Abstract:
The invention is a device and a method for manufacturing the device, namely an air moving device, such as a vacuum cleaner, yard air blower, or other air moving machinery. The device and method involves using compressible foam, molded into appropriate configurations to secure the mechanical components, such as the motor and fan, inside a housing for operation. In most cases the method would involve enclosing an Air Moving Motor and its supporting components between two molded pieces of foam. The foam would conform to significant features on the motor or accompanying devices. The assembly will be placed into a molded housing, using the housing to encase the assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the priority date of the provisional application entitled “Functional Encapsulation Patent” filed by Richard L. Coombs on Jul. 18, 2007 with application Ser. No. 60/950,526. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to an apparatus and method for simple and inexpensive manufacture of mechanical air moving devices, and more particularly to vacuum cleaners, yard air blowers, and other air moving machinery. 
     BACKGROUND OF THE INVENTION 
     Air moving apparatus such as vacuum cleaners, blowers, and other air conveyance devices have seen various technological advances since their first invention. Modern air conveyance devices are complex and contain a great number of component parts. The manufacture of these types of devices requires skilled labor and complex manufacturing machinery. Numerous fasteners are used to attach all of the components into a single functioning device. Overall, an appreciable amount of expense is required to assemble and test each device before it is ready for sale. 
     The cost of tooling and labor required to construct conventional air moving devices is considerable. High cost of manufacturing inevitably drives the cost of the final product higher. The skilled labor needed to assemble complex devices is costly and time consuming to train. Manufacturers also have difficulty in retaining a trained work force at profitable salaries. Additionally, a large number of various component parts in an air moving device may require numerous manufacturing steps. A large number of manufacturing steps and different component parts involved in constructing these devices creates an added expense in tooling costs required when setting up, maintaining, and operating a manufacturing facility. 
     With increased competition in global manufacturing markets, cost and efficiency related issues arise when manufacturing conventional air moving devices. Manufacturers must develop highly efficient and low cost means of production. This need requires abandoning conventional manufacturing techniques and product designs that are labor intensive and require a high number of component parts. A need exists for a method of manufacture and simple design of an air moving device that reduces the need for highly trained labor, decreases expensive tooling cost, and reduces the number of parts in order to efficiently produce high quality air moving devices. This need is met by a novel product design and method of manufacture that minimizes manufacture time, labor cost, material costs, tooling costs, and results in a high quality product. 
     SUMMARY OF THE INVENTION 
     The invention disclosed is an air moving device and a method of making an air moving device in a manner that greatly reduces the required number of parts and simplifies the steps of assembly. The simplicity of the design of the air moving device significantly reduces the manufacturing costs. The design of the air moving device also reduces the amount of noise that is allowed to propagate from the device housing. The air moving device may be constructed in a number of embodiments including an upright, canister, belt, handheld, or backpack vacuum. The air moving device may also be configured as a blower or a variety of other pneumatic conveyance apparatuses, such as a yard and leaf blower, an industrial air mover, a household fan, a furnace fan, an automotive fan, or other air moving devices 
     The core of the air moving device is a block assembly constructed of molded, compressible, foam that encapsulates a motor/fan assembly. The compressible foam assembly not only functions to encapsulate the motor/fan assembly, but also contains an integrated air conveying chamber. The air conveying chamber is molded into the compressible foam assembly with an air outlet path and an air inlet path located at different points on the surface of the compressible foam assembly. The motor/fan assembly within the compressible foam assembly draws air in the air inlet path and pushes air out the air outlet path. 
     The core of the air moving device is comprised of a compressible foam assembly that is enclosed by a device housing that may take forms such as those listed above, including an upright, canister, or backpack vacuum, or a blower or other conceivable pneumatic conveyance apparatus. 
     In one manner of constructing the air moving device, the compressible foam assembly core is constructed of molded, compressible, foam blocks that fit together, thus encapsulating a motor/fan assembly. Fitting the compressible blocks together not only functions to encapsulate the motor/fan assembly, but also forms an air conveying chamber. Part of the air conveying chamber is molded into the face of each of two compressible foam blocks. Alternatively, more than two blocks could be used or the foam block could be injected into the housing around the other components of the device. 
