blower

Abstract

A blower includes a blower housing defining a duct portion, a motor coupled to the blower housing and positioned within the duct portion, the motor including an output shaft, a fan coupled to the output shaft and rotatable with the output shaft to generate a primary airflow through the duct portion, a motor housing coupled to the blower housing and positioned within the duct portion, the motor positioned within the motor housing and the output shaft extending from the motor housing, the motor housing receiving a secondary airflow from the fan that travels through the motor housing.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of co-pending U.S. Patent Application No. 19 / 466,980, filed on Feb. 2, 2026, which claims priority to U.S. Provisional Patent Application No. 63 / 810,235, filed on May 22, 2025, and U.S. Provisional Patent Application No. 63 / 752,420, filed on Jan. 31, 2025, the entire contents of all of which are incorporated herein by reference.FIELD

[0002] The present disclosure relates to a blower, and more particularly to a battery powered blower.BACKGROUND

[0003] In many situations in which a blower is needed to direct an airflow into a confined space (e.g., for ventilation), an alternating current power source (e.g., a mains power outlet) may not be readily available and a user instead needs to rely on a generator or a utility truck to provide power, which may not be practical, for instance, due to size constraints, exhaust gas generation, etc.

[0004] The combined space to be ventilated by a blower may have a higher ambient temperature which may lead to uncomfortable working conditions for a person operating in the confined space, even with the introduction of an airflow to ventilate the confined space. In addition to higher ambient temperatures, the environment in which a blower is being used may have higher levels of dust or other particulate and operation of a blower in that environment would introduce the particulate into the confined space, also leading to poor working conditions.SUMMARY

[0005] The present disclosure provides, in one aspect, a blower configured to receive power from an alternating current power supply and a replaceable battery pack including: a blower housing defining a duct portion; a motor coupled to the blower housing and positioned within the duct portion, the motor including an output shaft; a fan coupled to the output shaft and rotatable with the output shaft to generate a primary airflow through the duct portion; and a motor housing coupled to the blower housing and positioned within the duct portion, the motor positioned within the motor housing and the output shaft extending from the motor housing, the motor housing receiving a secondary airflow from the fan that travels through the motor housing.

[0006] The present disclosure provides, in another aspect, a blower system configured to receive power from an alternating current power supply and a replaceable battery pack, the blower system including: a blower including a blower housing including a duct portion defining a blower axis; a motor coupled to the blower housing and positioned within the duct portion, the motor including an output shaft; a fan coupled to the output shaft and rotatable with the output shaft to generate a primary airflow through the duct portion; a motor housing coupled to the blower housing and positioned within the duct portion, the motor positioned within the motor housing and the output shaft extending from the motor housing, the motor housing receiving a secondary airflow from the fan that travels through the motor housing; and a duct holder couplable to the blower and including a flexible duct that is extendible from the duct holder and is configured to direct the primary airflow generated by the blower, the duct holder including a coupling assembly that engages a coupling feature of the blower to removably couple the duct holder to the blower.

[0007] The present disclosure provides, in another aspect, a blower system configured to receive power from an alternating current power supply and a replaceable battery pack, the blower system including: a blower including an electronic control unit configured to control operation of the blower, the electronic control unit configured to distribute power from a power source, receive one or more signals indicating a selected operating parameter, and output one or more blower control signals to control operation of the blower based on the selected operating parameter; a duct holder couplable to the blower and including a flexible duct, the flexible duct configured to extend from and direct an airflow generated by the blower; and a remote wirelessly coupled to the electronic control unit and configured to transmit a signal to the blower and receive a return signal from the blower, the remote including a user interface configured to display an operating condition of the blower, and receive an input from the user indicative of a selected working parameter.

[0008] Other features and aspects of the subject matter will become apparent by consideration of the following detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a perspective view of blower according to an embodiment of the disclosure.

[0010] FIG. 2 is a schematic illustrating a section view of the blower of FIG. 1.

[0011] FIG. 3 is a perspective view of another embodiment of a blower according to the disclosure.

[0012] FIG. 4 is a perspective view of another embodiment of a blower according to the disclosure.

[0013] FIG. 5 is a side view of a modular blower system according to an embodiment of the disclosure.

[0014] FIG. 6 is a perspective view of the blower of the modular blower system of FIG. 5.

[0015] FIG. 7 is another perspective view of the blower of the modular blower system of FIG. 5.

[0016] FIG. 8 is another perspective view of the blower of the modular blower system of FIG. 5.

[0017] FIG. 9 is a front view of an embodiment of a modular blower system, including a cooler module coupled to a blower.

[0018] FIG. 10 is a front view of another embodiment of a modular blower system.

[0019] FIG. 11 is a perspective view of the modular blower system of FIG. 10.

[0020] FIG. 12 is a section view of the modular blower system of FIG. 10.

[0021] FIG. 13 is a perspective view of another embodiment of a modular blower system, including a blower and a duct housing.

[0022] FIG. 14 is a section view of a portion of the modular blower system of FIG. 13 along plane 13.

[0023] FIG. 14A is a section view of a blower of the blower system of FIG. 13 along plane 13.

[0024] FIG. 14B is a section view of a portion of the modular blower system of FIG. 13 along section 14B-14B in FIG. 13.

[0025] FIG. 15 is section view of a portion of a modular blower system including a blower, a duct housing, and an embodiment of a coupling assembly.

[0026] FIG. 16 is section view of a portion of a modular blower system including a blower, a duct housing, and another embodiment of a coupling assembly.

[0027] FIG. 16A is a section view of a portion of the modular blower system of FIG. 16, including a blower and a duct housing.

[0028] FIG. 17 is a perspective view of a remote for a modular blower system.

[0029] FIG. 18 is a schematic diagram of a control process of a modular blower system according to any of the embodiments.

[0030] FIG. 19 is a schematic diagram of another control process of a modular blower system according to any of the embodiments.

[0031] FIG. 20 is a circuit diagram illustrating a portion of the control circuit of the electronic control unit.

[0032] Before any embodiments of the subject matter are explained in detail, it is to be understood that the subject matter is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The subject matter is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.DETAILED DESCRIPTION

[0033] FIGS. 1-4 illustrate embodiments of a confined-space blower 10 including a fan 15 coupled to a motor 20 supported in a blower housing 25. The fan 15 is rotated by the motor 20 to generate an airflow 30 through a flexible conduit 35 that is removably couplable to the blower housing 25. The flexible conduit 35 is positionable to direct the airflow 30 into a confined space (e.g. a sewer shaft). The blower housing 25 has a generally cylindrical cross-section and may include handles 40 and attachment structure 45 to which accessories may be coupled.

[0034] The blower housing 25 may support a display 50 that indicates the expected runtime of the blower 10 and a user interface 55 including controls to operate the blower 10 (e.g., to turn the blower on / off, change the operating mode / speed of the blower, set a timer, etc.).

[0035] A battery pack 60 provides a power source for the blower 10, allowing the blower 10 to be operated at a remote location where an alternating current power source may not be available. In some embodiments (FIGS. 1 and 3), the battery pack 60 is removably coupled, e.g., replaceable, to a battery receptacle 65 on the blower housing 25, e.g., by sliding the battery pack 60 relative to the battery receptacle 65. In the embodiment of FIG. 1, when the battery pack 60 is coupled to the battery receptacle 65, the battery pack 60 is arranged, when viewed from above the blower 10, with the battery pack axis 66 positioned parallel to a blower axis 67 defined through the blower housing 25 and along which the fan 15 and motor 20 are positioned. In the embodiment of FIG. 3, a battery pack 60 is couplable to the battery receptacle 65 such that the sliding axis 69 along which a battery pack 60 is slidable, which corresponds to the battery pack axis, is arranged perpendicular to the blower axis 67. In another embodiment (FIG. 4), the blower 10 is electrically connected to a battery pack 75 positioned remote from the blower 10 (i.e., not onboard the blower housing 25). In the embodiment of FIG. 4, the blower 10 is electrically connected to a portable power unit including a backpack unit 70 that is configured to be carried by a user (e.g., with shoulder straps). The backpack unit 70 has a battery receptacle (78) to which the battery pack 75 is attachable, and the backpack unit 70 is electrically connected (via a multi-conductor cable 80) to the blower 10.

[0036] With reference to FIGS. 5 – 8, in another embodiment, a blower 100 may be a component of a modular blower system 104. The modular blower system 104 includes one or more modules that are removably couplable to the blower 100. The modules may perform different functions to condition the airflow generated by the blower 100 as will be described in further detail below. Illustrated modules include a cooler module 108, a sensor module 112, a filter module 116, and a duct holder 120. The cooler module 108, sensor module 112, filter module 116, and duct holder 120 are coupled in line with the blower 100 such that an airflow 124 generated by the blower 100 is directed through each of the cooler module 108, blower 100, sensor module 112, filter module 116, and duct holder 120. The cooler module 108 and sensor module 112 are electrically coupled to the blower 100 as will be described in further details below. Embodiments of the modular blower system 104 may include the blower 100 and any combination of the cooler module 108, sensor module 112, filter module 116, and duct holder 120. In the embodiment of FIG. 5, the cooler module 108 is coupled to a first (i.e., upstream) side of the blower 100, whereas the sensor module 112 is coupled to the second (i.e., downstream) side of the blower 100 between the blower 100 and the filter module 116, and the duct holder 120 is coupled to the filter module 116 such that the filter module 116 is positioned between the sensor module 112 and the duct holder 120. In other embodiments, the blower 100, cooler module 108, the sensor module 112, the filter module 116, and duct holder 120 may be coupled in any combination.

[0037] With reference to FIG. 6, the blower 100 includes a body 128 to which a handle 132 is pivotally coupled and from which supports 136 extend to support the blower 100 on a work surface (e.g., the ground). The body 128 defines a duct 140 (e.g., a cylindrical duct; FIG. 7) extending through the body 128 through which the airflow 124 is directed. The duct 140 includes an inlet 144 through which air enters the duct 140 and an outlet 148 from which the airflow is directed (FIG. 8). In some embodiments, the airflow may be directed through the duct 140 in either direction (i.e., from the inlet 144 to the outlet 148, and in reverse, from the outlet 148 to the inlet 144), depending on the rotational direction of a fan 180. In the present disclosure, the inlet 144 defines an upstream side of the blower 100 and the outlet 148 defines a downstream side of the blower 100. It will be appreciated that when the blower 100 is operated in a manner to generate an airflow from the outlet 148 to the inlet 144, the inlet 144 and outlet 148 define a downstream side and an upstream side, respectively.

[0038] With reference to FIG. 6, the body 128 includes a battery interface 152 to removably receive a battery pack. The battery interface 152 includes rails 156 along which the battery pack is slidably received by the blower 100, terminals 160 to which the battery pack is electrically couplable to transfer electricity from the battery pack to the blower 100, and a latch mechanism 164 to removably secure the battery pack to the blower 100. The blower 100 also includes a user interface 168 engageable by the user to input working parameters of the modular blower system 104. Attachment structures 172 adjacent the inlet 144 and outlet 148 removably receive coupling structures (e.g., fasteners, clips, latchets, etc.) to couple the cooler module 108, sensor module 112, filter module 116, and duct holder 120 to the blower 100.

