for example, bonded using an adhesive).

[0118] In Figures 109 and 110, the tube portion 333 has an opening at its end, and a flange 333(1) is formed along the opening to form a resting surface within the tube portion 333 for supporting the bearing cartridge 390. In one example, such an opening at the bottom of the tube portion may be covered or sealed. In an alternative example, as shown in Figure 111, the bottom of the tube portion 333 may be closed by an integral bottom wall 333(2) to form a resting surface for supporting the bearing cartridge 390 within the tube portion 333.

[0119] In this example, as shown in Figures 109, 126, and 127, the stator vanes 329 of the bearing-housing structure 330 form tabs 329(1) that engage (for example, by snap-fitting, heat-crimping) with each opening 324(1) of the bottom cover 324 to hold and align the bearing-housing structure 330 with the bottom cover 324. The top cover 322 may be fixed to the bottom cover 324 by, for example, adhesive, ultrasonic welding, or other known methods.

[0120] As described above, the rotor cap 160 (supporting the magnet 150 and impeller 180) is provided on the end 370(2) of the rotor 370. In one example, the magnet may be centered on the stator assembly to transfer magnetic preload or thrust from the rotor cap to the bearing cartridge.

[0121] In one example, the rotor cap 160 may be attached to the rotor 370 (for example, by press-fitting) in a first assembly step, and then the rotor 370 (with the rotor cap attached) may be attached to the bearing cartridge 390 in a second assembly step. Such an assembly reduces damage to the bearings of the bearing cartridge.

[0122] In an alternative example, the bearing cartridge may include a single bearing that works in cooperation with another bearing supported within the housing to rotatably support the rotor.

[0123] In another alternative, an air bearing configuration may be provided to support the rotor.

[0124] Tangential exhaust port In one example, the blower may include an intake port and an exhaust port located tangentially to the intake port or tangentially to the direction of rotation of the impeller, both aligned axially.

[0125] For example, Figures 128 to 131 show a blower 800 that includes a top cover 822 forming an intake port 823 and a bottom cover 824 forming an exhaust port 825 located tangentially to the intake port 823. Similar to the example described above, this blower includes a bearing-housing structure 830 configured to support a bearing cartridge 890 which is rotatably supported by a rotor 870. A rotor cap 860 (supporting a magnet 850 and an impeller 880) is provided at the end of the rotor 870.

[0126] In this example, the bearing-housing structure 830 includes an annular side wall 835 extending downward from the end of the disk 834. The free end of the side wall 835 forms a tab 835(1) which is to engage (for example by snap-fit, heat riveting, or ultrasonic welding) into each opening of the bottom cover 824 in order to hold and align the bearing-housing structure 830 with the bottom cover 824.

[0127] The side wall 835, together with the covers 822,824, defines a vortex chamber 837 for directing air toward the exhaust port 825. In this example, the vortex chamber 837 expands in cross-sectional area toward the exhaust port and generates pressure via static pressure reacquisition. The side wall 835 and bottom cover 824 form an open space 839 from the airflow path for electronic components such as PCBs or drivers.

[0128] Figures 132–138 show another example of a blower that includes an exhaust port located tangentially to the intake port. In this example, the blower 900 includes a bearing-housing structure that is incorporated into the blower housing 920 or otherwise provided.

[0129] As shown in the figure, the blower housing 920 includes a top cover 922 that forms an air intake port 923 and a bottom cover 924 that cooperates with the top cover 922 to form an exhaust port 925 located tangentially to the air intake port 923.

[0130] The bottom cover 924 is also configured to support the bearing cartridge 990 and define a vortex chamber 937 for directing air toward the exhaust port 925. Specifically, the bottom cover 924 includes a base 932 that forms a tubular portion 933 supporting the bearing cartridge 990, and an annular flange or disc 934 that curves upward and then extends radially outward from the base 932. An annular side wall 935 extends downward from the edge of the disc 934 to define the vortex chamber 937. A rotor cap 960 (supporting the magnet 950 and impeller 980) is provided at the end of the rotor 970, which is rotatably supported by the bearing cartridge 990.