     A motor/fan engagement structure is also molded into the face of each compressible foam block to allow placement of the electric motor/fan assembly within the air conveying chamber. This motor/fan engagement structure is partially formed on each compressible foam block, so that when the blocks are fitted together, the motor/fan assembly is held securely in the middle of the air conveying chamber. The motor/fan assembly is placed in a manner that enables it to draw air through the air conveying chamber from the air inlet path on the outside of the compressible foam block assembly and push air to an air outlet path at another point on the outside of the compressible foam block assembly. The mated faces of the compressible foam blocks are made air tight around the periphery of the air conveying structure and the motor/fan assembly, by compressing the blocks together. 
     Additionally, the faces of the compressible foam blocks are molded so that the air conveying chamber has a serpentine shape between the air inlet path and the air outlet path, when the compressible foam blocks are mated together. This shape functions to dampen noise generated by the motor/fan assembly. 
     Further assembly of the device involves placing the mated compressible foam blocks, which encapsulate the motor/fan assembly, into the device housing. The device housing provides the overall structure and configuration of the air conveying device. The device housing can have separate portions that join together and encapsulate different outside surfaces of the compressible foam block assembly. Within the device housing, other components of the device may be placed around the foam block assembly. These other components may be objects such as wiring, power switches, filters, and air transmitting refuse collectors. These components are selectively placed into devices configured for specific purposes such as vacuuming, blowing, or other air conveying functions. These other components are placed adjacent the compressible foam blocks assembly in a tight fitting manner in order to eliminate the need of fasteners. 
     Once all of the parts of the air moving device are assembled, the separate portions of the device housing are sealed around the core components of the device including the compressible foam assembly. The completed device housing assembly functions to compress the foam block halves together as well as hold the other components together with a tight fit so that no fasteners are needed for assembly. 
     The assembled product allows the motor/fan assembly to draw air into an air inlet port on the surface of the device housing assembly. Air may then be drawn though an air transmitting refuse collector if the device is a vacuum cleaner, or the air may be drawn through a filter. The air then is drawn into the air inlet path of the compressible foam block assembly. The air is next drawn through part of the air conveying chamber and into the motor/fan assembly. The air is then discharged from the motor/fan assembly and pushed through another part of the air conveying chamber of the compressible foam block assembly. The air is then pushed out the air outlet path of the compressible foam block assembly may be pushed through a filter, depending on the intended purpose and construction of the invention. The air is then pushed out of an air outlet port on the surface of the air moving device housing. 
     The purpose of the foregoing Abstract is to enable the public, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection, the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. 
     Still other features and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description describing preferred embodiments 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 embodiments are to be regarded as illustrative in nature, and not as restrictive in nature. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  Illustrates a front view of the assembled device for which the construction and method of assembly are described. 
         FIG. 2  Illustrates a front view of the disassembled device for which the construction and method are described. 
         FIG. 3  Illustrates a front view of the filter assembly portion of the invention. 
         FIG. 4  Illustrates a view of the front face of the first compressible foam block with the molded half of the air conveying chamber visible, as well as the front side of the second compressible foam block. 
         FIG. 5  Illustrates a view of the back side of the first compressible foam block, as well as the back face of the second compressible foam block with the molded half of the air conveying chamber visible. 
         FIG. 6  Illustrates a perspective view of the combined first and second compressible foam blocks. 
         FIG. 7  Illustrates a perspective view of the first compressible foam block with the motor/fan assembly placed in the motor engagement structure of the first compressible foam block. 
         FIG. 8  is a logic diagram for the method of constructing the air moving device by forming the foam block assembly with two foam block halves. 
         FIG. 9  is a logic diagram for the method of constructing the air moving device by forming the foam block assembly within the device housing. 