[0039] With reference to FIG. 7, the blower 100 includes an electronic control unit 176, located on a side of the blower 100 opposite the user interface 168, that is configured to control the operation of the blower 100. The fan 180 is supported in the duct 140 adjacent the inlet 144. With reference to FIG. 8, the fan 180 is coupled to a motor 184 positioned in the duct 140. The motor 184 drives the fan 180 to rotate, generating an airflow. The motor may be, for instance, a brushless DC motor, although another type of motor may be used. One or more sensors 188 may be positioned in and coupled to sidewall of the duct 140 to monitor conditions of the airflow. In the present embodiment, the sensor 188 is an airspeed sensor (e.g., a pitot tube and differential pressure sensor) that measures the airspeed of the airflow and generates a signal indicating the airspeed. In other embodiments, the blower 100 may include a temperature sensor to measure the temperature of the air in the duct 140 or other sensors to monitor conditions of the blower 100. The blower 100 also includes a receptacle (not shown) that is configured to be coupled to AC mains power by a power cord to receive an alternating current power supply (AC power) from the AC mains power.

[0040] Returning to FIG. 5, the cooler module 108 is configured to cool the airflow. It will be appreciated that the cooled airflow, when directed into a confined space, the ambient temperature of the confined space is lowered, which may result in more comfortable working conditions in the confined space. The cooler module 108 is coupled to the blower 100. In the embodiment of FIG. 5, the cooler module 108 is coupled to the inlet 144 of the blower 100, that is, to an upstream side of the blower 100. The cooler module 108 is also electrically coupled to the blower 100, an in particular, to the electronic control unit 176. The cooler module receives power from the battery pack through the blower 100 and the electronic control unit 176, which distributes power from the battery pack to the cooler module 108.

[0041] In one embodiment, the cooler module 108 is a refrigerant cycle air conditioner including a compressor, a heat exchanger, an expansion valve, and an evaporative cooler fluidly coupled to one another. Refrigerant cycle air conditioners may require substantial power to operate. In one embodiment, the refrigerant cycle air conditioner is configured to receive AC power from a wall outlet as well as direct current from a battery pack coupled to the blower 100. The compressor could therefore receive about 1800 Watts of power from a mains power outlet. The compressor may be a variable speed compressor that is operable at two or more speeds (e.g., a high speed and a low speed). The compressor is configured to be switchable between different operation modes including an alternating current operation mode, a fixed-power operation mode, and a variable speed mode. In the first, alternating current operation mode, the blower 100 and cooler module 108 receive power from an alternating current power supply and the compressor is operable at a high speed only when the modular blower system 104 is coupled to an alternating current power supply. In the fixed-power operation ode, the blower 100 and cooler module 108 receive power from either of the AC power supply or the battery pack. When the modular blower system 104 is operating in the fixed power mode, regardless of the source of power, the compressor is operated at a high speed. It will be understood that operating the compressor at high speed while using power from the DC power supply impact runtime. In the variable speed mode, the compressor is operated at a high speed when receiving power from the AC power supply and is operated at a low speed when the compressor is receiving power from the battery pack. The user could also select the operating conditions of the blower 100 and cooler module 108 based on desired runtime and / or cooling needs.

[0042] FIG. 9 illustrates another embodiment of a refrigerant cycle air conditioner cooler module 108a coupled to a blower 100. The cooler module 108a and blower 100 constitute another embodiment of a modular blower system 104a, or a portion of a modular blower system 104a to which other modules are couplable. It should therefore be understood that modules of previously described embodiments may also be coupled to the blower 100. The cooler module 108a includes a heat exchanger 190 positioned within a duct portion 192 of the cooler module 108a. The airflow is received in the duct portion 192 and passes through / around the heat exchanger 190. A water reservoir 196 is coupled to the duct portion 192, and a water pump 200 coupled to the water reservoir 196 (e.g., positioned within the water reservoir 196) generates a flow of water through ducts 201 from the water reservoir 196 through the heat exchanger 190 and back to the water reservoir 196. A user adds a cooling medium (e.g., ice) to the water reservoir 196 to maintain the water in the cooler module 108a at a low temperature (e.g., at or near 32° F). In some embodiments of the water reservoir 196, the illustrated cooler module 108a requires a small amount of power (e.g., 10-30 W) during operation and reduces an ambient temperature of the confined space (e.g., a 25 °F temperature drop for a confined space having an ambient temperature of 110 °F).

[0043] In other embodiments, the cooler module 108 may be an evaporative cooler (or “swamp cooler”) that passes air over a wet media pad and cools the by evaporation of the water. Water is pumped from a reservoir to a media pad to drip down the media pad from the top of the media pad. In another embodiment, the media pad is partially submerged in a water sump and water wicks up the media pad.

[0044] In another embodiment, the cooler module 108 is a Peltier cooler including a thermoelectric Peltier module with a cold side attached to a heat sink placed in the airflow.

[0045] Other embodiments of cooling modules may include other types or configurations of cooling systems.

[0046] In still other embodiments, the cooler module 108 could instead be a heater module configured to generate heat (e.g., with a heating element positioned in the duct portion 192).

[0047] Returning to FIG. 5, the sensor module 112 includes one or more sensors 202 to measure or sense one or more conditions of the airflow before it enters the confined space. The sensor module 112 is electrically coupled to the electronic control unit 176 and generates signals that are received by the electronic control unit 176. In one embodiment, the sensor module measures the air quality of the airflow. The electronic control unit 176 receives the signal(s) from the sensor module 112 and determines whether the air quality exceeds pre-determined air quality threshold levels. In another embodiment, the sensor module 112 may include an airspeed sensor, a thermocouple, or another type of sensor configured to measure a parameter of the airflow. The sensor module 112 may receive power distributed by the electronic control unit 176 or may instead receive power from another source (e.g., a separate battery pack coupled to the sensor module 112, an AC source such as mains power, etc.). The sensor module 112 may instead communicate wirelessly (e.g., via Bluetooth or other wireless communication protocol) with the electronic control unit 176 or a wireless remote 900 (FIG. 17) held by the user that communicates, e.g., via a transceiver (not shown) incorporated in the electronic control unit 176. In the illustrated embodiment, the sensor module 112 is coupled to the outlet 148 of the blower 100 (e.g., the downstream side of the blower 100) although in other embodiments, the sensor module 112 may be coupled to the upstream side of the blower 100.

[0048] With continued reference to FIG. 5, the filter module 116 includes a filter 204. The filter 204 may be replaceable for regular maintenance when the filter 204 is saturated with particulate / contaminant. The filter 204 is configured to remove one or more types of particulates from the airflow. It will be appreciated that in working environments where dust, smoke, noxious fumes, or other particulates / contaminants are present, filtering the airflow results in better air quality of the airflow introduced into the confined space. In some embodiments, a filter may be configured (e.g., by mesh size, filter medium, etc.) to filter different types of particulates / contaminants from the airflow. For instance, a first filter is configured to remove a first type of particulate (e.g., dust) from the airflow, and a second filter is configured to remove a second type of particulate (e.g., smoke) from the airflow. In other embodiments, the filter module 116 may receive more than one replaceable filter. In still other embodiments, the filter may be configured as a general-purpose filter to remove more than one type of particulate / contaminant.

[0049] The duct holder 120 includes a flexible duct 208 that is extendible from the duct holder 120. The flexible duct 208 is positionable to direct the airflow generated by the blower 100. It will be appreciated that the flexible duct 208 can be positioned to direct the airflow linearly or non-linearly (e.g., at a direction different from, for instance, transverse to, the direction of the airflow). The flexible duct 208 is collapsible to be stowed within the duct holder 120 for storage and / or movement of the duct holder 120 and flexible duct 208 between worksites. The duct holder 120 is illustrated in FIG. 5 as being coupled to the blower 100 at a downstream side (i.e., coupled to the outlet 148, either coupled directly to the blower 100 to another one of the modules) of the blower 100. In other embodiments, the duct holder 120 can be coupled to the upstream side of the blower 100.

[0050] FIGS. 10 – 12 illustrate another embodiment of a blower system 304 that includes a blower 300 that is coupled to the cooler module 108a. The blower 300 is similar to the previously described blower 100, and similar features will be given a similar reference numeral, plus “200.”

[0051] With reference toFIGS. 10 – 12, the blower 300 includes a body 328 that defines a duct 340 having a substantially cylindrical shape that extends through the body 328. The duct 340 defines a blower axis 367. The fan 380 and motor 384 are supported in the duct 340 such that the fan 380 and motor 384 are arranged along the blower axis 367. The fan 380 and motor 384 are coupled and rotation of the fan 380 by the motor 384 generates an airflow 324 through the duct 340. The duct 340 includes an inlet 344 through which air enters the duct 340 and an outlet 348 from which the airflow is directed. In some embodiments, the airflow may be directed through the duct 340 in either direction (i.e., from the inlet 344 to the outlet 348, and in reverse, from the outlet 348 to the inlet 344), depending on the rotational direction of a fan 380. In the present disclosure, the inlet 344 defines an upstream side of the blower 300 and the outlet 348 defines a downstream side of the blower 300. The cooler module 108a is coupled to the inlet 344. It will be appreciated that when the blower 300 is operated in a manner to generate an airflow from the outlet 348 to the inlet 344, the inlet 344 and outlet 348 define a downstream side and an upstream side, respectively.

[0052] The body 328 includes a battery interface 352 that removably receives a battery pack 375. The battery interface 352 includes rails 356 along which the battery pack 375 is slidably received by the blower 300. In the illustrated embodiment, the battery pack 375 is slidably couplable to the battery interface 352 along a sliding axis 369 that is arranged perpendicular to the blower axis 367. Terminals (not shown) electrically couple the battery pack 375 to the battery interface 352 to transfer electricity from the battery pack 375 to the blower 300. A latch mechanism 364 removably secures the battery pack 375 to the blower 300. The blower 300 also includes a user interface 368 engageable by the user to input working parameters of the modular blower system 304. Attachment structures (not shown) adjacent the inlet 344 and outlet 348 removably receive coupling structures (e.g., fasteners, clips, latches, etc., embodiments of which are described in greater detail below) to couple the cooler module 108a, or other modules, to the blower 100.

[0053] The blower 300 includes an electronic control unit 176 that is supported, for instance, adjacent the battery interface 352. The electronic control unit 176 is configured to control the operation of the blower 300. The fan 380 is supported in the duct 340 closer to the inlet 344 than to the outlet 348. The blower 100 also includes a receptacle (not shown) that is configured to be coupled to AC mains power by a power cord to receive an alternating current power supply (AC power) from the AC mains power.

