Patent Publication Number: US-10786089-B2

Title: Built-in air pump assembly

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to air pumps, and more particularly to a built-in air pump that can be deployed for inflation and deflation of an inflatable product, such as an air mattress. 
     2. Description of the Prior Art 
     Inflatable products have become very popular. In particular, inflatable air mattresses have become a very useful item that has found use at homes, camping and other applications. These inflatable air mattresses are typically inflated and deflated by air pumps. Some of these mattresses have been provided with built-in air pumps that can be stored in a socket or space that is provided in the housing of the mattress, and then pulled out and deployed for use in inflating and deflating the mattress. 
     Many of the existing built-in air pumps suffer from a number of drawbacks. For example, the construction of these built-in air pumps can be complicated which leads to increased cost and reliability issues. In addition, many of the existing pump units have their vents exposed to the environment when the product is either inflated in use or deflated for storage (i.e., when the pump unit is not in use), so that the interior of the pump units can be contaminated by water or dirt. 
     In addition, many of the existing air pumps in the market have different functions due to the structural transformation of the air duct. These pumps have complicated air passages and many components that must be structurally matched, which often leads to large airflow loss and high air leakage during the inflation process. At the same time, the complicated structure also increases the difficulties and costs of production. 
     Therefore, there remains a need for more effective built-in air pumps that can be used with inflatable products, such as mattresses, and which avoids the drawbacks of the present pump units. 
     SUMMARY OF THE DISCLOSURE 
     In order to accomplish the objects of the present invention, there is provided a pump assembly for use with an inflatable product. The inflatable product has a chamber having an air inlet and an air outlet. The pump assembly has a pump unit that is positioned inside the chamber for inflating and deflating the chamber, the pump unit having a motor that is operatively coupled to a first blower and a second blower, with the first blower is fluidly coupled to the air inlet and the second blower is fluidly coupled to the air outlet. The chamber is inflated by intake of air through the air inlet to the first blower and then into the chamber, and the chamber is deflated by drawing air from the chamber to the second blower and then out of the chamber through the air outlet. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of the main components of a built-in pump assembly according to one embodiment of the present invention. 
         FIG. 2  is a perspective view of an inflatable mattress with the pump assembly of  FIG. 1  incorporated therein. 
         FIG. 3A  is an exploded view of the main components of  FIG. 1 . 
         FIG. 3B  is another exploded view of the main components of  FIG. 1 . 
         FIG. 4  is a cross-sectional view of the pump assembly of  FIGS. 1-3  showing the intake of air into the mattress. 
         FIG. 5  is a cross-sectional view of the pump assembly of  FIGS. 1-3  showing air being pumped out of the mattress. 
         FIG. 6A  is an exploded view illustrating the connection of the exhaust motor support and the protective net. 
         FIG. 6B  is an exploded view illustrating the connection of the intake motor support and the protective net. 
         FIG. 7  is an exploded view of the double blower assembly of the pump assembly of  FIGS. 1-5 . 
         FIG. 8A  and  FIG. 8B  illustrate how the knob is opened and closed. 
         FIG. 9  is a perspective assembled view of the pump assembly according to yet another embodiment of the present invention. 
         FIG. 10  is a cross-sectional view of the pump assembly of  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims. In certain instances, detailed descriptions of well-known devices and mechanisms are omitted so as to not obscure the description of the present invention with unnecessary detail. 
     Referring to  FIG. 2 , the pump assembly  20  of the present invention can be built in to the body  24  of an inflatable mattress  22 . Specifically, the inflatable mattress  22  can have an inflatable bladder or body  24 , and a recessed region  28  provided in a side wall  30  of the body  24 . The pump assembly  20  can be secured to the recessed region  28  by high frequency welding. 
     Referring now to  FIGS. 1 and 3-6B , the pump assembly  20  has a control housing assembly  40 , a pump unit that is a double-blower assembly  42 , and two connection tubes  44  and  46  that function as air ducts. The control housing assembly  40  houses the electronics and switches, air inlets, and air outlets, as explained in greater detail below. The double-blower assembly  42  is provided below the control housing assembly  40  and is separate and spaced-apart from the control housing assembly  40 . An intake connection tube  44  couples the air inlet of the control housing assembly  40  with one blower of the double-blower assembly  42 , and an exhaust connection tube  46  couples the air outlet of the control housing assembly  40  with the other blower of the double-blower assembly  42 . 