     
    
    
     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 industry manufacturing conventional air moving devices such as vacuum cleaners, air blowers, fans, or other air conveyance devices has produced devices that are manufactured with a high number of component parts. This requires skilled labor, lengthy production time, high tooling costs, and high cost of final products. A need for a simple and effective product design and method of manufacture for a variety of configurations of air moving devices is needed to reduce manufacturing costs of air moving devices. Filling this need increases business profitability in the global manufacturing marketplace and provides effective and more affordable air moving devices. 
     The device and the method of manufacture and product design disclosed herein solves the problems related to the high cost of manufacturing previously known to the air moving device industry. The invention disclosed herein show a simple air moving device design and method of construction utilizing a minimum number of component parts and assembly steps. This is achieved by producing an air conveying device with a core composed of two high temperature, compressible, foam block halves in which a motor/fan assembly and an air conveyance chamber is enclosed. This foam block assembly is mated with other component parts such as wiring, switches, filtration, or dust collection. All of the parts are snuggly fitted into an external, air moving device housing. Assembly of the device does not require special tools, nor does the device require fasteners to hold the parts together. All of the parts fit tightly together within the housing which snaps together to produce a finished product. This construction allows a relatively untrained assembler to quickly fit the simple pieces together into a working finished product, thereby reducing manufacturing and product costs. 
     Rather than using two block halves that fit together the foam blocks can also be cast in place surrounding the motor/fan assembly by injecting foam into the housing. The wiring and power switch can be in place within the housing before such an injection process. 
     In the following description and in the figures, like elements are identified with like reference numerals. The use of “or” indicates a non-exclusive alternative without limitation unless otherwise noted. The use of “including” means “including, but not limited to,” unless otherwise noted. 
     The illustration in  FIG. 1  represents a front view of the preferred embodiment of the invention in its fully assembled form. The embodiment of the device is that of a vacuum apparatus  10 . The housing  12  and lid  16  of the vacuum constitute the largest portion of the device which is configured in this embodiment as a backpack style vacuum. The housing  12  holds the majority of the components of the device and is sealable with the lid  16  to secure all of the components within the housing. The lid  16  seals across the front of the housing and is shaped to mate with the housing opening  18 . The housing opening is a large portal through which component parts of the vacuum device may be passed into or out of the housing. The lid  16  is secured over the housing opening by inserting the four lid tabs  20  into four tab slots  22  in the bottom and the upper edges of the housing opening  18  (shown in  FIG. 2 ). Inserting the tabs  20  into the tab slots  22  seals the lid around the periphery of housing opening  18 . 
     The upper half of the housing as represented in  FIG. 1  has two additional openings. One opening is a filtered airflow outlet  30 . The filtered airflow outlet allows air to pass out of the housing when the vacuum is operated. A filter assembly  28 , shown in  FIG. 3 , is positioned and held in place just below the periphery of the filter airflow outlet  30 . This filter assembly  28  functions to allow air to pass out of the device while filtering particulate matter from the device&#39;s internal airstream. Another opening on the upper half of the device is the housing airflow inlet  14 . The housing airflow inlet functions to allow the air to be drawn into the device while the vacuum apparatus  10  is in operation. An attachment elbow  32  may pass through the housing airflow inlet  14 . The elbow has an elbow airflow inlet  34  which is on the opposite end of the elbow from the end of the elbow that is inserted into the housing airflow inlet  14 . Air is drawn in the elbow airflow inlet  34  when the vacuum is in operation. The elbow airflow inlet  34  functions to allow attachment of hosing or other various tools that are used in vacuuming. 
     The illustrations in  FIG. 2  are a front perspective of the disassembled view of the internal and external components of the device.  FIG. 2 . Illustrates the front face of the first compressible foam block  24  and the front side of the second compressible foam block  26 .  FIG. 2  also illustrates the other components of the device. These are the lid  16 , the device housing  12 , the dust bag chamber  36 , the airflow inlet elbow  32 , the motor/fan assembly  48 , the first harness strap  40 , the second harness strap  42 , the power switch  74 , the power cord strain reliever  76 , the filter assembly filter grating  72 , the filter assembly plate  66 , the pleated filter medium  70 , and the filter case  68 . 