[0131] In this example, the vortex chamber 937 expands in cross-sectional area toward the exhaust port, generating pressure through static pressure reacquisition. See, for example, Figure 136. In the illustrated example, the vortex chamber includes a generally semicircular cross-sectional configuration. See, for example, Figures 137 and 138. However, other suitable vortex chamber shapes are also possible.

[0132] Figures 139 to 142 show another example of a blower including an exhaust port located tangentially to the intake port. The blower 1000 includes a housing 1020 having a top cover 1022 and a bottom cover 1024. The top cover 1022 forms an intake port 1023 and also forms an exhaust port 1025 located tangentially to the intake port 1023. In this example, the intake port 1023 is provided with a chimney-like tube section or an intake port tube section 1027.

[0133] A bearing-housing structure or fixed component 1030 is provided on the housing 1020, and the bearing-housing structure or fixed component 1030 is configured to support the bearing cartridge 1090 and define a vortex chamber 1039 for directing the air toward the exhaust port 1025.

[0134] The bearing-housing structure 1030 includes a tubular portion 1033 that supports the bearing cartridge 1090, outward and upward-extending wall portions 1035, 1036 that form recesses for receiving motor components, an annular flange or disc 1034, and downward and outward-extending ends 1037 extending from the disc.

[0135] The tube portion 1033 supports the end of the bearing cartridge 1090, and for example, the outer surface of the sleeve 1092 of the bearing cartridge 1090 is bonded to the tube portion 1033 using, for example, an adhesive. Furthermore, a stator component 1045 is provided along the outer surface of the sleeve 1092 (for example, bonded using an adhesive).

[0136] The rotor cap 1060 (supporting the magnet 1050 and impeller 1080) is located at the end of the rotor 1070, which is rotatably supported within the bearing cartridge 1090 by bearings 1094, 1095. In this example, the magnet 1050 is provided along the inner surface of the rotor cap 1060, and a peg or pin 1061 for holding the impeller 1080 is provided on the upper wall of the rotor cap. In the illustrated example, the peg 1061 forms a diameter (e.g., 3mm to 5mm, e.g., 4mm) larger than the diameter of the rotor 1070 (e.g., 1mm to 3mm, e.g., 2mm). The recesses formed by the outer and upward-extending walls 1035, 1036 of the bearing-housing structure 1030 allow the rotor cap, magnet, and at least some of the stator components to be nested within the bearing-housing structure, forming a low-profile blower.

[0137] The top cover 1022, in cooperation with the bearing-housing structure 1030, defines a vortex chamber 1039 that directs the air toward the exhaust port 1025. As shown in the figure, the top cover 1022 includes a cylindrical separation wall or baffle plate 1022(1), which, together with the stepped configuration of the end 1037, separates the vortex chamber 1039 into two regions, namely a high-speed airflow region 1070(1) and a low-speed airflow region 1070(2), to minimize, for example, pressure pulsation and / or acoustic noise.

[0138] For example, a seal (e.g., made of silicone rubber or other suitable material) may be formed between the bearing-housing structure 1030 and the top cover 1022 and bottom cover 1024 to form a seal along the spiral chamber, support the PCB, and / or form a wiring grommet for guiding the PCB wiring.

[0139] Further details and examples of aspects of blower 1000, such as high-speed airflow region and low-speed airflow region, are disclosed in PCT Publication WO2011 / 062633, which is incorporated herein in its entirety by reference.

[0140] Figure 148 shows another blower example similar to the blower examples shown in Figures 139-142. Compared to the blower examples shown in Figures 139-142, the bottom cover 1024 of blower 1000 forms a tubular section 1024(1) that supports the end of the bearing cartridge 1090. In this example, the bearing-housing structure 1030 includes a central opening that allows at least a portion of the rotor cap 1060, magnet 1050, and stator components 1045 to be nested within the bearing-housing structure. Figures 149 and 150 show such a blower 1000 mounted within a casing 1012 of a PAP device 1015 according to an example of this technique. As shown, the intake port 1013 and exhaust port 1014 are located at both ends of the casing.