     Double Blower Assembly  42   
     Referring to  FIGS. 6A, 6B and 7 , the double-blower assembly  42  has an intake cover  50 , an intake blower  52 , an intake motor support  54 , a protective net  56 , a motor  58 , an exhaust motor support  60 , an exhaust blower  62  and an exhaust cover  64 . The intake cover  50  and the intake motor support  54  are secured together to define an intake housing having a chamber with the intake blower  52  housed therein, and the exhaust cover  64  and the exhaust motor support  60  are secured together to define an exhaust housing having a chamber with the exhaust blower  62  housed therein. 
     The protective net  56  is secured between the two motor supports  54  and  60 . In particular, as best shown in  FIGS. 6A, 6B and 7 , the protective net  56  is made of a plurality of net strands  70 , with four net strands having notches  66  at their ends that are adapted to be fitted into aligned holes  76  that are provided in spaced-apart manner along the periphery of the motor supports  54  and  60 . The motor  58  is housed inside the protective net  56 , and screws  82  can be used to secure the motor  58  to the two motor supports  54  and  60  via openings  83 , thereby causing the protective net  56  to be retained in place between the two motor supports  54  and  60 . The strands  70  of the protective net  56  can be made from a polymer material, such as Acrylonitrile Butadiene Styrene (ABS), and spaces  72  are defined between adjacent strands  70 . These spaces  72  extend circumferentially around the protective net  56 . The net  56  can have a concave or V-shape. 
     The motor  58  has a single shaft  74  having a first end that extends through an opening  78  in the intake motor support  54  to be connected to the intake blower  52 , and a second end that extends through an opening  80  in the exhaust motor support  60  to be connected to the exhaust blower  62 . 
     The intake cover  50  has a hollow L-shaped arm or elbow  84  extending therefrom and is threadably coupled to the intake connection tube  44 . Similarly, the exhaust cover  64  has an outlet port  90  (see  FIG. 7 ) extending upwardly therefrom and is coupled to the exhaust connection tube  46 . 
     Openings  79  and  81  are provided in the inner walls of the motor supports  54  and  60 , respectively, (see  FIGS. 6A and 6B ) allow air to be transferred to and from the chambers of the intake housing and exhaust housing, respectively, to the region  96  surrounded by the protective net  56 . The openings  79  can be angular slits provided along the edge of the wall of the motor support  54  that also carries the opening  78 , while the openings  81  can be two semi-circular openings provided on the same wall of the motor support  60  as the other opening  80 . The motor  58  is retained or housed in this region  96 . Thus, when air is being pumped from the external environment into the interior of the mattress body  24 , the air passes through the tube  86  into the intake housing where the intake blower  52  directs the air out through the openings  79  to the region  96  surrounded by the net  56 , and then the air escapes into the interior of the mattress body  24  via the spaces  72  between the strands  70 . See  FIG. 4  and the arrows that show the air flow. Conversely, when air is being pumped from the interior of the mattress body  24  to the external environment, the air is drawn in to the region  96  surrounded by the net  56  by the exhaust blower  62 , and from the region  96  surrounded by the net  56 , the air is drawn into the chamber of the exhaust housing via the openings  81 , and then exits through the outlet port  90  through the tube  92  into the external environment. See  FIG. 5  and the arrows that show the air flow. In this regard, it can be seen that positioning the motor  58  inside the region  96  surrounded by the net  56  allows the motor  58  to be cooled when air is either drawn in to, or drawn out from, the interior of the mattress body  24 . 
     Control Housing Assembly  40   
     Referring to  FIGS. 1, 3A, 3B, 4 and 5 , the control housing assembly  40  has a housing that has an elongated generally rectangular section  102 , and a storage section  104  that extends downwardly from one end of the rectangular section  102 . A cover  106  covers the opened upper end of the rectangular section  102 , and together with the rectangular section  102 , defines an interior compartment  108 . Four openings are provided in the cover  106 , an intake opening  110 , an exhaust opening  112 , a control button opening  114 , and a storage opening  116 . 
     An intake knob  118  extends through the intake opening  110 . An exhaust knob  120  extends through the exhaust opening  112 . A control button  122  extends through the control button opening  114 . A storage lid  124  is pivotably coupled to the storage opening  116 . The storage section  104  can be used to house the electrical wiring and power plug  98 , with access to the internal storage space  126  of the storage section  104  provided by lifting or closing the storage lid  124 . The storage section  104  can also be a battery compartment (not shown) if the pump assembly  20  is used with a DC motor. The control button  122  is used to turn the motor  58  on or off. In this regard, the control button  122  is coupled to wires  130  that electrically connect the control button  122  to the motor  58 . 