     The illustration in  FIG. 3  displays the filter assembly  28  in its assembled configuration. The back side of the filter assembly  28  is composed of the filter plate  66  with a void space in its center. The construction of the filter assembly is such that the pleated filter medium  70  is placed on top of the filter plate  66 . A filter grating  72  is then placed on top of the pleated filter medium  70 . A filter casing  68  is the placed around the periphery of the pleated filter medium  70  and the filter grating  72 , such that the filter casing  68  fixes the pleated filter medium  70  and the filter grating  72  to the filter plate  66 . Air may pass through the void space of the filter plate  66 , and through the pleated filter medium  70  and filter grating  72 . Besides the pleated filter shown, other filter modes may be used with the device and method of the invention, including but not limited to bag filters, vortex, centrifugal filters, and other filtration mechanisms. 
     The illustration in  FIG. 4  is a view of the front face of the first compressible foam block  24  and a view of the front side of the second compressible foam block  26 . Several functional aspects of the first compressible foam block  24  are visible on its front face as seen in  FIG. 4 . These functional aspects are molded at the time of the first compressible foam block&#39;s  24  manufacture. These functional aspects are a first compressible foam block air inlet molded half  52 , a molded half of the air conveying chamber  60 , a molded half of the motor engagement structure  64 , a continuation of the molded half of the air conveying chamber  60 , and a first compressible foam block molded half of the air outlet  56 . 
     The illustrations within  FIG. 5  are a view of the back side of the first compressible foam block  24  and a view of the back face of the second compressible foam block  26 . The back face of the second foam block  26  contains a mirror image configuration of the same functional aspects that are molded into the front face of the in the first foam block  24  as illustrated in  FIG. 4 . The functional aspects of the second foam block  26  are a second compressible foam block air inlet molded half  54 , a molded half of the air conveying chamber  60 , a molded half of the motor engagement structure  64 , a continuation of the molded half of the air conveying chamber  60 , and a second compressible foam block air outlet  58 . 
     When viewing  FIGS. 4 and 5  it is important to note that a portion of the air conveying chamber  60  that is molded into the face of each compressible foam block half is constructed in a manner that is serpentine in shape. When the first and second compressible foam blocks mated together, the air conveying chamber that is formed is a curved or sinusoidal passageway that dampens noise generated by the motor/fan assembly  48 . It is important to note that the whole air conveying chamber  60 , as well as the whole air inlet and outlet are constructed when the front face of the first compressible foam block  24  and the back face of the second compressible foam block  26  are mated together into a compressible foam block assembly  62 . 
     The illustration in  FIG. 6  is a perspective representation of the first compressible foam block  24  and the second compressible foam block  26  mated together to form a compressible foam block assembly  62 . Again, the front face of the first compressible foam block  24  is mated with the back face of the second compressible foam block  26 . This combination constitutes a compressible foam block assembly  62 . As stated above the front face of the first compressible foam block  24  and the back face of the second compressible foam block  26  are molded in mirror images of one another so that the air conveying chamber  60 , the motor engagement structure  64 , and the inlet and outlet molded halves of each compressible foam block align and seal against one another. The mirror image molding construction provides an air tight fit when the first and second foam blocks are mated and compressed together. Thus the joining of the two compressible foam blocks forms a compressible foam block assembly air inlet path  44 , a compressible foam block assembly air outlet path  46 , a complete motor engagement structure  64 , and a complete air conveying chamber  60 . 
     The illustration in  FIG. 7  is a perspective view the first compressible foam block  24  with the motor/fan assembly  48  placed within the molded half of the motor engagement structure  64 . The outer surface of the motor/fan assembly  48  contains orienting tabs  50  that provide additional support for the motor/fan assembly while in operation. The orienting tabs  50  fit into slots in the front face of the first compressible foam block and the back face of the second compressible foam block. This functions to keep the motor/fan assembly  48  stationary while the motor mechanism within the motor/fan assembly  48  is spinning and generates torque forces. 
