Patent Publication Number: US-11028911-B2

Title: Actuator and applications of same

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application is a divisional patent application of U.S. patent application Ser. No. 14/710,392, filed May 12, 2015, now issued U.S. Pat. No. 10,094,456, which itself claims priority to and the benefit of U.S. provisional patent application No. 61/992,757, filed May 13, 2014, and Chinese patent application Nos. CN201420286872.4 and CN201410239511.9, both filed May 30, 2014 in the State Intellectual Property Office of P.R. China, which are incorporated herein in their entireties by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to driving devices, and more particularly to actuators for converting a rotating motion into a linear reciprocating motion and applications of the same. 
     BACKGROUND OF THE INVENTION 
     The background description provided herein is for the purpose of generally presenting the context of the present invention. The subject matter discussed in the background of the invention section should not be assumed to be prior art merely as a result of its mention in the background of the invention section. Similarly, a problem mentioned in the background of the invention section or associated with the subject matter of the background of the invention section should not be assumed to have been previously recognized in the prior art. The subject matter in the background of the invention section merely represents different approaches, which in and of themselves may also be inventions. Work of the presently named inventors, to the extent it is described in the background of the invention section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present invention. 
     Driving of an instrument or furniture such as, for example, an office desk, a table, a bed, a chair or the like often requires an actuator that is configured to convert a rotary motion into a reciprocating linear motion, so as to cause movements of an adjustable element in a structure in which the actuator is incorporated. For such an actuator, a reversible electric motor is utilized to generate the rotary motion and a transmission member is coupled to the electric motor so as to convert the rotary motion of the electric motor into the reciprocating linear motion of the actuator. Typically, a coil spring is employed in the transmission member to exert a braking force when the electric motor is deactivated. However, when the coil spring exerts the braking force, which is caused by friction, undesirable heat may be generated, which may not only have adverse consequences for the braking effect, but may also damage its surrounding structure. Further, such an actuator is structurally and operably very complicated, and costly in fabrication. 
     In addition, the electric motor is usually secured in a cabinet of the actuator by a foam plastic block filling an interior of the cabinet entirely, where the foam plastic block defines a recess therein, and the electric motor is tightly received in the recess of the foam plastic block, i.e., the foam plastic block entirely covers the electric motor sides. When the electric motor operates, its rotor is rotating back and forth rapidly, thereby generating heat therein. The use of the foam plastic block may degrade the heat dissipation performance of the actuator. On the other hand, when heated, the foam plastic block is easy to he distorted, easy aging or even to be melt, which may make the recess no longer match the electric motor tightly, thereby causing vibrations of the electric motor, and in turn, affecting the performance of the actuator. 
     Therefore, a heretofore unaddressed need exists in the art to address the aforementioned deficiencies and inadequacies. 
     SUMMARY OF THE INVENTION 
     In one aspect, the invention relates to an actuator for converting a rotating motion into a linear reciprocating motion. In one embodiment, the actuator includes a motor having a front end and an output worm shaft extending from the front end. 
     The actuator also includes a transmission mechanism that comprises a bracket mounted onto the front end of the motor, having a base, and a fixing pin extending from the base along a direction perpendicularly to the worm shaft of the motor; a worm wheel having a first side, an opposite, second side, and a polygon-shaped recess defined in the second side, the worm wheel attached onto the base through the fixing pin on the first side, and meshing with the worm shaft of the motor; and a connector having a first end portion and a second end portion extending oppositely from the first end portion, the first end portion formed in a polygon shape substantially complemental to that of the polygon-shaped recess such that the first end portion is tightly received in the polygon-shaped recess. 
     Further, the actuator also includes an adjustable member operatively connected to the second end portion of the connector of the transmission mechanism, such that when the motor rotates in one direction, the adjustable member is in an extending movement, and when the motor rotates in the other direction, the adjustable member is in a retracting movement. 
     In one embodiment, the transmission mechanism further comprises a cushion member placed between walls of the polygon-shaped recess of the worm wheel and the first end portion of the connector. 