[0054] As shown in FIG. 12, the cooler module 108a includes an inlet duct portion 390 that is coupled to the inlet 344. An outlet duct portion 394 is coupled to the outlet 348. In one embodiment, the outlet duct portion 394 is formed integrally with the body 328. In other embodiments, the outlet duct portion 394 is removably coupled to the body 328. The inlet duct portion 390 defines an inlet passage 398 through which air passes to the inlet 344 and the outlet duct portion 394 defines an outlet passage 402 through which the airflow travels upon leaving the outlet 348. Each of the inlet passage 398 and outlet passage 402 have a height 406, 410 between the upper and lower surfaces 414, 418 of the inlet passage 398 and the upper and lower surfaces 422, 426 of the outlet passage 402, respectively. The heights 406, 410 of the inlet duct portion 390 and the outlet duct portion 394 have variable heights, with the heights of each the inlet duct portion 390 and outlet duct portion 394 changing along the blower axis 367. The heights 406, 410 each have a minimum height 406a, 410a that is less than the diameter 432 of the duct 340.

[0055] FIGS. 13 – 14 illustrate another embodiment of a blower system 504 that includes a blower 500 that is coupled to a duct holder 520. The blower 500 is similar to the previously described blower 100 and only differences between the blowers 100, 500 will be described in further detail. As shown in FIG. 13, the duct holder 520 includes a cover 524 that is pivotally coupled to the body 528 of the of the duct holder 520. A cover latch assembly 532 is pivotally coupled to body 528. The cover latch assembly 532 includes a latch handle 536 coupled to the body 528 and a latch 540 is pivotally coupled to the latch handle 536. Rotation of the latch handle 536 draws the latch 540 toward or pushes the latch 540 away from a catch 544 on the cover 524. With reference to FIG. 14, a flexible conduit 548 is supported within the body 528 and is extendible from the body 528 when the cover 524 is opened.

[0056] The blower 500 includes a motor 552 supported in a motor housing 556 that is coupled to the interior surface 560 of the blower housing 525. The interior surface 560 defines a duct portion 564 that extends along a blower axis 592. Vanes 562 extend between the interior surface 560 and the motor housing 556 to support the motor 552 and motor housing 556 within the duct portion 564. The vanes 562 are shaped to guide the airflow generated by the fan 576. The motor shaft 568 of the motor 552 is coupled to a hub 572 of the fan 576. The fan 576 further includes a semi-spherical nose 580 extending from the hub 572. Blades 584 extend helically about tubular portion 588 of the fan 576. The tubular portion 588 extends along the blower axis 592 from the semi-spherical nose 580.

[0057] Similar to the previously described embodiments of a blower 10, 100, the motor 552 of the blower 500 is a brushless DC motor that is operable to rotate the fan 576 in both clockwise and counterclockwise directions such that the direction of the airflow 530 (e.g., the primary airflow through the blower 500) generated by rotation of the fan 576 is reversible. The motor 552 may be operable at different speeds that are indicative of different volumetric flow rates (measured, for instance, in cubic feet per minute, or cfm). The speed may be continuously variable, or individually selectable, e.g., discrete, or non-continuous, speeds (e.g., high speed, medium speed, low speed). Exemplary speeds will be discussed in greater detail below with regard to the electronic control unit.

[0058] With reference to FIG. 14A, the blower 500 is configured such that a portion of the airflow 530 travels through the motor housing 556 to cool the motor 552. In the illustrated embodiment, the primary airflow 530 flows through the blower housing 525 in a first direction from the left side of the figure to the right side of the figure, as illustrated in FIG. 14A. The portion of the primary airflow 530 that travels through the motor housing 556 is a secondary airflow 534. The internal profile of the motor housing 556 creates a zone of low pressure within the motor housing 556 that draws the secondary airflow 534 into the motor housing 556 through a motor housing inlet 538 at the second end 542 of the motor housing 556 opposite first end at adjacent to which the nose 580 of the fan 576 is supported. The secondary airflow 534 travels through the motor housing 556 in a second direction opposite the first direction from the motor housing inlet 538 toward the nose 580, and passing along and through the motor 552. The secondary airflow 534 exits the motor housing 556 through outlets 546 in the nose 580 and rejoins the primary airflow 530. A cap 582 is coupled to the nose 580 and at least partially shields the outlets 546 from the airflow 530, thereby mitigating the increase in ambient pressure (e.g., ram air) within the motor housing 556 that would result from the airflow 530 entering the outlets 546. The cap 582 is coupled to the motor shaft 568 to rotate with the fan 576. The cap 582 deflects and directs the secondary airflow 534 to flow along the nose 580 to rejoin the primary airflow 530.

[0059] With reference to FIG. 14B, the secondary airflow 534 (shown in FIG. 14A, and traveling into the page, when viewing FIG. 14B) is a first cooling airflow. A second cooling airflow 535 is directed through the electronic control unit support portion 526 of the blower housing 525 external to the duct portion 564 defined by the interior surface 560 of the blower housing 525. The second cooling airflow 535 is generated by a fan 537 supported in the blower housing 525. The second cooling airflow 535 travels over a printed circuit board assembly 539 (“PCBA”) supported in the blower housing 525. The printed circuit board assembly 539 may include the electronic control unit (e.g., electronic control unit 176, shown in FIG. 20). A heat sink 543 may be coupled to the printed circuit board assembly 539 to further facilitate cooling of the printed circuit board assembly 539. In other embodiments, a portion of the primary airflow may be directed into the electronic control unit support portion 526 to provide the second cooling airflow 535.

[0060] Returning to FIG. 13, the duct holder 520 is couplable to the blower 500 by a draw latch 596 (e.g., an elastomeric draw latch) that receives a protrusion 600 on the blower housing 525, with the draw latch 596 stretching to engage the protrusion 600 resulting in tension through the draw latch 596 pulling the blower 500, via the protrusion 600, and the duct holder 520 toward one another. The draw latch 596 is one embodiment of a coupling assembly 604 and the protrusion 600 is an example of a coupling feature of the blower. In other embodiments, other latch styles or coupling assemblies may be used.

[0061] FIGS. 15 and 16 illustrate other embodiments of coupling assemblies 704, 804.

[0062] With reference to FIG. 15, the coupling assembly 704 includes a collar 708 rotatably supported on the duct holder 520. The collar 708 has an inner channel 712 and a recess 716 that communicates the inner channel 712 and an exterior 720 of the collar 708. A coupling feature, e.g., a tab 724, extends radially outwardly from the outer surface 728 of the blower housing 525. The inner channel 712 receives the tab 724 through the recess 716. When the tab 724 is received in the inner channel 712, the collar 708 is rotatable, thereby misaligning the recess 716 and the tab 724, preventing removal of the tab 724 from the inner channel 712 and securing the duct holder 520 to the blower 500.

[0063] With reference to FIG. 16, the coupling assembly 804 includes a button 808 that is slidably supported by the duct holder 812 at the outer circumference 816 of the duct holder 812 (e.g., in the handle 820). A spring 824 biases the button 808 to a first, extended position (shown in FIG. 16). The button 808 includes a coupling flange 828 that extends from the button 808 through the handle 820. A pin 832 is also slidably supported in the handle 820 at the outer circumference 816 of the duct holder 812. A spring 836 biases the pin 832 to an extended position (shown in FIG. 16). The coupling flange 828 engages the pin 832. The pin 832 has a tapered end 840. A coupling feature, e.g., a tab 844, extends from the blower 500 and includes a hole 848 that receives the pin 832. The duct holder 812 is vertically downwardly slidable relative to the blower 500 such that the tapered end 840 engages the tab 844, sliding the pin 832 relative to the handle 820 against the bias of the spring 836. The pin 832 is received in the hole 848 when the pin 832 and the hole 848 are aligned and the pin 832 is in the extended position, securing the blower 500 to the duct holder 812. To detach the blower 500 from the duct holder 812, the button 808 is depressed against the bias of the spring 824. Engagement of the coupling flange 828 with the pin 832 moves the pin 832 with the button 808 to remove the pin 832 from the hole 848. As shown in FIG. 16A, the blower 500 and duct holder 812 may include other features to align and position the duct holder 812 relative to the blower 500. In the illustrated embodiment, a ridge 852 extends radially outwardly and downwardly from the outer circumference 816 of the duct holder 812 and is received in a recess 856 of the blower 500. The duct holder 812 also includes recesses 860 (e.g., two recesses) that extend into the duct holder 812 and receive ridges 864 extending from the blower 500. The recesses 860 are positioned on opposite sides of the coupling assembly 804 of the duct holder 812. Other positioning features may be included in addition to or in place of the alternating recesses and ridges.

[0064] With reference to FIG. 17, in some embodiments, the electronic control unit 176 may include a transceiver configured to communicate wirelessly (e.g., via Bluetooth or other wireless communication protocol) with a wireless remote 900 held by a user within the confined space, or within a distance or line-of-sight of the electronic control unit 176 of the modular blower system 104, 304, 504. In the illustrated embodiment, the remote 900 is configured as a dedicated handheld remote 900 configured to work only with one or more modular blower systems 104, 304, 504 (modular blower system 504 shown in FIG. 17). In other embodiments, the remote may be configured as a standalone device, e.g., a smartphone, not dedicated specifically to the modular blower system 104, 304, 504. In still other embodiments, the remote 900 may be configured to communicate with the electronic control unit 176 via intervening repeaters or other devices that are configured to increase the range between the remote 900 and the electronic control unit 176 to areas and distances that would otherwise be beyond line-of-sight between the remote 900 and the electronic control unit 176.

[0065] The transceiver 902 of the remote 900 is configured to transmit one or more signals to the electronic control unit 176 of the blower 500 and receive one or more signals (e.g., a return signal) from the electronic control unit 176 that are indicative of the operating conditions of the blower 500. The remote 900 includes a user interface 904 that is engageable by a user to select or input working parameters, perform other control operations of the modular blower system 104, 304, 504, or remotely monitor operation of the modular blower system 104, 304, 504. For instance, the user may be able to control the speed of the blower 10, 100, 300, 500 (blower 500 shown in FIG. 17) by engaging the user interface 904 (e.g., depressing a button). The user interface 904 may also be configured to display a status of the modular blower system 104, 304, 504. For instance, for a battery-powered blower system, the user interface 904 may display a state of charge of the battery to the user, a power source in use (e.g., AC power, battery power). The remote 900 may also display a speed mode selected (e.g., high speed, low speed, etc.) that is indicative of the fan speed. In still other embodiments, the user interface 904 of the remote 900 may include an auditory indicator (e.g., a piezoelectric buzzer 908) that indicates that the state of charge of the battery pack has reached a minimum state of charge threshold that indicates that battery pack is near the end of its useable charge (e.g., 10% of useable charge) and that the blower needs to be coupled to another power source (e.g., a fully charged battery pack or AC mains power). It should be understood that the useable state of charge may be different that the actual state of charge in order to prevent the charge of the battery pack from being completely expended.

