Integrated Motor-Fan Blower Housing for Compact Assembly
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Solution Overview
Problem
Existing blowers face challenges in downsizing due to the obstructive arrangement of the motor and fan components, which hinders design optimization and increases assembly complexity, and require separate steps for attaching the fan to the motor shaft, leading to inefficient manufacturing.
Innovation Solution
The blower design integrates the motor and fan assembly within a housing, with the motor and stator housed inside a motor case, and utilizes a detachable battery pack as a leg for freestanding support, allowing for improved assembly efficiency and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the fan is arranged outside the motor case to be exposed to the air path, then the motor and fan can be separately assembled, but the blower size increases and design freedom is restricted
Solution Approach 1:
The patent merges the motor case and fan housing into a single integrated motor case structure. The motor case simultaneously serves as the motor housing and the fan housing, eliminating the need for separate fan housing components. This integration allows the fan to be positioned inside the motor case while maintaining separate assembly capabilities through modular component design.
Solution Approach 2:
The patent implements a nested arrangement where the fan is positioned inside the motor case, with the fan housing nested within the motor case structure. The motor rotates the fan blades that are housed within the same casing, creating a compact nested configuration that reduces overall blower size while maintaining functional separation.
2Adaptability or versatility
If the fan is arranged outside the motor case, then the motor and fan can be independently manufactured, but the number of assembly steps increases
Solution Approach 1:
The motor case is designed to integrate multiple functions: it houses the motor, serves as the fan housing, and provides the structural framework for the blower. This merging of functions reduces the number of separate components and assembly steps while maintaining design freedom through modular element integration.
Solution Approach 2:
The motor case serves multiple purposes simultaneously: it is the housing for the motor, the housing for the fan, and the structural body of the blower. This multi-functionality reduces the overall component count and simplifies the assembly process while preserving design flexibility.
3Device complexity
If the battery pack is mounted in conventional positions, then the structure is simple, but the blower is difficult to hang and place balanced
Solution Approach 1:
The battery pack is designed to serve dual functions: it provides power supply and acts as a balancing weight for the blower. By positioning the battery pack at the rear end of the handle, it counterbalances the motor assembly at the front, enabling easy hanging and stable placement without requiring additional counterweight structures.
Solution Approach 2:
The battery pack automatically serves as the counterweight component, eliminating the need for separate balancing mechanisms. The rearward positioning of the battery pack creates a natural counterbalance to the forward-positioned motor, allowing the blower to be self-balancing for hanging and placement operations.
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
This configuration enables a compact, easily assembled blower with enhanced mounting efficiency and balanced design, facilitating easy hanging and placement, while maintaining high air speed and reduced noise levels.
Implementation Method 1
a rotor using a permanent magnet; a stator core; and a coil wound around the stator core
Implementation Method 2
a fan fixed to the driving shaft and configured to generate an air flow by using a suction force
Data Source
AI summary
A blower with assembly performance that is improved by downsizing of a housing resulted from unitization of a blower fan and a motor is provided. In a blower including a housing configured to house the motor and the blower fan therein and to include an air intake port sucking the air flow thereinto and a tubular air exhaust port configured to exhaust out the air flow toward a front side direction, the motor and the blower fan as an assembly embedded into a motor case are housed in a main body section of a housing. A brushless DC motor is adopted as the motor, and a motor circuit board is mounted on a front side of the motor. A semiconductor switch element is mounted on the motor circuit board, and the motor is driven at 40,000 revolutions/second or more.