     In one embodiment, the transmission mechanism is devoid of a coil spring. 
     In one embodiment, the actuator further comprises a housing and mounting means for mounting the motor in the housing, where the housing has side walls and a bottom wall defining an opening therewith, and a cover adapted to cover the opening, and the mounting means is devoid of a foam plastic block. 
     In one embodiment, the mounting means comprises two or more support posts formed on the cover of the housing to define a space therebetween, and two or more sleeve members attached to the respective support posts, such that, as assembled, the motor is tightly positioned in the space, where the two or more cover sleeve members are formed of an elastic material. 
     In another embodiment, the mounting means comprises two or more support posts&#39; formed on the bottom wall of the housing to define a space therebetween, and two or more sleeve members attached to the respective support posts&#39;, such that, as assembled, the motor is tightly positioned in the space, where the two or more cover sleeve members are formed of an elastic material. 
     In yet another embodiment, the mounting means comprises at least one Ω-shaped clamp and two or more screws to securely mount the motor on the bottom wall of the housing, such that, as assembled, the motor is tightly positioned between the Ω-shaped clamp and the bottom wall of the housing. In one embodiment, the mounting means further comprises one or more cushions placed between the Ω-shaped clamp and the motor, where the one or more cushions are formed of an elastic material. 
     In one embodiment, the actuator further includes an elastic pad placed between the motor and the bottom wall of the housing. 
     In another aspect, the invention relates to an actuator for converting a rotating motion into a linear reciprocating motion. In one embodiment, the actuator includes a motor having a front end and an output worm shaft extending from the front end; a transmission mechanism operatively coupled to the output worm shaft of the motor for converting a rotating motion of the motor into a linear reciprocating motion, where the transmission mechanism is devoid of a coil spring; and a housing and mounting means for mounting the motor in the housing, where the mounting means is devoid of a foam plastic block. 
     In one embodiment, the transmission mechanism comprises a bracket mounted onto the front end of the motor, having a base, and a fixing pin extending from the base along a direction perpendicularly to the worm shaft of the motor; a worm wheel having a first side, an opposite, second side, and a polygon-shaped recess defined in the second side, the worm wheel attached onto the base through the fixing pin on the first side, and meshing with the worm shaft of the motor; a connector having a first end portion and a second end portion extending oppositely from the first end portion, the first end portion formed in a polygon shape substantially complemental to that of the polygon-shaped recess such that the first end portion is tightly received in the polygon-shaped recess; and a cushion member placed between walls of the polygon-shaped recess of the worm wheel and the first end portion of the connector. 
     In another embodiment, the transmission mechanism comprises a bracket mounted onto the front end of the motor, having a base, and a fixing pin extending from the base along a direction perpendicularly to the worm shaft of the motor; a worm wheel having a first side, an opposite, second side, a recess defined in the second side, and limiting structures spaced-apart formed on walls of the recess, the worm wheel attached onto the base through the fixing pin on the first side, and meshing with the worm shaft of the motor; a gasket&#39; having flanges radially protruded from a perimeter of the gasket, placed in the recess of the worm wheel such that each limiting structure is tightly positioned between two adjacent flanges; and a connector having a first end portion and a second end portion extending oppositely from the first end portion, the first end portion formed with engaging posts, placed in the recess of the worm wheel such that each engaging post is tightly positioned between two adjacent flanges and between two adjacent limiting structures, whereby each flange of the gasket is tightly positioned between a respective limiting structure and a respective engaging post. 
     In one embodiment, the housing has side walls and a bottom wall defining an opening therewith, and a cover adapted to cover the opening. 
     In one embodiment, the mounting means comprises two or more support posts formed on the cover of the housing to define a space therebetween, and two or more sleeve members attached to the respective support posts, such that, as assembled, the motor is tightly positioned in the space, where the two or more cover sleeve members are formed of an elastic material. 
     In another embodiment, the mounting means comprises two or more support posts&#39; formed on the bottom wall of the housing to define a space therebetween, and two or more sleeve members attached to the respective support posts&#39;, such that, as assembled, the motor is tightly positioned in the space, where the two or more cover sleeve members are formed of an elastic material. 