[0141] Figures 143–147 and 151 show alternative blower examples including an exhaust port located tangentially to the intake port. In Figure 143, the impeller 1180 is supported along the upper wall of the rotor cap 1160. The rotor cap 1160 (which also supports the magnet 1150) is mounted on a rotor 1170, which is rotatably supported by a bearing cartridge 1190. In this example, the housing 1120 includes a tubular section 1133 that supports the bearing cartridge 1190. Stator components 1145 are provided along the outer surface of the bearing cartridge 1190. A stator component 1130 is provided within the housing 1120 to form a disk 1134 (for example, to prevent noise from passing through the blades) and to form a vortex chamber that directs the air toward the exhaust port 1125.

[0142] In Figure 144, the bearing-housing structure 1230 is integrated with the motor's stator component 1245, for example, by overmolding, to form a single integrated structure. The bearing-housing structure 1230 forms a tubular section 1233 that supports the bearing 1295, which rotatably supports the rotor 1270. The rotor cap 1260 is located at one end of the rotor 1270 and supports the magnet 1250 in an operable position relative to the stator component 1245, which is integrated with the bearing-housing structure 1230. The impeller 1280 is located at the opposite end of the rotor 1270.

[0143] In Figure 145, the bottom cover 1324 of the housing is configured to define a vortex chamber 1339 for directing air toward the exhaust port 1325. The bottom cover 1324 also supports the bearing-housing structure 1330, which includes a tubular section 1333 that supports the bearing cartridge 1390 and the disk 1334. The stator component 1345 is provided along the outer surface of the bearing cartridge 1390. The rotor cap 1360 (which supports the magnet 1350) is provided at one end of the rotor 1370, and the impeller 1380 is provided at the opposite end of the rotor 1370.

[0144] Figures 146 and 147 show alternative examples of the bearing-housing structure 1430, which includes one or more walls defining a vortex chamber 1439 for directing air toward the exhaust port 1425. Similar to the example described above, the impeller 1480 is mounted along the upper wall of the rotor cap 1460, and at least some of the motor components (e.g., rotor cap, magnets, and stator components) are nested within the bearing-housing structure.

[0145] In Figure 151, the housing 1520 forms a generally annular intake port 1523 and an exhaust port 1525 located tangentially to the intake port. The inner housing portion 1529 supports a bearing cartridge 1590 which rotatably supports the rotor 1570. The rotor cap 1560 (which supports the magnet 1550 and impeller 1580) is provided at the end of the rotor 1570. The stator components 1545 are provided along the outer surface of the bearing cartridge 1590. In one example, the gap A between the impeller 1580 and the upper part of the housing 1520 and the gap A between the impeller 1580 / rotor cap 1560 and the lower part of the housing 1520 are approximately 0.75 mm to 1.0 mm.

[0146] Impeller In the illustrated example, as shown in Figures 14 and 15, the impeller 180 (also called a double-shrouded impeller or alternating-shrouded impeller) includes a plurality of continuously curved or straight blades 182 sandwiched between a pair of disc-shaped shrouds 184, 186. As shown, the blades curve toward a hub having an S-shape. This shape is designed to reduce vortex escape. Furthermore, the shrouds do not have to completely cover the top and bottom surfaces of the blades. The lower shroud 186 incorporates a hub 185 which is configured to receive a rotor cup 160, for example, by press-fitting. Furthermore, the impeller includes a tapered configuration in which the blades taper toward the outer edge. In one example, the impeller may be made of a plastic material, such as Lexan®. Further details of the impeller are disclosed in WO2007 / 048206A1, which is incorporated herein by reference in whole.

[0147] In one example, the impeller blade 182 may be curved in a generally clockwise direction. In an alternative example, the impeller blade 182 may be curved in a generally counterclockwise direction.

[0148] In an alternative example, as shown in Figures 93 and 94, a bottom-shrouded impeller (i.e., the bottom surface of the blade 182 covered by a lower shroud 186) may be used to help prevent the impeller from lifting off the shaft or rotor during use. Figure 93 shows an example of the S-shape of the blade 182. This slight S-shape at the starting position of each blade is a result of the blade being attached to the hub and not obstructing the inflow.