[0066] With reference to FIGS. 18-19, the electronic control unit 176 is configured to perform operations to control operation of a modular blower system, such as any of the previous described modular blower systems 104. Among the operations performed by the electronic control unit 176 are disturbing power from the power source(s) (e.g., alternating current from mains power and converted to direct current, direct current from one or more battery packs coupled to the blower 100 or other modules of the modular blower system 104, etc.), receiving signals from the user interface 168 indicating working parameters selected by the user, receiving signals from one or more sensors (e.g., the airspeed sensor 188, air quality sensor 202) indicating the operating conditions of the modular blower system 104, distributing power to the blower 100, including the motor 184, the cooler module 108, 108a, and sensor module 112, and outputting one or more control signals to the blower and / or the cooler module 108, 108a to control operation of the blower 100 and the cooler module 108, 108a. The electronic control unit 176 may also include a memory to store pre-defined characteristics of the modular blower system 104, such as the cross-sectional area of the duct 140, maximum and / or minimum operating conditions, minimum allowable flow rates, etc.

[0067] In the present embodiment, the airspeed sensor 188 outputs a signal indicative of the airspeed of the airflow, the battery pack coupled to the battery interface 152 generates a signal indicating the battery energy that is received by the electronic control unit 176, and the air quality sensor 202 outputs an air quality signal indicating the air quality of the airflow, and each signal is received by the electronic control unit 176. These signals are indicative of the operating conditions of the modular blower system 104. Other signals related to the operating conditions of the modular blower system 104 may be generated by other sensors and received by the electronic control unit 176.

[0068] The electronic control unit 176 also receives signals from the user interface 168. A user engages the user interface 168 to input working parameters of the modular blower system 104. Signals indicating those working parameters are received by the electronic control unit 176. In the present embodiment, the user engages the user interface 168 to input working parameters such as the runtime (duration of operation of the modular blower system 104), fan speed, confined space volume, number of air changes per unit time (e.g., number of air changes per hour), and minimum airflow rate. Once set by the user, the minimum airflow rate and other working parameters may be set in the modular blower system 104.

[0069] In response to the signals received from the sensors indicating the working parameters and the operating conditions, the electronic control unit 176 determines the total maximum power of the modular blower system 104. Based on that determination, the electronic control unit 176 also outputs blower control signals to control operation of the blower 100 and cooler control signals to control operation of the cooler module 108, 108a, based on the maximum power of the modular blower system 104.

[0070] In one embodiment illustrated in FIG. 18, the electronic control unit 176 receives a battery energy signal, e.g., current draw, (an operating condition) from the battery pack and a runtime signal from the user interface 168 (a working parameter) at step 1001, determines the total maximum power of the modular blower system 104 at step 1002, and outputs a signal to the blower 100 to control operation of the blower 100 (i.e., the speed at which the motor 184 rotates the fan 180) at step 1003 to operate the blower 100 for the entirety of the desired runtime. At step 1004, the motor 184 operates at the speed determined by the electronic control unit 176.

[0071] In another embodiment shown in FIG. 19 the electronic control unit 176 performs the same steps as identified above for steps 1001 and 1002. At step 1005, the user can input a working parameter (e.g., fan speed or cooling condition). At step 1006, the electronic control unit 176 determines the total maximum power for the modular blower system 104. At step 1007, the electronic control unit 176 outputs a blower control signal to adjust the fan speed and / or outputs a cooler control signal to control the cooler module 108, 108a to maintain the constant total power of the modular blower system 104 over the selected runtime. Following step 1007, a user could adjust, via the user interface 168, the cooling or heating generated by the cooler module 108, 108a, and the electronic control unit 176 adjusts the fan speed to maintain constant power at step 1007.

[0072] The electronic control unit 176 may perform other control operations, in addition to, or instead of the steps described above. In another embodiment, the electronic control unit 176 receives a signal from the airspeed sensor 188 indicating the airspeed of the airflow generated by the blower 100. The electronic control unit 176 then determines the flow rate based on the airspeed of the airflow and the pre-defined cross-sectional area of the duct 140. The electronic control unit 176 then compares the calculated flow rate to a minimum flow rate. The minimum flow rate may have been set by a user and stored as a predefined value. The controller then controls operation of the blower 100 to maintain the minimum airflow rate if below the minimum flow rate. In another embodiment, the electronic control unit 176 determines a minimum airflow rate based on the working parameters input by a user, including the confined space volume and the number of air changes. The electronic control unit 176 receives a volume signal indicating the confined space volume and a change signal indicating the number of changes from the user interface 168 following input to the user interface 168 by the user. The electronic control unit 176 determines the flow rate based on the airspeed signal provided by the airspeed sensor 188 and the cross-sectional area of the duct 140. The controller then determines a minimum airflow rate based on the confined space volume and the number of air changes, compares the flow rate to the minimum flow rate, and maintains the minimum airflow rate if the flow rate is below the minimum airflow rate, by outputting a control signal to the blower 100.

[0073] In any of the previously described embodiments of a user interface (e.g., user interface 608, shown in FIG. 13), the user interface may include an auditory indicator 612 (e.g., a piezoelectric buzzer) that provides an audible indication of the state of charge of the battery pack. The auditory indicator 612 may be activated, for instance, when the useable state of charge of the battery pack is at10% charge, or below. In other embodiments, the state of charge at which the auditory indicator 612 is activated may be set by a user.

[0074] FIG. 20 illustrates a portion of an exemplary electronic control unit 176 at least partially supported (e.g., on a printed circuit board assembly, “PCBA”) in any of the embodiments of a blower 10, 100, 500.

[0075] The electronic control unit 176 is electrically coupled to a receptacle 1104 that is configured to be couplable to AC mains power by a power cord to receive an alternating current power supply. The electronic control unit 176 is also electrically coupled to receive power from a battery pack through the battery pack interface (e.g., battery interface 152). The electronic control unit 176 includes one or more solid-state drives, or “SSD.” In the illustrated embodiment, the electronic control unit 176 includes one SSD 1108 electrically coupled to an AC power source and another SSD 1112 electrically coupled to the battery interface 152. The electronic control unit 176 distributes the power received from the battery pack and AC power source to other components of the blower 500, such as a datalogger 1116, the user interface 608 (including a transceiver 1120 wirelessly coupled to the remote 900), and to the motor 552 of the blower 500. The electronic control unit 176 also includes one or more sensors, e.g., any of the previously described sensors, or a Hall sensor 1124 coupled to the motor 552 to determine the rotational position of the motor 552. Other components may be included in, or coupled to communicate with the electronic control unit 176, such as an inverter, charging electronics, etc.

[0076] The electronic control unit 176 is configured to operate the blower 500 at one or more speeds, or volumetric flow rates. In one embodiment, exemplary low, medium, and high volumetric flow rates at which the electronic control unit 176 may operate the blower 500 are 700 cfm, 800 cfm, and 900 cfm, for instance, as measured at the outlet of the blower 500. The blower may be operable at another speed, e.g., a maximum, or boost, speed, for a short period of time (e.g., 15 minutes). An exemplary maximum volumetric flow rate may be, for instance, 1100 cfm. It will be appreciated that when operating at the maximum flow rate, the battery pack charge would drain quicker than at lower flow rates, and as such, the period of time the blower 500 could operate would also decrease. In the illustrated embodiment, the electronic control unit 176 may determine the power source (e.g., AC mains power, battery pack) and control operation of the blower 500 based on the power source from which power is being received. When connected to AC mains power, the electronic control unit 176 may operate the blower 500 at the maximum flow rate for an unlimited amount of time as long as the blower 500 is coupled to AC mains power. If the electronic control unit 176 determines that the blower 500 is receiving power from the battery pack and is not coupled to AC mains power, the electronic control unit 176 may limit the duration of time the blower 500 is operated at the maximum flow rate. If the blower 500 is powered by the battery pack while operating at the maximum flow rate and is subsequently coupled to AC mains power, the electronic control unit 176 may revert operation from a limited duration to an unlimited duration, and vice versa, if disconnected from AC mains power. The electronic control unit 176 may also be configured to start the blower 500 at a predetermined start time (e.g., based on a timer or a clock) and / or stop the blower after a designated time period (e.g., a time period set by a user) or at a set time of day.

[0077] It should be understood that the descriptions of the blowers and blower modules described above are considered non-limiting, and features of any of the embodiments of blowers and blower modules described above may be incorporated into other embodiments. Although the subject matter has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the subject matter as described.

[0078] Various features of the invention are set forth in the following claims.

Examples

Embodiment Construction

[0033]FIGS. 1-4 illustrate embodiments of a confined-space blower 10 including a fan 15 coupled to a motor 20 supported in a blower housing 25. The fan 15 is rotated by the motor 20 to generate an airflow 30 through a flexible conduit 35 that is removably couplable to the blower housing 25. The flexible conduit 35 is positionable to direct the airflow 30 into a confined space (e.g. a sewer shaft). The blower housing 25 has a generally cylindrical cross-section and may include handles 40 and attachment structure 45 to which accessories may be coupled.

[0034]The blower housing 25 may support a display 50 that indicates the expected runtime of the blower 10 and a user interface 55 including controls to operate the blower 10 (e.g., to turn the blower on / off, change the operating mode / speed of the blower, set a timer, etc.).

[0035]A battery pack 60 provides a power source for the blower 10, allowing the blower 10 to be operated at a remote location where an alternating current power source...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of co-pending U.S. Patent Application No. 19 / 466,980, filed on Feb. 2, 2026, which claims priority to U.S. Provisional Patent Application No. 63 / 810,235, filed on May 22, 2025, and U.S. Provisional Patent Application No. 63 / 752,420, filed on Jan. 31, 2025, the entire contents of all of which are incorporated herein by reference.FIELD

[0002] The present disclosure relates to a blower, and more particularly to a battery powered blower.BACKGROUND

[0003] In many situations in which a blower is needed to direct an airflow into a confined space (e.g., for ventilation), an alternating current power source (e.g., a mains power outlet) may not be readily available and a user instead needs to rely on a generator or a utility truck to provide power, which may not be practical, for instance, due to size constraints, exhaust gas generation, etc.

[0004] The combined space to be ventilated by a blower may have a higher ambient temperature which may lead to uncomfortable working conditions for a person operating in the confined space, even with the introduction of an airflow to ventilate the confined space. In addition to higher ambient temperatures, the environment in which a blower is being used may have higher levels of dust or other particulate and operation of a blower in that environment would introduce the particulate into the confined space, also leading to poor working conditions.SUMMARY

[0005] The present disclosure provides, in one aspect, a blower configured to receive power from an alternating current power supply and a replaceable battery pack including: a blower housing defining a duct portion; a motor coupled to the blower housing and positioned within the duct portion, the motor including an output shaft; a fan coupled to the output shaft and rotatable with the output shaft to generate a primary airflow through the duct portion; and a motor housing coupled to the blower housing and positioned within the duct portion, the motor positioned within the motor housing and the output shaft extending from the motor housing, the motor housing receiving a secondary airflow from the fan that travels through the motor housing.