     In yet another embodiment, the mounting means comprises at least one Ω-shaped clamp and two or more screws to securely mount the motor on the bottom wall of the housing, such that, as assembled, the motor is tightly positioned between the Ω-shaped clamp and the bottom wall of the housing. In one embodiment, the mounting means further comprises one or more cushions placed between the Ω-shaped clamp and the motor, where the one or more cushions are formed of an elastic material. 
     In certain embodiments, the mounting means may include other types of the mounting means, such us, springs placed between the side walls of the housing and the motor to secure the motor in the housing, and screws to mount the motor to the bottom (or top), or the side walls of the housing, etc. 
     In one embodiment, the actuator further has an elastic pad placed between the motor and the bottom wall of the housing. 
     In one embodiment, the actuator further also has a gasket member placed between the motor and the cover. 
     In one embodiment, the actuator further has an adjustable member operatively connected to the second end portion of the connector of the transmission mechanism, such that when the motor rotates in one direction, the adjustable member is in an extending movement, and when the motor rotates in the other direction, the adjustable member is in a retracting movement. 
     According to the invention, the motor is mounted in the housing by the mounting means, and there is devoid of a foam plastic block. 
     In certain embodiments, the actuator is utilized in power lifting columns that can be used in many applications, such as in adjustments of office desks, furniture and others. 
     These and other aspects of the present invention will become apparent from the following description of the preferred embodiment taken in conjunction with the following drawings, although variations and modifications therein may be effected without departing from the spirit and scope of the novel concepts of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings illustrate one or more embodiments of the invention and together with the written description, serve to explain the principles of the invention. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment, and wherein: 
         FIG. 1  shows a power lifting column having an actuator according to one embodiment of the invention. 
         FIG. 2A  shows an exploded view of an actuator according to one embodiment of the invention. 
         FIG. 2B  shows a partially exploded view of an actuator according to one embodiment of the invention. 
         FIGS. 3A-3D  show partially exploded and cross-sectional views of an actuator according to one embodiment of the invention. 
         FIGS. 4A-4D  show partially exploded and cross-sectional views of an actuator according to one embodiment of the invention. 
         FIGS. 5A-5C  show partially exploded and cross-sectional views of an actuator according to one embodiment of the invention. 
         FIGS. 6A-6C  show partially exploded and cross-sectional views of an actuator according to one embodiment of the invention. 
         FIG. 7  shows an exploded view of an actuator according to one embodiment of the invention. 
         FIGS. 8A and 8B  show partially exploded views of an actuator according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numerals refer to like elements throughout. 
     The terms used in this specification generally have their ordinary meanings in the art, within the context of the invention, and in the specific context where each term is used. Certain terms that are used to describe the invention are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the invention. For convenience, certain terms may be highlighted, for example using italics and/or quotation marks. The use of highlighting has no influence on the scope and meaning of a term; the scope and meaning of a term is the same, in the same context, whether or not it is highlighted. It will be appreciated that same thing can be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, nor is any special significance to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and in no way limits the scope and meaning of the invention or of any exemplified term. Likewise, the invention is not limited to various embodiments given in this specification. 
     It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     It will be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the invention. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising”, or “includes” and/or “including” or “has” and/or “having” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof. 
     Furthermore, relative terms, such as “lower” or “bottom”, “upper” or “top”, and “left” and “right”, may be used herein to describe one element&#39;s relationship to another element as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one of the figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower”, can therefore, encompasses both an orientation of “lower” and “upper”, depending of the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
     As used herein, “around”, “about” or “approximately” shall generally mean within 20 percent, preferably within 10 percent, and more preferably within 5 percent of a given value or range. Numerical quantities given herein are approximate, meaning that the term “around”, “about” or “approximately” can be inferred if not expressly stated. 
     The description will be made as to the embodiments of the present disclosure in conjunction with the accompanying drawings. In accordance with the purposes of this disclosure, as embodied and broadly described herein, this disclosure, in one aspect, relates to an actuator for converting a rotating motion into a linear reciprocating motion and applications of the same. 