     The intake knob  118  has a hollow cylindrical body  136  that can have ribbed outer surfaces  138  to allow the user to grip and turn the knob  118 . A generally circular central hub  140  is provided at the upper end of the knob  118 , with the hub  140  connected to the body  136  by spokes  142 . Air passages  144  are defined between the spokes  142 . The central hub  140  extends into the hollow interior of the body  136  and terminates at a holder  146 . A flange  148  extends around the external wall of the hub  140 , and a silicone seal  150  is positioned under the flange  148  and secured by the holder  146 . The holder  146  has a conical shape so that it can more efficiently direct airflow. In addition, the thickness of the body  136  adjacent its upper end is slightly greater than the thickness elsewhere, so as to define an annular ridge  152 . A latch button  202  is provided on the outer surface of the cylindrical body  136  adjacent the lower end thereof. See also  FIGS. 8A and 8B . 
     A cylindrical guide wall  200  extends downwardly from the opening  110  in the cover  106 . A portion of the cylindrical wall of the guide wall  200  is cut out to define a rest shoulder  206 , a guide rail surface  204 , and a slot  166 . The latch button  202  is adapted to be seated in the rest shoulder  206  when the knob  118  is opened (see  FIG. 8A ), is adapted to slide downwardly along the guide rail surface  204 , and to be secured at the slot  166  when the knob  118  is closed (see  FIG. 8B ). 
     A first cylindrical wall  160  is defined inside the rectangular section  102  under the intake opening  110 . A second cylindrical wall  162  is defined inside the first cylindrical wall  160 , and extends through an opening  164  in the bottom wall of the rectangular section  102  to an annular flange  100 . See  FIG. 5 . The annular flange  100  is adapted to communicate with the open upper end of an inner tube  86 ; in particular, the open upper end of the inner tube  86  extends into and through the opening  164  surrounded by the flange  100 . The interior of the second cylindrical wall  162  defines an air channel  180  that communicates with the tubes  86  and  44  via the opening  164 . A spring  168  is adapted to be seated in the space  170  between the two cylindrical walls  160  and  162 , surrounding the second cylindrical wall  162 . 
     The intake knob  118  is adapted to extend through the intake opening  110  and has an annular lower lip  172  that functions to retain the knob  118  inside the space  170  by engaging an annular ledge  174  defined at the intake opening  110  at the cover  106 . The spring  168  is seated in the space  170  and extends upwardly to surround the central hub  140 , with the upper end of the spring  168  abutting the annular ridge  152  to retain the upper end of the spring  168  inside the knob  118 . 
     In use, the knob  118  can be turned clockwise to seal the air channel  180  by turning and pressing the knob  118  down, and which causes the latch button  202  to travel from the rest shoulder  206  to the slot  166 . In this position, the holder  146  extends into the interior of the second cylindrical wall  162  and the silicone seal  150  and the flange  148  sit on the annular upper edge of the second cylindrical wall  162  to seal the air channel  180  shut. In addition, in this position, the bottom edge of the body  136  sits adjacent the bottom of the cylindrical walls  160  and  162 . See  FIG. 5 . 
     The knob  118  can also be turned counter-clockwise to open the intake opening  110 . Turning the knob  118  counter-clockwise will allow the bias of the spring  168  to automatically cause the knob  118  to be pushed up, causing the latch button  202  to move from the slot  166  to the rest shoulder  206 . The annular lower lip  172  retains the knob  118  inside the space  170  by engaging the annular ledge  174  defined at the intake opening  110  at the cover  106  to prevent the knob  118  from being disengaged from the cover  106 . Ambient air can now pass through the air passages  144  into the interior of the body  136 , and then travel into the air channel  180 , through the opening  164 , and into the tube  86  and then the arm  84 . As best shown in  FIG. 4 , the bottom of the tube  86  communicates with the opened top end of the arm  84 , with the connection tube  44  acting as a sleeve to encircle the lower end of the tube  86  and the upper end of the arm  84  by a threadable engagement. 
     The construction and operation of the exhaust knob  120  can be identical to that of the intake knob  118 . Similarly, two cylindrical walls  190  and  192  can also be provided under the exhaust opening  112 , and have the same construction, and operate in the same manner, as the cylindrical walls  160  and  162  under the intake opening  110 . 
     In use, the knob  120  can be turned clockwise to seal the air channel  194  by turning and pressing the knob  120  down, and then engaging a latch button (not shown, but the same as  202 ) with a slot (not shown, but the same as  166 ). In this position, the central hub of the knob  120  extends into the interior of the second cylindrical wall  192  and a silicone seal (similar to  150 ) and a flange (similar to  148 ) sit on the annular upper edge of the second cylindrical wall  192  to seal the air channel  194  shut. In addition, in this position, the bottom edge of the body of the knob  120  sits adjacent the bottom of the cylindrical walls  190  and  192 . See  FIG. 4 . 