[0006] The present disclosure provides, in another aspect, a blower system configured to receive power from an alternating current power supply and a replaceable battery pack, the blower system including: a blower including a blower housing including a duct portion defining a blower axis; a motor coupled to the blower housing and positioned within the duct portion, the motor including an output shaft; a fan coupled to the output shaft and rotatable with the output shaft to generate a primary airflow through the duct portion; a motor housing coupled to the blower housing and positioned within the duct portion, the motor positioned within the motor housing and the output shaft extending from the motor housing, the motor housing receiving a secondary airflow from the fan that travels through the motor housing; and a duct holder couplable to the blower and including a flexible duct that is extendible from the duct holder and is configured to direct the primary airflow generated by the blower, the duct holder including a coupling assembly that engages a coupling feature of the blower to removably couple the duct holder to the blower.

[0007] The present disclosure provides, in another aspect, a blower system configured to receive power from an alternating current power supply and a replaceable battery pack, the blower system including: a blower including an electronic control unit configured to control operation of the blower, the electronic control unit configured to distribute power from a power source, receive one or more signals indicating a selected operating parameter, and output one or more blower control signals to control operation of the blower based on the selected operating parameter; a duct holder couplable to the blower and including a flexible duct, the flexible duct configured to extend from and direct an airflow generated by the blower; and a remote wirelessly coupled to the electronic control unit and configured to transmit a signal to the blower and receive a return signal from the blower, the remote including a user interface configured to display an operating condition of the blower, and receive an input from the user indicative of a selected working parameter.

[0008] Other features and aspects of the subject matter will become apparent by consideration of the following detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a perspective view of blower according to an embodiment of the disclosure.

[0010] FIG. 2 is a schematic illustrating a section view of the blower of FIG. 1.

[0011] FIG. 3 is a perspective view of another embodiment of a blower according to the disclosure.

[0012] FIG. 4 is a perspective view of another embodiment of a blower according to the disclosure.

[0013] FIG. 5 is a side view of a modular blower system according to an embodiment of the disclosure.

[0014] FIG. 6 is a perspective view of the blower of the modular blower system of FIG. 5.

[0015] FIG. 7 is another perspective view of the blower of the modular blower system of FIG. 5.

[0016] FIG. 8 is another perspective view of the blower of the modular blower system of FIG. 5.

[0017] FIG. 9 is a front view of an embodiment of a modular blower system, including a cooler module coupled to a blower.

[0018] FIG. 10 is a front view of another embodiment of a modular blower system.

[0019] FIG. 11 is a perspective view of the modular blower system of FIG. 10.

[0020] FIG. 12 is a section view of the modular blower system of FIG. 10.

[0021] FIG. 13 is a perspective view of another embodiment of a modular blower system, including a blower and a duct housing.

[0022] FIG. 14 is a section view of a portion of the modular blower system of FIG. 13 along plane 13.

[0023] FIG. 14A is a section view of a blower of the blower system of FIG. 13 along plane 13.

[0024] FIG. 14B is a section view of a portion of the modular blower system of FIG. 13 along section 14B-14B in FIG. 13.

[0025] FIG. 15 is section view of a portion of a modular blower system including a blower, a duct housing, and an embodiment of a coupling assembly.

[0026] FIG. 16 is section view of a portion of a modular blower system including a blower, a duct housing, and another embodiment of a coupling assembly.

[0027] FIG. 16A is a section view of a portion of the modular blower system of FIG. 16, including a blower and a duct housing.

[0028] FIG. 17 is a perspective view of a remote for a modular blower system.

[0029] FIG. 18 is a schematic diagram of a control process of a modular blower system according to any of the embodiments.

[0030] FIG. 19 is a schematic diagram of another control process of a modular blower system according to any of the embodiments.

[0031] FIG. 20 is a circuit diagram illustrating a portion of the control circuit of the electronic control unit.

[0032] Before any embodiments of the subject matter are explained in detail, it is to be understood that the subject matter is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The subject matter is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.DETAILED DESCRIPTION

[0033] FIGS. 1-4 illustrate embodiments of a confined-space blower 10 including a fan 15 coupled to a motor 20 supported in a blower housing 25. The fan 15 is rotated by the motor 20 to generate an airflow 30 through a flexible conduit 35 that is removably couplable to the blower housing 25. The flexible conduit 35 is positionable to direct the airflow 30 into a confined space (e.g. a sewer shaft). The blower housing 25 has a generally cylindrical cross-section and may include handles 40 and attachment structure 45 to which accessories may be coupled.

[0034] The blower housing 25 may support a display 50 that indicates the expected runtime of the blower 10 and a user interface 55 including controls to operate the blower 10 (e.g., to turn the blower on / off, change the operating mode / speed of the blower, set a timer, etc.).

[0035] A battery pack 60 provides a power source for the blower 10, allowing the blower 10 to be operated at a remote location where an alternating current power source may not be available. In some embodiments (FIGS. 1 and 3), the battery pack 60 is removably coupled, e.g., replaceable, to a battery receptacle 65 on the blower housing 25, e.g., by sliding the battery pack 60 relative to the battery receptacle 65. In the embodiment of FIG. 1, when the battery pack 60 is coupled to the battery receptacle 65, the battery pack 60 is arranged, when viewed from above the blower 10, with the battery pack axis 66 positioned parallel to a blower axis 67 defined through the blower housing 25 and along which the fan 15 and motor 20 are positioned. In the embodiment of FIG. 3, a battery pack 60 is couplable to the battery receptacle 65 such that the sliding axis 69 along which a battery pack 60 is slidable, which corresponds to the battery pack axis, is arranged perpendicular to the blower axis 67. In another embodiment (FIG. 4), the blower 10 is electrically connected to a battery pack 75 positioned remote from the blower 10 (i.e., not onboard the blower housing 25). In the embodiment of FIG. 4, the blower 10 is electrically connected to a portable power unit including a backpack unit 70 that is configured to be carried by a user (e.g., with shoulder straps). The backpack unit 70 has a battery receptacle (78) to which the battery pack 75 is attachable, and the backpack unit 70 is electrically connected (via a multi-conductor cable 80) to the blower 10.

[0036] With reference to FIGS. 5 – 8, in another embodiment, a blower 100 may be a component of a modular blower system 104. The modular blower system 104 includes one or more modules that are removably couplable to the blower 100. The modules may perform different functions to condition the airflow generated by the blower 100 as will be described in further detail below. Illustrated modules include a cooler module 108, a sensor module 112, a filter module 116, and a duct holder 120. The cooler module 108, sensor module 112, filter module 116, and duct holder 120 are coupled in line with the blower 100 such that an airflow 124 generated by the blower 100 is directed through each of the cooler module 108, blower 100, sensor module 112, filter module 116, and duct holder 120. The cooler module 108 and sensor module 112 are electrically coupled to the blower 100 as will be described in further details below. Embodiments of the modular blower system 104 may include the blower 100 and any combination of the cooler module 108, sensor module 112, filter module 116, and duct holder 120. In the embodiment of FIG. 5, the cooler module 108 is coupled to a first (i.e., upstream) side of the blower 100, whereas the sensor module 112 is coupled to the second (i.e., downstream) side of the blower 100 between the blower 100 and the filter module 116, and the duct holder 120 is coupled to the filter module 116 such that the filter module 116 is positioned between the sensor module 112 and the duct holder 120. In other embodiments, the blower 100, cooler module 108, the sensor module 112, the filter module 116, and duct holder 120 may be coupled in any combination.

[0037] With reference to FIG. 6, the blower 100 includes a body 128 to which a handle 132 is pivotally coupled and from which supports 136 extend to support the blower 100 on a work surface (e.g., the ground). The body 128 defines a duct 140 (e.g., a cylindrical duct; FIG. 7) extending through the body 128 through which the airflow 124 is directed. The duct 140 includes an inlet 144 through which air enters the duct 140 and an outlet 148 from which the airflow is directed (FIG. 8). In some embodiments, the airflow may be directed through the duct 140 in either direction (i.e., from the inlet 144 to the outlet 148, and in reverse, from the outlet 148 to the inlet 144), depending on the rotational direction of a fan 180. In the present disclosure, the inlet 144 defines an upstream side of the blower 100 and the outlet 148 defines a downstream side of the blower 100. It will be appreciated that when the blower 100 is operated in a manner to generate an airflow from the outlet 148 to the inlet 144, the inlet 144 and outlet 148 define a downstream side and an upstream side, respectively.

[0038] With reference to FIG. 6, the body 128 includes a battery interface 152 to removably receive a battery pack. The battery interface 152 includes rails 156 along which the battery pack is slidably received by the blower 100, terminals 160 to which the battery pack is electrically couplable to transfer electricity from the battery pack to the blower 100, and a latch mechanism 164 to removably secure the battery pack to the blower 100. The blower 100 also includes a user interface 168 engageable by the user to input working parameters of the modular blower system 104. Attachment structures 172 adjacent the inlet 144 and outlet 148 removably receive coupling structures (e.g., fasteners, clips, latchets, etc.) to couple the cooler module 108, sensor module 112, filter module 116, and duct holder 120 to the blower 100.

[0039] With reference to FIG. 7, the blower 100 includes an electronic control unit 176, located on a side of the blower 100 opposite the user interface 168, that is configured to control the operation of the blower 100. The fan 180 is supported in the duct 140 adjacent the inlet 144. With reference to FIG. 8, the fan 180 is coupled to a motor 184 positioned in the duct 140. The motor 184 drives the fan 180 to rotate, generating an airflow. The motor may be, for instance, a brushless DC motor, although another type of motor may be used. One or more sensors 188 may be positioned in and coupled to sidewall of the duct 140 to monitor conditions of the airflow. In the present embodiment, the sensor 188 is an airspeed sensor (e.g., a pitot tube and differential pressure sensor) that measures the airspeed of the airflow and generates a signal indicating the airspeed. In other embodiments, the blower 100 may include a temperature sensor to measure the temperature of the air in the duct 140 or other sensors to monitor conditions of the blower 100. The blower 100 also includes a receptacle (not shown) that is configured to be coupled to AC mains power by a power cord to receive an alternating current power supply (AC power) from the AC mains power.

[0040] Returning to FIG. 5, the cooler module 108 is configured to cool the airflow. It will be appreciated that the cooled airflow, when directed into a confined space, the ambient temperature of the confined space is lowered, which may result in more comfortable working conditions in the confined space. The cooler module 108 is coupled to the blower 100. In the embodiment of FIG. 5, the cooler module 108 is coupled to the inlet 144 of the blower 100, that is, to an upstream side of the blower 100. The cooler module 108 is also electrically coupled to the blower 100, an in particular, to the electronic control unit 176. The cooler module receives power from the battery pack through the blower 100 and the electronic control unit 176, which distributes power from the battery pack to the cooler module 108.