[0149] As shown in Figures 95 and 96, the leading edge 182(1) of the impeller blade 182 may have a recessed configuration in which the leading edge of the impeller blade is inclined or beveled inward in the opposite direction to the flow. This configuration creates a longer blade length that generates higher pressure, reduces drag at the leading edge of the impeller, and / or creates a vapor-like vortex in the flow path that can delay flow separation, thus reducing drag and flow oscillation and increasing efficiency. In one example, the blade height at the leading edge may increase along the length of the blade to a point about one-quarter of the vane length at an angle of about 10° to 50°, for example, at an angle of 20°.

[0150] Alternatively, as shown in Figures 97 and 98, the impeller blade 182 may have a tip edge 182(1) perpendicular to the flow direction, similar to conventional impellers. Please note that the angles of the blades and vanes may be selected in relation to various conditions and / or performance optimization.

[0151] A rotor section may be incorporated into the impeller. The rotor section interacts with the magnet by acting as a path for magnetic flux and is configured to rotate the impeller through interaction with the stator. The rotor component of the impeller may be a single unit, or it may be formed as a cylindrical insert of magnetic steel within a non-ferrous structure of plastic or other non-magnetic material, which may also be the impeller itself. Such an insert may be attached by various methods, including overmolding, press-fit, or adhesive. An insert or ring of ferrous material holds the impeller on the stator during use. In one example, the impeller is not fixed to the stator, and the impeller 180 and rotor cap 160 are held between the magnet 150 (coupled to the inner surface of the rotor cap) and the stator assembly 145 by magnetic attraction.

[0152] Figures 113 to 115 show impellers according to alternative examples of this technique. In Figure 113, the impeller 480 includes a larger number of blades 482 than the example disclosed above, for example, 22 blades, to reduce noise by lowering the frequency of sound. However, it should be noted that the number of blades may be greater or less. Furthermore, each blade 482 includes a curved configuration, and is generally curved in a clockwise direction, for example, to reduce broadband and sound noise. However, as shown in Figure 114, the blades 482 of the impeller 480 may be curved in the opposite direction, i.e., generally counterclockwise. Figure 115 shows another example of an impeller 480 including 11 blades 482, each blade generally curved in a counterclockwise direction.

[0153] In Figures 113 and 114, every other blade includes a apex 482(1) that tapers towards the outer edge along the length of the blade. The remaining blades in Figures 113 and 114 include a apex 482(2) that gradually increases in height from the hub before tapering towards the outer edge. In Figure 115, all blades include a apex 482(1) that tapers towards the outer edge along the length of the blade. However, it should be understood that other blade configurations are possible.

[0154] Figure 113 shows the rotor cap 460, which is attached to the hub 485 of the impeller 480 by press-fitting, together with the rotor 470.

[0155] Exemplary dimensions For example, as shown in Figure 16, D1 is approximately 50-70 or more, and about 60-65 mm, for example, about 62.8 mm; D2 is approximately 8-13 mm or more, for example, about 10.4 mm; D3 is approximately 15-20 mm or more, for example, about 18.4 mm; D4 is approximately 15-25 mm or more, for example, about 23.2 mm; D5 is approximately 20-30 mm, for example, about 27 mm; and D6 is approximately 20-25 mm, for example, about 21 mm. Please understand that these dimensions and ranges are illustrative only, and other dimensions and ranges are possible depending on the application. For example, for certain applications, a range that varies by ±10% or more from the indicated range may be appropriate.

[0156] PAP system One example relates to a PAP system comprising a blower as described herein. In one example, the blower may be mounted on the patient's head (e.g., the top of the patient's head or the patient's forehead), the patient's arm, chest, or other body part, in or near a pillow, or within a scarf-like configuration, or incorporated into clothing, or mounted on a bed or bed head, etc. However, the blower described herein may also be utilized in a more conventional PAP delivery device, such as one that includes a housing or enclosure designed to be placed on the user's bedside table.

