Embossed Combustion Air Blower Housing for Furnace Airflow Control
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Solution Overview
Problem
Existing combustion air blowers with permanent split capacitor motors are expensive and fail to provide sufficient thermal efficiency, especially when used with furnaces of varying capacities.
Innovation Solution
A combustion air blower utilizing a shaded pole motor, embossed housing, and interchangeable baffles to control airflow, which includes an impeller fan and a discharge conduit with specific wall configurations to restrict airflow effectively, thereby enhancing thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a permanent split capacitor motor is used in a combustion air blower, then the motor provides reliable operation, but the system becomes more expensive and fails to provide sufficient thermal efficiency
Solution Approach 1:
The patent replaces the expensive permanent split capacitor motor with a more economical motor design that achieves reliable operation through alternative means, specifically using a motor housing with integrated mounting features and a simplified construction approach that reduces manufacturing cost while maintaining operational reliability
Solution Approach 2:
The patent integrates the motor mounting structure directly into the motor housing by providing mounting tabs that extend from the housing walls, eliminating the need for separate mounting brackets or additional fastening components. This merging of functions reduces part count, simplifies assembly, and lowers overall system cost while maintaining reliable motor operation
2Adaptability or versatility
If interchangeable baffles are used to control airflow for different furnace capacities, then adaptability improves, but device complexity increases
Solution Approach 1:
The patent divides the airflow control function into modular components by providing a motor housing with integrated mounting tabs that can accommodate different baffle configurations. The housing itself is segmented into walls with specific tabs (first tab on first wall, second tab on second wall, etc.) that allow selective installation of different baffle types depending on furnace capacity requirements, enabling adaptability without requiring a completely different housing design for each application
Solution Approach 2:
The motor housing is designed as a universal component that can serve multiple furnace capacity requirements through its integrated mounting tab structure. The housing walls include multiple tabs positioned at different locations that can accommodate various baffle configurations, allowing a single housing design to provide adaptability across different applications without increasing overall device complexity
3Loss of energy
If the discharge conduit includes multiple walls with embossments to restrict airflow, then thermal efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies embossments selectively at specific locations on the discharge conduit walls rather than uniformly across the entire housing. Each wall (first, second, third, and fourth walls) has embossments positioned at particular locations to restrict airflow in specific directions, creating local quality variations that optimize thermal efficiency while keeping the overall manufacturing process relatively simple through targeted rather than comprehensive modification
4Manufacturing precision
If embossments extend inwardly into the discharge passageway to restrict airflow, then airflow control precision improves, but device complexity increases
Solution Approach 1:
Instead of adding complex external components or separate airflow restriction devices, the patent inverts the approach by creating airflow restriction directly through the discharge conduit walls themselves using embossments. The embossments extend inwardly from the wall surfaces to reduce the effective cross-sectional area of the discharge passageway, achieving precise airflow control through the wall structure itself rather than through additional separate components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective and efficient airflow control system that maintains or improves thermal efficiency across different furnace capacities, using a shaded pole motor and embossments to optimize airflow restriction, outperforming systems with permanent split capacitor motors.
Implementation Method 1
The embossment is in one or more of the second wall, the third wall, and the fourth wall, and the embossment extends inwardly into the discharge passageway such that the embossment restricts airflow within the discharge passageway
Implementation Method 2
the baffle extends inwardly into the discharge passageway from the first wall towards the second wall and restricts airflow within the discharge passageway
Implementation Method 3
combustion air blowers include an impeller fan driven by a permanent split capacitor motor
Data Source
AI summary
A combustion air blower includes a blower housing, an impeller fan within the blower housing, and an embossment to restrict airflow from the combustion air blower. The blower housing has a discharge conduit defining a discharge passageway. The discharge conduit is adapted and configured to receive a baffle such that, when the baffle is received, the baffle extends inwardly into the discharge passageway from a first wall towards a second wall opposite the first wall. The baffle restricts airflow within the discharge passageway. The embossment is in the discharge passageway and in the second wall and extends towards the first wall such that the embossment restricts airflow within the discharge passageway. The embossment cooperates with a baffle to provide a reduced cross sectional area of the discharge passageway in comparison to an upstream portion.