[0041] In one embodiment, the cooler module 108 is a refrigerant cycle air conditioner including a compressor, a heat exchanger, an expansion valve, and an evaporative cooler fluidly coupled to one another. Refrigerant cycle air conditioners may require substantial power to operate. In one embodiment, the refrigerant cycle air conditioner is configured to receive AC power from a wall outlet as well as direct current from a battery pack coupled to the blower 100. The compressor could therefore receive about 1800 Watts of power from a mains power outlet. The compressor may be a variable speed compressor that is operable at two or more speeds (e.g., a high speed and a low speed). The compressor is configured to be switchable between different operation modes including an alternating current operation mode, a fixed-power operation mode, and a variable speed mode. In the first, alternating current operation mode, the blower 100 and cooler module 108 receive power from an alternating current power supply and the compressor is operable at a high speed only when the modular blower system 104 is coupled to an alternating current power supply. In the fixed-power operation ode, the blower 100 and cooler module 108 receive power from either of the AC power supply or the battery pack. When the modular blower system 104 is operating in the fixed power mode, regardless of the source of power, the compressor is operated at a high speed. It will be understood that operating the compressor at high speed while using power from the DC power supply impact runtime. In the variable speed mode, the compressor is operated at a high speed when receiving power from the AC power supply and is operated at a low speed when the compressor is receiving power from the battery pack. The user could also select the operating conditions of the blower 100 and cooler module 108 based on desired runtime and / or cooling needs.

[0042] FIG. 9 illustrates another embodiment of a refrigerant cycle air conditioner cooler module 108a coupled to a blower 100. The cooler module 108a and blower 100 constitute another embodiment of a modular blower system 104a, or a portion of a modular blower system 104a to which other modules are couplable. It should therefore be understood that modules of previously described embodiments may also be coupled to the blower 100. The cooler module 108a includes a heat exchanger 190 positioned within a duct portion 192 of the cooler module 108a. The airflow is received in the duct portion 192 and passes through / around the heat exchanger 190. A water reservoir 196 is coupled to the duct portion 192, and a water pump 200 coupled to the water reservoir 196 (e.g., positioned within the water reservoir 196) generates a flow of water through ducts 201 from the water reservoir 196 through the heat exchanger 190 and back to the water reservoir 196. A user adds a cooling medium (e.g., ice) to the water reservoir 196 to maintain the water in the cooler module 108a at a low temperature (e.g., at or near 32° F). In some embodiments of the water reservoir 196, the illustrated cooler module 108a requires a small amount of power (e.g., 10-30 W) during operation and reduces an ambient temperature of the confined space (e.g., a 25 °F temperature drop for a confined space having an ambient temperature of 110 °F).

[0043] In other embodiments, the cooler module 108 may be an evaporative cooler (or “swamp cooler”) that passes air over a wet media pad and cools the by evaporation of the water. Water is pumped from a reservoir to a media pad to drip down the media pad from the top of the media pad. In another embodiment, the media pad is partially submerged in a water sump and water wicks up the media pad.

[0044] In another embodiment, the cooler module 108 is a Peltier cooler including a thermoelectric Peltier module with a cold side attached to a heat sink placed in the airflow.

[0045] Other embodiments of cooling modules may include other types or configurations of cooling systems.

[0046] In still other embodiments, the cooler module 108 could instead be a heater module configured to generate heat (e.g., with a heating element positioned in the duct portion 192).

[0047] Returning to FIG. 5, the sensor module 112 includes one or more sensors 202 to measure or sense one or more conditions of the airflow before it enters the confined space. The sensor module 112 is electrically coupled to the electronic control unit 176 and generates signals that are received by the electronic control unit 176. In one embodiment, the sensor module measures the air quality of the airflow. The electronic control unit 176 receives the signal(s) from the sensor module 112 and determines whether the air quality exceeds pre-determined air quality threshold levels. In another embodiment, the sensor module 112 may include an airspeed sensor, a thermocouple, or another type of sensor configured to measure a parameter of the airflow. The sensor module 112 may receive power distributed by the electronic control unit 176 or may instead receive power from another source (e.g., a separate battery pack coupled to the sensor module 112, an AC source such as mains power, etc.). The sensor module 112 may instead communicate wirelessly (e.g., via Bluetooth or other wireless communication protocol) with the electronic control unit 176 or a wireless remote 900 (FIG. 17) held by the user that communicates, e.g., via a transceiver (not shown) incorporated in the electronic control unit 176. In the illustrated embodiment, the sensor module 112 is coupled to the outlet 148 of the blower 100 (e.g., the downstream side of the blower 100) although in other embodiments, the sensor module 112 may be coupled to the upstream side of the blower 100.

[0048] With continued reference to FIG. 5, the filter module 116 includes a filter 204. The filter 204 may be replaceable for regular maintenance when the filter 204 is saturated with particulate / contaminant. The filter 204 is configured to remove one or more types of particulates from the airflow. It will be appreciated that in working environments where dust, smoke, noxious fumes, or other particulates / contaminants are present, filtering the airflow results in better air quality of the airflow introduced into the confined space. In some embodiments, a filter may be configured (e.g., by mesh size, filter medium, etc.) to filter different types of particulates / contaminants from the airflow. For instance, a first filter is configured to remove a first type of particulate (e.g., dust) from the airflow, and a second filter is configured to remove a second type of particulate (e.g., smoke) from the airflow. In other embodiments, the filter module 116 may receive more than one replaceable filter. In still other embodiments, the filter may be configured as a general-purpose filter to remove more than one type of particulate / contaminant.

[0049] The duct holder 120 includes a flexible duct 208 that is extendible from the duct holder 120. The flexible duct 208 is positionable to direct the airflow generated by the blower 100. It will be appreciated that the flexible duct 208 can be positioned to direct the airflow linearly or non-linearly (e.g., at a direction different from, for instance, transverse to, the direction of the airflow). The flexible duct 208 is collapsible to be stowed within the duct holder 120 for storage and / or movement of the duct holder 120 and flexible duct 208 between worksites. The duct holder 120 is illustrated in FIG. 5 as being coupled to the blower 100 at a downstream side (i.e., coupled to the outlet 148, either coupled directly to the blower 100 to another one of the modules) of the blower 100. In other embodiments, the duct holder 120 can be coupled to the upstream side of the blower 100.

[0050] FIGS. 10 – 12 illustrate another embodiment of a blower system 304 that includes a blower 300 that is coupled to the cooler module 108a. The blower 300 is similar to the previously described blower 100, and similar features will be given a similar reference numeral, plus “200.”

[0051] With reference toFIGS. 10 – 12, the blower 300 includes a body 328 that defines a duct 340 having a substantially cylindrical shape that extends through the body 328. The duct 340 defines a blower axis 367. The fan 380 and motor 384 are supported in the duct 340 such that the fan 380 and motor 384 are arranged along the blower axis 367. The fan 380 and motor 384 are coupled and rotation of the fan 380 by the motor 384 generates an airflow 324 through the duct 340. The duct 340 includes an inlet 344 through which air enters the duct 340 and an outlet 348 from which the airflow is directed. In some embodiments, the airflow may be directed through the duct 340 in either direction (i.e., from the inlet 344 to the outlet 348, and in reverse, from the outlet 348 to the inlet 344), depending on the rotational direction of a fan 380. In the present disclosure, the inlet 344 defines an upstream side of the blower 300 and the outlet 348 defines a downstream side of the blower 300. The cooler module 108a is coupled to the inlet 344. It will be appreciated that when the blower 300 is operated in a manner to generate an airflow from the outlet 348 to the inlet 344, the inlet 344 and outlet 348 define a downstream side and an upstream side, respectively.

[0052] The body 328 includes a battery interface 352 that removably receives a battery pack 375. The battery interface 352 includes rails 356 along which the battery pack 375 is slidably received by the blower 300. In the illustrated embodiment, the battery pack 375 is slidably couplable to the battery interface 352 along a sliding axis 369 that is arranged perpendicular to the blower axis 367. Terminals (not shown) electrically couple the battery pack 375 to the battery interface 352 to transfer electricity from the battery pack 375 to the blower 300. A latch mechanism 364 removably secures the battery pack 375 to the blower 300. The blower 300 also includes a user interface 368 engageable by the user to input working parameters of the modular blower system 304. Attachment structures (not shown) adjacent the inlet 344 and outlet 348 removably receive coupling structures (e.g., fasteners, clips, latches, etc., embodiments of which are described in greater detail below) to couple the cooler module 108a, or other modules, to the blower 100.

[0053] The blower 300 includes an electronic control unit 176 that is supported, for instance, adjacent the battery interface 352. The electronic control unit 176 is configured to control the operation of the blower 300. The fan 380 is supported in the duct 340 closer to the inlet 344 than to the outlet 348. The blower 100 also includes a receptacle (not shown) that is configured to be coupled to AC mains power by a power cord to receive an alternating current power supply (AC power) from the AC mains power.

[0054] As shown in FIG. 12, the cooler module 108a includes an inlet duct portion 390 that is coupled to the inlet 344. An outlet duct portion 394 is coupled to the outlet 348. In one embodiment, the outlet duct portion 394 is formed integrally with the body 328. In other embodiments, the outlet duct portion 394 is removably coupled to the body 328. The inlet duct portion 390 defines an inlet passage 398 through which air passes to the inlet 344 and the outlet duct portion 394 defines an outlet passage 402 through which the airflow travels upon leaving the outlet 348. Each of the inlet passage 398 and outlet passage 402 have a height 406, 410 between the upper and lower surfaces 414, 418 of the inlet passage 398 and the upper and lower surfaces 422, 426 of the outlet passage 402, respectively. The heights 406, 410 of the inlet duct portion 390 and the outlet duct portion 394 have variable heights, with the heights of each the inlet duct portion 390 and outlet duct portion 394 changing along the blower axis 367. The heights 406, 410 each have a minimum height 406a, 410a that is less than the diameter 432 of the duct 340.

[0055] FIGS. 13 – 14 illustrate another embodiment of a blower system 504 that includes a blower 500 that is coupled to a duct holder 520. The blower 500 is similar to the previously described blower 100 and only differences between the blowers 100, 500 will be described in further detail. As shown in FIG. 13, the duct holder 520 includes a cover 524 that is pivotally coupled to the body 528 of the of the duct holder 520. A cover latch assembly 532 is pivotally coupled to body 528. The cover latch assembly 532 includes a latch handle 536 coupled to the body 528 and a latch 540 is pivotally coupled to the latch handle 536. Rotation of the latch handle 536 draws the latch 540 toward or pushes the latch 540 away from a catch 544 on the cover 524. With reference to FIG. 14, a flexible conduit 548 is supported within the body 528 and is extendible from the body 528 when the cover 524 is opened.

[0056] The blower 500 includes a motor 552 supported in a motor housing 556 that is coupled to the interior surface 560 of the blower housing 525. The interior surface 560 defines a duct portion 564 that extends along a blower axis 592. Vanes 562 extend between the interior surface 560 and the motor housing 556 to support the motor 552 and motor housing 556 within the duct portion 564. The vanes 562 are shaped to guide the airflow generated by the fan 576. The motor shaft 568 of the motor 552 is coupled to a hub 572 of the fan 576. The fan 576 further includes a semi-spherical nose 580 extending from the hub 572. Blades 584 extend helically about tubular portion 588 of the fan 576. The tubular portion 588 extends along the blower axis 592 from the semi-spherical nose 580.