     Assembly of the vacuum device requires placing the first compressible foam block  24  vertically within the left side of the housing  12 . The first compressible foam block  24  is placed in contact within the housing  12  so that the back side of the first compressible foam block contacts the rear inside wall of the housing. The first compressible foam block air inlet molded half  52  is oriented at the bottom end of the housing  12  and the first compressible foam block air outlet molded half  56  is aligned in the upper half of the housing with the filtered airflow outlet  30 . From this configuration, the front face of the first compressible foam block containing the molded half of the air conveying chamber  60  and the molded half of the motor engagement structure  64  is visible and accessible through the housing opening  18 . 
     Once the first foam block  24  is correctly positioned within the housing  12 , the motor/fan assembly  48  may be placed in the motor engagement structure  64  molded half of the first compressible foam block  24 . After the motor/fan assembly  48  is properly seated in the molded half of the motor engagement structure  64  of the first compressible foam block  24 , and the orienting tabs  50  of the motor/fan assembly  48  are secured within the front face of the first compressible foam block, the wiring may be connected to the motor/fan assembly  48 . The wiring may pass through channels within the first compressible foam block  24  and connect to a power switch  74  that is mountable to and accessible on the outside of the housing  12 . Once the wiring and the switching mechanism are in place the device is wired for connection to a power supply. An external power supply cord attaches to the power switch  74  and passes through a hole in the housing. The external power supply cord is attached to the housing by a conical cord strain reliever  76  that relieves tension stress at the junction between the external power supply cord and the housing  12 . 
     The second compressible foam block may be placed within the housing once the first foam block  24 , the motor/fan assembly  48 , the wiring, and power switch  74  are placed within the housing  12 . The second foam block may be inserted into the housing  12  through the housing opening  18 . The second foam block is aligned with the first foam block so that the second compressible foam block air inlet molded half  54  is aligned with the first compressible foam block air inlet molded half  52  at the bottom end of the housing. Additionally, the second compressible foam block air outlet molded half  58  is aligned with the first compressible foam block air outlet molded half  56 . This alignment insures that the compressible foam block assembly air outlet path is aligned with the filtered airflow outlet  30  of the housing  12 . 
     After partial placement of the second compressible foam block  26  within the housing, the motor engagement structure  64  of the second foam block  26  is tightly secured to the top of the motor/fan assembly  48 . The remaining edges of the two foam blocks are mated together. Thereafter, compressing the two blocks together forms the compressible foam block assembly  62  with the complete air conveying chamber  60 , complete compressible foam block assembly air inlet path  44  inside the housing&#39;s bottom end, and the compressible foam block assembly air outlet path  46  aligned with the filtered airflow outlet  30  at the top end of the housing  12 . 
     Once the compressible foam block assembly  62 , motor/fan assembly  48 , wiring, and power switch  74  are placed within the housing  12 , the other components of the vacuum may be placed within the housing. It is important to note that no additional fasteners are needed to assemble the device and that all of the component parts of the device fit tightly into housing, thereby holding one another into place. 
     The filter assembly  28  is slid into place within the housing  12 , between the filtered airflow outlet  30  and the compressible foam block assembly air outlet  46 . A groove is provided on the front side of the second compressible foam block  26  to allow insertion of the filter assembly  28 . 
     The dust bag chamber  36  is placed within the right side of the housing  12 , opposite the compressible foam block assembly  62 . The dust bag chamber  36  functions to hold a conventional vacuum filter bag within the housing. The dust bag chamber  36 , illustrated in  FIG. 2 , is a semi-tubular structure with a dust bag chamber grating  38  forming its bottom end and a collar forming its top end. One side of the dust bag chamber&#39;s  36  semi-tubular structure is open to allow access to a vacuum filter bag. 