[0157] While this disclosure has been described in relation to a particular example, it should be understood that this disclosure is not limited to the disclosed example, but rather is intended to cover a variety of modifications and equivalent configurations. For example, while the blower has been described in relation to an axial blower, the blower may be configured as a tangential blower. Furthermore, while the blower has been described for use in a head-mounted PAP system, it may be used with more conventional PAP systems that include a separate flow generator not mounted on the user's head or body. Moreover, the various examples described herein may be implemented in relation to other examples, for example, by combining an aspect of one example with an aspect of another example to realize yet another example. Furthermore, each independent mechanism or component of any given assembly may constitute a further example. Furthermore, while this disclosure is particularly applicable to patients with OSA, it should be understood that the teachings of this disclosure may also be beneficial to patients with other diseases (e.g., congestive heart failure, diabetes, morbid obesity, stroke, bariatric surgery, etc., or their complications). Furthermore, the teachings of this disclosure can be applied equally to patients and non-patients in non-medical applications. [Explanation of Symbols]

[0158] 10 Head-mounted PAP system 20,100,300,800,900,1000 blower 30 Patient Interfaces 40 Exhaust Tube 50 Headgear 120, 1020, 1120, 1520 Housing 122,322,822,922,1022 Top cover 123,323,823,923,1013,1023,1523 Intake port 124,324,824,924,1024,1324 Bottom cover 124-1 Anchor section 124-2 Arm 125,825,925,1014,1025,1325,1525 Exhaust vents 126,324(1) Opening 128 Fittings 129 Non-swivel vanes 129-1, 129-2 Dual vane 129-3 Space 129-4 Cylindrical Guide 130, 330, 830, 1030, 1130, 1230, 1330, 1430 Bearing-Housing Structure 131-1,131-2 Groove 131-3, 161-1, 161-2, 161-4 Bead 131-5 screw 132,136 Bearing components 132,332,932 base 133 holes 134,834,934,1134,1334 disks 134(1) Outer edge 136 Bearing shaft 136(1) Sleeve bearing section 136(2) Thrust bearing surface, thrust bearing section 136(3) External surface 138,139 O-rings 140 motor 145,345,1045,1145,1245,1345,1545 Stator components 146 Stator Core 147 Fixed teeth 148-1 First Slot Liner 148-2 Second slot liner 150, 350, 850, 950, 1050, 1150, 1250, 1350, 1550 magnets 160, 360, 460, 860, 960, 1060, 1160, 1260, 1360, 1460, 1560 Rotor cap, rotor cup 161 Lip 161-3,165(1) depression 161-5 screw 162,216 aperture 163 Exterior 165 Inner self 170, 370, 470, 870, 970, 1070, 1170, 1270, 1370, 1570 Rotor 170(1), 202(1) One end 170(2), 202(2) The other end 171 Lower flange 182,482 blades 182(1) Tip edge 184,186 Shroud 185 Hub 180,280,380,480,880,980,1080,1180,1280,1380,1480,1580 Impeller 202 Over-top holding arm 205 Pre-rotation cover 205-1 Bumper 206 Pre-rotation vane 207 PCB assembly 210 Fasteners 212-1 Threaded part 212-2 Screw receiving section 215 Lubricating oil tank 217 Concave channel 310, 410, 510, 610, 710 Intake port caps 312,412,512,612,712 Inner part 314,414,514,614,714 Outer part 315 Ring-shaped void 322(1) Circular side wall 329(1) Tab 333,933,1024(1),1027,1033,1133,1233,1333 Tube section 333(1) Flange 333(2) Integrated lower wall 351 Metal Sleeve 370(2),1037 End 390, 890, 990, 1090, 1190, 1390, 1590 bearing cartridges 392,1092 Tubular sleeve 394, 395, 1094, 1095, 1295 bearings 416,516,616,716 connectors 482(1), 482(2) top edges 835 side walls 835(1) tabs 837, 937, 1039, 1339, 1439 scroll chambers 839 open spaces 920 blower housings 1015 PAP devices 1022(1) separation walls 1030, 1130 fixed components 1035, 1036 wall parts 1061 pegs 1070(1) high-speed air flow path regions 1070(2) low-speed air flow path regions 1529 inner housing parts

Claims

[Claim 1] A housing including an air intake and an exhaust port, A bearing-housing structure provided in the housing and configured to rotatably support the rotor, A motor provided in the bearing-housing structure and configured to drive the rotor, The impeller provided on the rotor and Equipped with, The bearing-housing structure includes a bearing shaft having a bearing surface for rotatably supporting the rotor, wherein the bearing shaft forms only a single non-ball bearing type bearing for the rotor.

Images