[0057] Similar to the previously described embodiments of a blower 10, 100, the motor 552 of the blower 500 is a brushless DC motor that is operable to rotate the fan 576 in both clockwise and counterclockwise directions such that the direction of the airflow 530 (e.g., the primary airflow through the blower 500) generated by rotation of the fan 576 is reversible. The motor 552 may be operable at different speeds that are indicative of different volumetric flow rates (measured, for instance, in cubic feet per minute, or cfm). The speed may be continuously variable, or individually selectable, e.g., discrete, or non-continuous, speeds (e.g., high speed, medium speed, low speed). Exemplary speeds will be discussed in greater detail below with regard to the electronic control unit.

[0058] With reference to FIG. 14A, the blower 500 is configured such that a portion of the airflow 530 travels through the motor housing 556 to cool the motor 552. In the illustrated embodiment, the primary airflow 530 flows through the blower housing 525 in a first direction from the left side of the figure to the right side of the figure, as illustrated in FIG. 14A. The portion of the primary airflow 530 that travels through the motor housing 556 is a secondary airflow 534. The internal profile of the motor housing 556 creates a zone of low pressure within the motor housing 556 that draws the secondary airflow 534 into the motor housing 556 through a motor housing inlet 538 at the second end 542 of the motor housing 556 opposite first end at adjacent to which the nose 580 of the fan 576 is supported. The secondary airflow 534 travels through the motor housing 556 in a second direction opposite the first direction from the motor housing inlet 538 toward the nose 580, and passing along and through the motor 552. The secondary airflow 534 exits the motor housing 556 through outlets 546 in the nose 580 and rejoins the primary airflow 530. A cap 582 is coupled to the nose 580 and at least partially shields the outlets 546 from the airflow 530, thereby mitigating the increase in ambient pressure (e.g., ram air) within the motor housing 556 that would result from the airflow 530 entering the outlets 546. The cap 582 is coupled to the motor shaft 568 to rotate with the fan 576. The cap 582 deflects and directs the secondary airflow 534 to flow along the nose 580 to rejoin the primary airflow 530.

[0059] With reference to FIG. 14B, the secondary airflow 534 (shown in FIG. 14A, and traveling into the page, when viewing FIG. 14B) is a first cooling airflow. A second cooling airflow 535 is directed through the electronic control unit support portion 526 of the blower housing 525 external to the duct portion 564 defined by the interior surface 560 of the blower housing 525. The second cooling airflow 535 is generated by a fan 537 supported in the blower housing 525. The second cooling airflow 535 travels over a printed circuit board assembly 539 (“PCBA”) supported in the blower housing 525. The printed circuit board assembly 539 may include the electronic control unit (e.g., electronic control unit 176, shown in FIG. 20). A heat sink 543 may be coupled to the printed circuit board assembly 539 to further facilitate cooling of the printed circuit board assembly 539. In other embodiments, a portion of the primary airflow may be directed into the electronic control unit support portion 526 to provide the second cooling airflow 535.

[0060] Returning to FIG. 13, the duct holder 520 is couplable to the blower 500 by a draw latch 596 (e.g., an elastomeric draw latch) that receives a protrusion 600 on the blower housing 525, with the draw latch 596 stretching to engage the protrusion 600 resulting in tension through the draw latch 596 pulling the blower 500, via the protrusion 600, and the duct holder 520 toward one another. The draw latch 596 is one embodiment of a coupling assembly 604 and the protrusion 600 is an example of a coupling feature of the blower. In other embodiments, other latch styles or coupling assemblies may be used.

[0061] FIGS. 15 and 16 illustrate other embodiments of coupling assemblies 704, 804.

[0062] With reference to FIG. 15, the coupling assembly 704 includes a collar 708 rotatably supported on the duct holder 520. The collar 708 has an inner channel 712 and a recess 716 that communicates the inner channel 712 and an exterior 720 of the collar 708. A coupling feature, e.g., a tab 724, extends radially outwardly from the outer surface 728 of the blower housing 525. The inner channel 712 receives the tab 724 through the recess 716. When the tab 724 is received in the inner channel 712, the collar 708 is rotatable, thereby misaligning the recess 716 and the tab 724, preventing removal of the tab 724 from the inner channel 712 and securing the duct holder 520 to the blower 500.

[0063] With reference to FIG. 16, the coupling assembly 804 includes a button 808 that is slidably supported by the duct holder 812 at the outer circumference 816 of the duct holder 812 (e.g., in the handle 820). A spring 824 biases the button 808 to a first, extended position (shown in FIG. 16). The button 808 includes a coupling flange 828 that extends from the button 808 through the handle 820. A pin 832 is also slidably supported in the handle 820 at the outer circumference 816 of the duct holder 812. A spring 836 biases the pin 832 to an extended position (shown in FIG. 16). The coupling flange 828 engages the pin 832. The pin 832 has a tapered end 840. A coupling feature, e.g., a tab 844, extends from the blower 500 and includes a hole 848 that receives the pin 832. The duct holder 812 is vertically downwardly slidable relative to the blower 500 such that the tapered end 840 engages the tab 844, sliding the pin 832 relative to the handle 820 against the bias of the spring 836. The pin 832 is received in the hole 848 when the pin 832 and the hole 848 are aligned and the pin 832 is in the extended position, securing the blower 500 to the duct holder 812. To detach the blower 500 from the duct holder 812, the button 808 is depressed against the bias of the spring 824. Engagement of the coupling flange 828 with the pin 832 moves the pin 832 with the button 808 to remove the pin 832 from the hole 848. As shown in FIG. 16A, the blower 500 and duct holder 812 may include other features to align and position the duct holder 812 relative to the blower 500. In the illustrated embodiment, a ridge 852 extends radially outwardly and downwardly from the outer circumference 816 of the duct holder 812 and is received in a recess 856 of the blower 500. The duct holder 812 also includes recesses 860 (e.g., two recesses) that extend into the duct holder 812 and receive ridges 864 extending from the blower 500. The recesses 860 are positioned on opposite sides of the coupling assembly 804 of the duct holder 812. Other positioning features may be included in addition to or in place of the alternating recesses and ridges.

[0064] With reference to FIG. 17, in some embodiments, the electronic control unit 176 may include a transceiver configured to communicate wirelessly (e.g., via Bluetooth or other wireless communication protocol) with a wireless remote 900 held by a user within the confined space, or within a distance or line-of-sight of the electronic control unit 176 of the modular blower system 104, 304, 504. In the illustrated embodiment, the remote 900 is configured as a dedicated handheld remote 900 configured to work only with one or more modular blower systems 104, 304, 504 (modular blower system 504 shown in FIG. 17). In other embodiments, the remote may be configured as a standalone device, e.g., a smartphone, not dedicated specifically to the modular blower system 104, 304, 504. In still other embodiments, the remote 900 may be configured to communicate with the electronic control unit 176 via intervening repeaters or other devices that are configured to increase the range between the remote 900 and the electronic control unit 176 to areas and distances that would otherwise be beyond line-of-sight between the remote 900 and the electronic control unit 176.

[0065] The transceiver 902 of the remote 900 is configured to transmit one or more signals to the electronic control unit 176 of the blower 500 and receive one or more signals (e.g., a return signal) from the electronic control unit 176 that are indicative of the operating conditions of the blower 500. The remote 900 includes a user interface 904 that is engageable by a user to select or input working parameters, perform other control operations of the modular blower system 104, 304, 504, or remotely monitor operation of the modular blower system 104, 304, 504. For instance, the user may be able to control the speed of the blower 10, 100, 300, 500 (blower 500 shown in FIG. 17) by engaging the user interface 904 (e.g., depressing a button). The user interface 904 may also be configured to display a status of the modular blower system 104, 304, 504. For instance, for a battery-powered blower system, the user interface 904 may display a state of charge of the battery to the user, a power source in use (e.g., AC power, battery power). The remote 900 may also display a speed mode selected (e.g., high speed, low speed, etc.) that is indicative of the fan speed. In still other embodiments, the user interface 904 of the remote 900 may include an auditory indicator (e.g., a piezoelectric buzzer 908) that indicates that the state of charge of the battery pack has reached a minimum state of charge threshold that indicates that battery pack is near the end of its useable charge (e.g., 10% of useable charge) and that the blower needs to be coupled to another power source (e.g., a fully charged battery pack or AC mains power). It should be understood that the useable state of charge may be different that the actual state of charge in order to prevent the charge of the battery pack from being completely expended.

[0066] With reference to FIGS. 18-19, the electronic control unit 176 is configured to perform operations to control operation of a modular blower system, such as any of the previous described modular blower systems 104. Among the operations performed by the electronic control unit 176 are disturbing power from the power source(s) (e.g., alternating current from mains power and converted to direct current, direct current from one or more battery packs coupled to the blower 100 or other modules of the modular blower system 104, etc.), receiving signals from the user interface 168 indicating working parameters selected by the user, receiving signals from one or more sensors (e.g., the airspeed sensor 188, air quality sensor 202) indicating the operating conditions of the modular blower system 104, distributing power to the blower 100, including the motor 184, the cooler module 108, 108a, and sensor module 112, and outputting one or more control signals to the blower and / or the cooler module 108, 108a to control operation of the blower 100 and the cooler module 108, 108a. The electronic control unit 176 may also include a memory to store pre-defined characteristics of the modular blower system 104, such as the cross-sectional area of the duct 140, maximum and / or minimum operating conditions, minimum allowable flow rates, etc.

[0067] In the present embodiment, the airspeed sensor 188 outputs a signal indicative of the airspeed of the airflow, the battery pack coupled to the battery interface 152 generates a signal indicating the battery energy that is received by the electronic control unit 176, and the air quality sensor 202 outputs an air quality signal indicating the air quality of the airflow, and each signal is received by the electronic control unit 176. These signals are indicative of the operating conditions of the modular blower system 104. Other signals related to the operating conditions of the modular blower system 104 may be generated by other sensors and received by the electronic control unit 176.

[0068] The electronic control unit 176 also receives signals from the user interface 168. A user engages the user interface 168 to input working parameters of the modular blower system 104. Signals indicating those working parameters are received by the electronic control unit 176. In the present embodiment, the user engages the user interface 168 to input working parameters such as the runtime (duration of operation of the modular blower system 104), fan speed, confined space volume, number of air changes per unit time (e.g., number of air changes per hour), and minimum airflow rate. Once set by the user, the minimum airflow rate and other working parameters may be set in the modular blower system 104.

[0069] In response to the signals received from the sensors indicating the working parameters and the operating conditions, the electronic control unit 176 determines the total maximum power of the modular blower system 104. Based on that determination, the electronic control unit 176 also outputs blower control signals to control operation of the blower 100 and cooler control signals to control operation of the cooler module 108, 108a, based on the maximum power of the modular blower system 104.

[0070] In one embodiment illustrated in FIG. 18, the electronic control unit 176 receives a battery energy signal, e.g., current draw, (an operating condition) from the battery pack and a runtime signal from the user interface 168 (a working parameter) at step 1001, determines the total maximum power of the modular blower system 104 at step 1002, and outputs a signal to the blower 100 to control operation of the blower 100 (i.e., the speed at which the motor 184 rotates the fan 180) at step 1003 to operate the blower 100 for the entirety of the desired runtime. At step 1004, the motor 184 operates at the speed determined by the electronic control unit 176.

