Abstract:
An improved vacuum motor air intake for use on vacuum motor device with a funnel shaped shroud enclosing a portion of the vacuum motor housing adjacent a fan assembly. Combined with the funnel shaped shroud, a conical air deflection body directs air entering the motor in a laminar flow pattern.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to air intakes for vacuum motors, and more particularly relates to improved vacuum motor air intakes for creating a more laminar flow into a vacuum motor housing. 
     2. Background Information 
     Various types of airflow generating devices, for example vacuum cleaner motors, are known in the prior art. Vacuum cleaner motors typically have a motor located within a housing, with the motor configured for driving a shaft. Attached to this driven shaft is an air moving diffuser plate of fan blades. The motor housing extends above and around the diffuser plate/fan blade, enclosing it and creating a compression chamber. Adjacent to the compression chamber is typically located an air intake aperture though which air is drawn into the motor housing, from which it is vented out of the bottom of the motor housing. Other types of airflow generating devices are also known in the prior art. 
     One of the greatest sources of inefficiency in this style of airflow generating device is turbulence. The fan is typically held onto the motor through use of a retaining means such as a nut and bolt. As airflow enters through the air intake aperture, turbulence forms as the air deflects at less than ideal angles off the nut, rotor spindle and washer surfaces, and off the flat surface of the diffuser plate/fan. What is needed is a manner of making the airflow into such an airflow-generating device housing more laminar and less turbulent. 
     SUMMARY OF THE INVENTION 
     The present invention is an improved vacuum motor air intake for use on a vacuum motor device or other airflow-generating device. The vacuum motor device has a motor, including a driven shaft, typically electrically powered, a motor housing and a fan assembly which is mounted on the drive shaft. Additionally, the motor housing has a shroud extending above and adjacent to the fan assembly enclosing a portion of the motor housing. The shroud includes an air intake aperture for allowing air to be drawn into the motor housing. This air is then moved through the vacuum motor housing and out through an exit. 
     One embodiment of the improved vacuum motor air intake utilizes an airflow deflection body which attaches to the vacuum motor device. This airflow deflection body is used to make airflow into and through the intake aperture and into the motor housing more laminar. In some embodiments, this airflow deflection body will be attached, either to the fan blade itself, or to the driven shaft, to the air intake aperture itself, or it may be suspended above or into the air intake aperture. Other attachments are also envisioned. Another embodiment of the improved vacuum motor air intake utilizes a cowl having a generally funnel shaped aperture for directing airflow to and through the air intake aperture and into the motor housing. This cowl attaches to the motor housing through use of a cowl attachment means. The combination airflow deflection body and the cowl serve to make airflow into and through the motor housing more laminar, less turbulent, and therefore more efficient, faster, and higher volume. 
     Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description wherein I have shown and described only the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated by carrying out my invention. As will be realized, the invention is capable of modification in various obvious respects all without departing from the invention. Accordingly, the drawings and description of the preferred embodiment are to be regarded as illustrative in nature, and not as restrictive. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a cross-sectional view of a prior art vacuum motor. 
     FIG. 2 is a perspective view of one embodiment of an airflow deflection body of the present invention. 
     FIG. 3 is a perspective view of one embodiment of a cowl utilized with the present invention. 
     FIG. 4 is an exploded, cross-sectional view of a second embodiment of the present invention. 
     FIG. 5 is an exploded, cross-sectional view of one embodiment of the present invention. 
     FIG. 6 is a side view of the embodiment of FIG. 5 shown assembled. 
     FIG. 7 is an exploded, cross-sectional view of a third embodiment of the present invention. 
     FIG. 8 is a cross-sectional view of the embodiment of FIG. 7 shown assembled. 
     FIG. 9 is a cross-sectional view of the fourth embodiment of the present invention. 
     FIG. 10 is a cross-sectional view of the fifth embodiment of the present invention shown assembled. 
     FIG. 11 is a perspective view of an embodiment of the invention. 
     FIG. 12 is an exploded perspective view of an embodiment of the invention. 
     FIG. 13 is a perspective view of an embodiment of the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     While the invention is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims. 
     The present invention is an improved vacuum motor air intake for use on a vacuum motor device, the improved air intake providing for more laminar flow of air into and through the motor&#39;s housing. 
     Referring initially to FIG. 1, a prior art style of a vacuum motor is shown. The vacuum motor has a motor assembly  74  which drives a spindle  76 . A fan blade or diffuser plate  72  is attached to the motor assembly through use of a nut  78  and typically a washer, which is threaded onto the threaded spindle  76 . Extending from or attaching to the motor assembly  74  is a shroud cover  80  which has an air inlet  82  adjacent to the center of the diffuser plate  72 . A space is formed between the shroud cover and the upper surface of the diffuser plate  72  so as to create a compression chamber  84 . The rotation of the diffuser plate  72  causes air to be drawn into the inlet  82 , and compresses the air within the compression chamber, thereby causing movement and exhaust of the air out of the compression chamber  84 . The arrows marked as  100  shows the general airflow through such a motor and compression chamber. 
     One of the largest losses of efficiency with such a motor is the fact that airflow coming in through the inlet  82  is turbulent, and thus does not flow in a laminar flow. Turbulence occurs as air impacts and passes over the spindle, nut, washer, and diffuser plate upper surface. This turbulent flow impedes airflow through the motor housing, thereby decreasing the airflow. This decrease in airflow has the result of decreasing the amount of suction the vacuum motor can provide. 