     The dust bag chamber  36  is placed within the housing  12  so the collar at the top end of the dust bag chamber fits closely to the housing airflow inlet  14  located at the upper end of the device housing  12 . The collar accepts the inserted end of the elbow  32  when it is placed though the housing airflow inlet  14 . The collar also functions to accept the opening of a conventional vacuum filter bag. 
     The dust bag chamber grating  38  located at the bottom of the bag chamber  36 , functions to support a filter bag placed within the bag chamber while also allowing air flow. Installation of the dust bag chamber  36  within the housing  12  orients the bottom end of the dust bag chamber  36  and the dust bag chamber grating  38  adjacent to the compressible foam block assembly air inlet  44 , which is also in the bottom end of the device housing. This allows air to flow freely through the dust bag chamber grating  38  and into the compressible foam block assembly air inlet. 
     Placement of the lid  16  over the housing opening  18  functions to further compress the compressible foam block assembly  62 , insuring an air tight fit between the first and second compressible foam blocks and to insure that the motor/fan assembly generates adequate vacuum through the air conveying chamber  60 . The lid  16  is held in place by a series of lid tabs  20  molded around the periphery of the lid. These tabs correspond to tab slots  22  that are cut around the periphery of the housing opening  18 . Inserting all of the lid tabs  20  into the tab slots  22  insures that the lid is held securely in place in an airtight manner, thus completing the assembly of the device. 
     When switched on, the motor/fan assembly draws air into the sealed device housing  12  at the housing airflow inlet  14  and discharges air out of the filtered airflow outlet  30 . The path of the air though the vacuum device is as follows: air is vacuumed into the housing airflow inlet  14  through the elbow. The air then passes into the dust bag chamber  36  which contains a filter bag. The filter bag collects and traps any debris carried within the air stream. The air is then drawn through the porous surface of the conventional filter bag and through the dust bag chamber grating  38  in the bottom of dust bag chamber  36 . The air then passes from the base of the dust bag chamber to the compressible foam block assembly air inlet path  44 . The air then passes into the first part of the air conveying chamber  60  within the compressible foam block assembly  62 . The air is then pulled through the motor/fan assembly and discharged into the second part of the air conveying chamber  60  within the compressible foam block assembly  62 . The air passes through the serpentine passageway of the air conveying chamber  60  and through the air outlet path of the compressible foam block assembly  62 . The air then passes through the filter assembly  28 , trapping any remaining particulate matter that was not trapped by the conventional filter bag. The air is then discharged from the device housing  12  through the filtered airflow outlet  30 . 
       FIG. 8  is a logic flow diagram for the above described method of assembling an air moving device. Step  78  involves forming the device housing. Step  80  includes forming the first block. Step  82  involves placing the first block within the device housing. Step  84  involves placing the motor/fan assembly within the first block. Step  86  involves placing the second block in corresponding contact with the first foam block in the housing. Step  88  involves placing the switch, wiring, and power source connections within the housing so that all of the components are correctly wired. A step  90  the air moving device is completed. 
       FIG. 9  is a logic flow diagram that illustrates a method of constructing the air moving device. Step  92  is the start of the process of forming the device housing. The next step  94  is installing the power switch and wiring to the motor/fan assembly and placing the motor/fan assembly within the device housing. Step  96  involves forming the block assembly with air inlet and outlet paths. This step can be accomplished within the device housing by way of injecting the foam block material into the housing and around the other components of the device such as the motor/fan assembly. In step  98 , a motor/fan engagement structure is formed around the motor/fan assembly as the foam solidifies. In step  100  the device housing is sealed and the air moving device is completed. 
     The exemplary embodiments shown in the figures and described above illustrate but do not limit the invention. It should be understood that there is no intention to limit the invention to the specific form disclosed; rather, 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. For example, while the exemplary embodiments illustrate a functional encapsulation vacuum, the invention is not limited to use as a vacuum and may be embodied in other configurations and used for other purposes of than as a vacuum. While the invention is not limited to use as vacuum, it is expected that various embodiments of the invention will be particularly useful in such devices. Hence, the foregoing description should not be construed to limit the scope of the invention, which is defined in the following claims. 
     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.