[0071] In another embodiment shown in FIG. 19 the electronic control unit 176 performs the same steps as identified above for steps 1001 and 1002. At step 1005, the user can input a working parameter (e.g., fan speed or cooling condition). At step 1006, the electronic control unit 176 determines the total maximum power for the modular blower system 104. At step 1007, the electronic control unit 176 outputs a blower control signal to adjust the fan speed and / or outputs a cooler control signal to control the cooler module 108, 108a to maintain the constant total power of the modular blower system 104 over the selected runtime. Following step 1007, a user could adjust, via the user interface 168, the cooling or heating generated by the cooler module 108, 108a, and the electronic control unit 176 adjusts the fan speed to maintain constant power at step 1007.

[0072] The electronic control unit 176 may perform other control operations, in addition to, or instead of the steps described above. In another embodiment, the electronic control unit 176 receives a signal from the airspeed sensor 188 indicating the airspeed of the airflow generated by the blower 100. The electronic control unit 176 then determines the flow rate based on the airspeed of the airflow and the pre-defined cross-sectional area of the duct 140. The electronic control unit 176 then compares the calculated flow rate to a minimum flow rate. The minimum flow rate may have been set by a user and stored as a predefined value. The controller then controls operation of the blower 100 to maintain the minimum airflow rate if below the minimum flow rate. In another embodiment, the electronic control unit 176 determines a minimum airflow rate based on the working parameters input by a user, including the confined space volume and the number of air changes. The electronic control unit 176 receives a volume signal indicating the confined space volume and a change signal indicating the number of changes from the user interface 168 following input to the user interface 168 by the user. The electronic control unit 176 determines the flow rate based on the airspeed signal provided by the airspeed sensor 188 and the cross-sectional area of the duct 140. The controller then determines a minimum airflow rate based on the confined space volume and the number of air changes, compares the flow rate to the minimum flow rate, and maintains the minimum airflow rate if the flow rate is below the minimum airflow rate, by outputting a control signal to the blower 100.

[0073] In any of the previously described embodiments of a user interface (e.g., user interface 608, shown in FIG. 13), the user interface may include an auditory indicator 612 (e.g., a piezoelectric buzzer) that provides an audible indication of the state of charge of the battery pack. The auditory indicator 612 may be activated, for instance, when the useable state of charge of the battery pack is at10% charge, or below. In other embodiments, the state of charge at which the auditory indicator 612 is activated may be set by a user.

[0074] FIG. 20 illustrates a portion of an exemplary electronic control unit 176 at least partially supported (e.g., on a printed circuit board assembly, “PCBA”) in any of the embodiments of a blower 10, 100, 500.

[0075] The electronic control unit 176 is electrically coupled to a receptacle 1104 that is configured to be couplable to AC mains power by a power cord to receive an alternating current power supply. The electronic control unit 176 is also electrically coupled to receive power from a battery pack through the battery pack interface (e.g., battery interface 152). The electronic control unit 176 includes one or more solid-state drives, or “SSD.” In the illustrated embodiment, the electronic control unit 176 includes one SSD 1108 electrically coupled to an AC power source and another SSD 1112 electrically coupled to the battery interface 152. The electronic control unit 176 distributes the power received from the battery pack and AC power source to other components of the blower 500, such as a datalogger 1116, the user interface 608 (including a transceiver 1120 wirelessly coupled to the remote 900), and to the motor 552 of the blower 500. The electronic control unit 176 also includes one or more sensors, e.g., any of the previously described sensors, or a Hall sensor 1124 coupled to the motor 552 to determine the rotational position of the motor 552. Other components may be included in, or coupled to communicate with the electronic control unit 176, such as an inverter, charging electronics, etc.

[0076] The electronic control unit 176 is configured to operate the blower 500 at one or more speeds, or volumetric flow rates. In one embodiment, exemplary low, medium, and high volumetric flow rates at which the electronic control unit 176 may operate the blower 500 are 700 cfm, 800 cfm, and 900 cfm, for instance, as measured at the outlet of the blower 500. The blower may be operable at another speed, e.g., a maximum, or boost, speed, for a short period of time (e.g., 15 minutes). An exemplary maximum volumetric flow rate may be, for instance, 1100 cfm. It will be appreciated that when operating at the maximum flow rate, the battery pack charge would drain quicker than at lower flow rates, and as such, the period of time the blower 500 could operate would also decrease. In the illustrated embodiment, the electronic control unit 176 may determine the power source (e.g., AC mains power, battery pack) and control operation of the blower 500 based on the power source from which power is being received. When connected to AC mains power, the electronic control unit 176 may operate the blower 500 at the maximum flow rate for an unlimited amount of time as long as the blower 500 is coupled to AC mains power. If the electronic control unit 176 determines that the blower 500 is receiving power from the battery pack and is not coupled to AC mains power, the electronic control unit 176 may limit the duration of time the blower 500 is operated at the maximum flow rate. If the blower 500 is powered by the battery pack while operating at the maximum flow rate and is subsequently coupled to AC mains power, the electronic control unit 176 may revert operation from a limited duration to an unlimited duration, and vice versa, if disconnected from AC mains power. The electronic control unit 176 may also be configured to start the blower 500 at a predetermined start time (e.g., based on a timer or a clock) and / or stop the blower after a designated time period (e.g., a time period set by a user) or at a set time of day.

[0077] It should be understood that the descriptions of the blowers and blower modules described above are considered non-limiting, and features of any of the embodiments of blowers and blower modules described above may be incorporated into other embodiments. Although the subject matter has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the subject matter as described.

[0078] Various features of the invention are set forth in the following claims.

Examples

Embodiment Construction

[0033]FIGS. 1-4 illustrate embodiments of a confined-space blower 10 including a fan 15 coupled to a motor 20 supported in a blower housing 25. The fan 15 is rotated by the motor 20 to generate an airflow 30 through a flexible conduit 35 that is removably couplable to the blower housing 25. The flexible conduit 35 is positionable to direct the airflow 30 into a confined space (e.g. a sewer shaft). The blower housing 25 has a generally cylindrical cross-section and may include handles 40 and attachment structure 45 to which accessories may be coupled.

[0034]The blower housing 25 may support a display 50 that indicates the expected runtime of the blower 10 and a user interface 55 including controls to operate the blower 10 (e.g., to turn the blower on / off, change the operating mode / speed of the blower, set a timer, etc.).

[0035]A battery pack 60 provides a power source for the blower 10, allowing the blower 10 to be operated at a remote location where an alternating current power source...

Claims

1. A blower configured to receive power from an alternating current power supply and a replaceable battery pack, the blower comprising: a blower housing defining a duct portion;a motor coupled to the blower housing and positioned within the duct portion, the motor including an output shaft;a fan coupled to the output shaft and rotatable with the output shaft to generate a primary airflow through the duct portion; anda motor housing coupled to the blower housing and positioned within the duct portion, the motor positioned at least partially within the motor housing, the motor housing receiving a secondary airflow from the fan that travels through the motor housing.

2. The blower of claim 1, wherein the primary airflow travels through the duct portion in a first direction, and the secondary airflow travels through the motor housing in a second direction that is opposite to the first direction.

3. The blower of claim 2, wherein the secondary airflow comprises a portion of the primary airflow.

4. The blower of claim 1, wherein the fan is coupled to the output shaft adjacent a first end of the motor housing and a second end of the motor housing defines a motor housing inlet that receives the secondary airflow.

5. The blower of claim 4, wherein the fan defines one or more outlets through which the secondary airflow flows.

6. The blower of claim 5, further comprising a cap coupled to rotate with the fan, the cap at least partially shielding the one or more outlets from the primary airflow.

7. The blower of claim 6, wherein the cap is coupled to the output shaft.

8. The blower of claim 1, wherein the secondary airflow is a first cooling airflow, and wherein a second cooling airflow is generated to flow through the blower housing external to the duct portion and is configured to cool an electronic control unit supported in the blower housing.

9. The blower of claim 8, wherein a cooling fan is supported in the blower housing and generates the second cooling airflow.

10. A blower system configured to receive power from an alternating current power supply and a replaceable battery pack, the blower system comprising: a blower includinga blower housing including a duct portion defining a blower axis,a motor coupled to the blower housing and positioned within the duct portion, the motor including an output shaft,a fan coupled to the output shaft and rotatable with the output shaft to generate a primary airflow through the duct portion, anda motor housing coupled to the blower housing and positioned within the duct portion, the motor positioned within the motor housing and the output shaft extending from the motor housing, the motor housing receiving a secondary airflow from the fan that travels through the motor housing; anda duct holder couplable to the blower and including a flexible duct that is extendible from the duct holder and is configured to direct the primary airflow generated by the blower, the duct holder including a coupling assembly that engages a coupling feature of the blower to removably couple the duct holder to the blower.

11. The blower system of claim 10, wherein the duct holder is slidable relative to the blower in a direction perpendicular to the blower axis of the blower to engage the coupling assembly with the coupling feature.

12. The blower system of claim 11, wherein the coupling assembly includes a pin slidably supported in the duct holder at an outer circumference of the duct holder, the coupling feature of the blower is a tab that extends radially from the blower and includes a hole that receives the pin.

13. The blower system of claim 12, wherein the coupling assembly further includes a button slidably supported at an outer circumference of the duct holder and biased to a first position by a first spring, the button including a coupling flange extending therefrom, the pin is biased to an extended position by a second spring, the coupling flange engaging the pin.

14. The blower system of claim 13, wherein the blower includes a recess that receives a ridge extending radially outwardly from the duct holder.

15. The blower system of claim 10, wherein the coupling assembly includes a collar rotatably supported on the duct holder and having an inner channel and a recess communicating the inner channel and an exterior of the collar, the coupling feature is a tab extending from the blower, the inner channel receiving the tab through the recess, and wherein misalignment of the recess and the tab couples the duct holder to the blower.

16. A blower system configured to receive power from an alternating current power supply and a replaceable battery pack, the blower system comprising: a blower including an electronic control unit configured to control operation of the blower, the electronic control unit configured todistribute power from a power source,receive one or more signals indicating a selected operating parameter, andoutput one or more blower control signals to control operation of the blower based on the selected operating parameter;a duct holder couplable to the blower and including a flexible duct, the flexible duct configured to extend from and direct an airflow generated by the blower; anda remote wirelessly coupled to the electronic control unit and configured to transmit a signal to the blower and receive a return signal from the blower, the remote including a user interface configured todisplay an operating condition of the blower, andreceive an input from the user indicative of a selected working parameter.

17. The blower system of claim 16, wherein the user interface further includes an auditory indicator that outputs an auditory signal to a user.

18. The blower system of claim 17, wherein the auditory signal is indicative that a state of charge of the battery has reached a minimum charge threshold.

19. The blower system of claim 16, wherein the user interface is configured to display a fan speed and / or a battery state of charge.

20. The blower system of claim 16, wherein the selected operating parameter is a fan speed selection.

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