     Referring now to FIG. 2, one embodiment of an airflow deflection body  20  utilized in the present invention is shown. The airflow deflection body  20  serves as a means of creating a laminar flow of air through the inlet  82 , and deflecting such air through the compression chamber for diffusion by the diffusion plate. The airflow deflection body  20  is configured to attach to or cover the vacuum motor&#39;s spindle and nut, thereby providing a smooth surface for the air to flow across as it is moved into and through the motor housing of the vacuum motor. A recess in the side not shown would accommodate the spindle, nut, and washer of the diffusion plate. One method of attachment is to include in the airflow deflection body shown in FIG. 2 a threaded shaft (not shown) which threads on the spindle, thus replacing the nut. 
     Referring now to FIG. 3, one embodiment of a cowl  40  utilized in the present invention is shown. This embodiment of a cowl  40  is, through use of a shroud connection  44 , configured to attach to the shroud cover of a vacuum motor. This is done in such a matter that the air inlet or orifice  50  defined therein is aligned with the air inlet or orifice of the shroud cover. Leading to the orifice  50  is a direction body  48 , which is generally funnel shaped, as shown. By directing airflow in such a manner into the inlet of the vacuum motor, a more laminar airflow is achieved. The shroud connection  44  can be a friction fit, can twist into a locking position, can be glued or screwed in position, and can be attached by any conventional means. 
     FIG. 4 shows a partial exploded view of the embodiment of an airflow deflection body  20  shown in FIG. 2 and a cowl embodiment shown in FIG. 3, utilized with a motor assembly  74 . This motor assembly  74  has a diffuser plate  72 , a shroud cover  80 , and a compression chamber  84  between them. The airflow deflection body  20  is able to pass through the inlet  82  and attach to the spindle  76  and/or nut  78 , through use of a nut connection  22 , or other means. Examples of such attachment means include friction fits, adhesives, threading, pressing, etc. In use, airflow through the inlet  82  is more laminarly deflected past the nut and spindle, and along the flat upper surface of the diffuser plate. Optionally, a cowl  40  can be utilized to further increase the laminar flow of air through the inlet  82 . The cowl embodiment shown has a shroud connection means  44  for allowing the cowl to attach through the use of a friction fit to the shroud cover and/or motor housing. Other types of shroud connections are also envisioned, such as a snap-on fitting, twist and lock, use of adhesives, threading, pressing, screwing, etc. Obviously, the cowl could also be molded in the same piece as the shroud cover  80 . The direction body  48  will extend inwards for defection of air into the inlet  82  through an orifice  50  defined therein, which aligns with the inlet  82  of the shroud cowl  80 . Initial testing of the version shown in FIG. 4 shows an increase in efficiency of about 8%, and eventual improvements in efficiency of 8-12% are expected with the various embodiments. 
     Referring now to FIG. 5, another embodiment of the present invention  10  is shown. In this embodiment, the airflow deflection body  20 , and the cowl  40  are integrated into a solitary unit. The cowl  40  has a shroud connection  44  for connecting to the inlet  82 . The cowl  40  preferably also contains a number of airflow direction veins  52  for directing airflow into the inlet  82  and for attaching to and supporting the airflow deflection body  20 . The cowl  40  could also be attached to the shroud at the periphery. 
     FIG. 6 shows a view of the embodiment of FIG. 5 as installed. This embodiment snaps into place over a prior art motor assembly  74  and shroud cover  80 . It is thus useful as a retrofit to existing vacuum or air blowing motors. When installed as shown, the nut  78 , spindle  76  and washer are shielded from interaction with incoming air. The airflow deflecting body is suspended above the nut  78 , and spindle  76 . 
     Referring now to FIG. 7, another embodiment of the present invention  10  is shown. In this embodiment the airflow deflecting body  20  is integrally connected to the inlet  50  of the cowl  40  by a series of support vanes  48  which hold the airflow deflection body  20  suspended above the nut and washer assembly when installed, as shown in FIG. 8. A series of channeling canals are defined by the interface of the support vanes  52 . The sides of the funnel inlet and the air deflecting body  20  direct the flow of incoming air away from the nut and spindle  76  and washer assembly and on to the blades of the fan assembly, thereby providing for a more laminar flow of air. 
     The cowl  40  further preferably comprises a dome filter connection for connection with a dome filter  60  or screen. FIG. 8 shows an embodiment mounted on a prior art motor assembly and shroud cover  80  with a dome filter  60 . 
     The cowl containing the airflow deflecting body  20 , is attached to shroud cover  80  by means of a shroud connection  44 , which is configured for a friction fit over the shroud cover  80 . 
     FIG. 9 showed another embodiment of the present invention. In the embodiment shown in FIG. 9, a cowl  40  is fitted over the shroud cover  80  of a motor assembly  74 . The shroud cover  44  slopes from the periphery towards an orifice  50  with a direction body  48 . The function of the airflow directing body is accomplished by a modification of the fan blade or diffusion plate itself, in which the fan blade is shaped to include an airflow deflection body  24 . In the version shown in FIG. 9, a nut and spindle are used to hold the airflow deflection body and fan blade  24  to the spindle  76  for the motor. A further rounded conical shape insert could also be placed over the nut and the recess in which it is enclosed, to help achieve more laminar flow of air around the fan motor. 
     FIG. 10 shows the cowl  44  mounted on a motor assembly  74 . A direction body  48  causes air to be directed into the orifice  50 . An airflow directing body  20  replaces the nut and washer and attaches to the spindle  76  by means of threads  26 . 
     FIGS. 11 and 12 are perspective views of a cowl  40  such as that shown in FIGS. 5 and 6. FIG. 13 is a perspective and cutaway view of a cowl  40  as shown in FIGS. 7 and 8. 
     While there is shown and described the present preferred embodiment of the invention, it is to be distinctly understood that this invention is not limited thereto but may be variously embodied to practice within the scope of the following claims. From the foregoing description, it will be apparent that various changes may be made without departing from the spirit and scope of the invention as defined by the following claims.