     The knob  120  can also be turned counter-clockwise to open the exhaust opening  112 . Turning the knob  120  counter-clockwise will cause the latch button to move from the slot to a rest shoulder, and the bias of the spring  196  will automatically cause the knob  120  to be pushed up. Air from inside the inflatable mattress  24  can now pass through the outlet port  90 , and the inner tube  92  into the air channel  194 , and then exit through the air passages  198  in the knob  120 . See  FIG. 5 . The connection tube  46  acts as a sleeve to encircle the lower end of the tube  92  and the upper end of the outlet port  90  by a threadable engagement 
     Operation 
     When the inflatable mattress  24  is to be inflated, the user opens the intake knob  118  in the manner described above, and then presses the control button  122  to turn on the motor  58 . As explained above, air is then delivered from the external environment through the air passages  144  into the air channel  180  and then into the tube  86 , and then through the arm or elbow  84  into the intake housing where the intake blower  52  directs the air out through the openings  79  to the region  96  surrounded by the net  56 , and then the air escapes into the interior of the mattress body  24  via the spaces  72  in the net  56 . When the mattress  24  has been inflated, the user turns off the motor  58  but pressing the control button  122  again, and then pushes the intake knob  118  down to seal the air channel  180 . 
     When the inflatable mattress  24  is to be deflated, the user opens the exhaust knob  120  in the manner described above, and then presses the control button  122  to turn on the motor  58 . As explained above, the exhaust blower  62  draws air drawn into the region  96  surrounded by the net  56  via the spaces  72 , and from the region  96  surrounded by the net  56 , the air is drawn into the chamber of the exhaust housing via the openings  81 , and then exits through the outlet port  90  through the tube  92 , the air channel  194  and the air passages  198  into the external environment. 
     It should be noted that both blowers  52  and  62  are turned on during inflation and deflation. However, inflation and deflation performance is not negatively impacted because one of the knobs  118  or  120  seals either the inlet or the outlet shut, thereby creating a vacuum state for the inlet or outlet that is sealed 
     Alternative Embodiment 
       FIGS. 9-10  illustrate another embodiment of the present invention. The embodiment in  FIGS. 9-10  is the same as the embodiment in  FIGS. 1-7 , except that the knobs  118  and  120  are now replaced by screw caps  1118  and  1120 . Otherwise, all the other elements that are the same as those in the embodiment of  FIGS. 1-7  have the same numeral designations. 
     In the embodiment of  FIGS. 9-10 , the springs  168  are now omitted as they are unnecessary. Each screw cap  1118  and  1120  has a generally cylindrical ledge  1122  with a curved slot  1124  cut out of a portion of the ledge  1122 . The curved slot  1124  is adapted to receive a curved ridge (not shown) extending from the base  1126  of the rectangular section  102 . The ledge  1122  surrounds the cylindrical wall  162  or  192  when the screw cap  1118  or  1120  is screwed tight to shut the air channels  180  and  194 . The inflate/deflate operations of this embodiment are identical to the inflate/deflate operations of the embodiment in  FIGS. 1-7 . 
     Benefits 
     The pump assembly  20  of the present invention provides a number of important benefits. First, the construction of the double-blower assembly  42  with the motor  58  supported between the two blowers  52  and  62  allows air to be delivered into and out of the body  24  very quickly. In particular, the air that is drawn in by the intake blower  52  exits the intake motor support  54  and spreads out very quickly around the motor  58 , through the net  56  and into the body  24 . Conversely, air that is drawn from the body  24  by the exhaust blower  62  can enter the exhaust motor support  60  from all over the net  56  and the motor  58 , thereby speeding up the exhaust of air from the body  24 . In fact, the net  56  can even be omitted to provide less obstruction to the air flow. 
     Second, the double-blower assembly  42  of the present invention improves efficiency. For example, by increasing power by only 8%, the double blower assembly  42  can achieve an increase in pressure by 60%. 
     Third, unlike many conventional pump units which utilize the same channels and tubes to draw in air and to exhaust air, the double blower assembly  42  of the present invention provides separate and independent inlets and outlets, which greatly reduces the loss caused by the flow resistance of the compressed air. This provides for rapid inflation and maximized air compression, with compression flow increased by more than 150% compared with the traditional pumps in the market Fourth, the construction of the double blower assembly  42  is simple, thereby making it easier and cheaper for mass production and after-sale service. 
     The above detailed description is for the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims. In certain instances, detailed descriptions of well-known devices, components, mechanisms and methods are omitted so as to not obscure the description of the present invention with unnecessary detail.