       FIG. 1  shows a power lifting column that utilizes the invented actuator to convert a rotating motion into a linear reciprocating motion. The power lifting column includes an outer tube  1301 , a middle tube  1 : 302  and an inner tube  1303  telescopically connected to one another, and a housing  151 . The invented actuator, as described below, is positioned inside the tubes  1301 - 1303  and the housing  151  to drive the tubes  1301 - 1303  to be extended or retracted so as to lift or lower an instrument, furniture or an object in which the lifting column is incorporated. In one embodiment, one end of the outer tube  1301  is attached to, preferably welded to the housing  151 , as shown in  FIG. 1 . In another embodiment, one end of the inner tube  1303  is attached to, preferably welded to the housing  151  (not shown). The power lifting columns can be used in many applications, such as in adjustments of office desks, furniture and others. 
     Referring to  FIGS. 2A-4D , the actuator  100  is shown according to one embodiment of the invention. In this exemplary embodiment, the actuator  100  includes a motor  110 , a transmission mechanism  120  operatively coupled to the motor  110 , and a housing  151  and mounting means for mounting the motor  110  in the housing  150 , and an adjustable member  130  operatively connected to the transmission mechanism  120 , such that when the motor  110  rotates in one direction, the adjustable member  130  is in an extending movement, and when the motor  110  rotates in the other direction, the adjustable member  130  is in a retracting movement. 
     The motor  110  is a reversible electric motor having a front end and an output worm shaft  112  extending from the front end. 
     The transmission mechanism  120  has a bracket  121  mounted onto the front end of the motor  110 . The bracket  121  has a base  122 , and a fixing pin  1221  extending from the base  122  along a direction perpendicularly to the worm shaft  112  of the motor  110 . The transmission mechanism  120  also has a worm wheel  123 . The worm wheel  123  has a first side  1231 , an opposite, second side  1232 , and a polygon-shaped recess  124  defined in the second side  1232 . The worm wheel  123  is attached onto the base  122  of the bracket  121  through the fixing pin  1221  at the first side  1231 , and is mechanically meshing with the worm shaft  112  of the motor  110 . The transmission mechanism  120  further has a connector  127  having a first end portion  1271  and a second end portion  1272  extending oppositely from the first end portion  1271 . The first end portion  1271  is formed in a polygon shape substantially complemental to that of the polygon-shaped recess  124  such that, as assembled, the first end portion  1271  is tightly received in the polygon-shaped recess  124 . In addition, the transmission mechanism  120  also has a cushion member  125  placed between walls of the polygon-shaped recess  124  of the worm wheel  123  and the first end portion  1271  of the connector  127 . In certain embodiments, the cushion member  125  is formed of an elastic material such as rubber. 
     According to the embodiment of the invention, as shown in  FIGS. 2A and 3B , the transmission mechanism  120  is devoid of a coil spring. 
     The housing  151  has side walls  1511  and a bottom wall  1512  defining an opening  152  therewith, and a cover  159  adapted to cover the opening  152 . In addition, the bottom wall  1512  has a window  1513  and also a plurality of holes  1514  defined on the side walls  1512 . 
     In one embodiment, as shown in  FIGS. 2A and 4A-4D , the mounting means comprises four support posts  158  formed on the cover  159  of the housing  151  to define a space therebetween, and four sleeve members  157  attached to the respective support posts  158 . In one embodiment, the four support posts  158  and the cover  159  are integrally formed of a rigid material such as plastic or metal. In certain embodiments, the four sleeve members  157  are formed of an elastic material. As assembled, the motor  110  is tightly positioned in the space. 
     In another embodiment, as shown in  FIGS. 5A-5C , the mounting means comprises two support posts  158 ′ formed on the bottom wall  1512  of the housing  151  to define a space therebetween, and two sleeve members  157 ′ attached to the respective support posts  158 ′. In one embodiment, the two support posts  158 ′ and the bottom wall  1512  are integrally formed of a metal. In another embodiment, the support posts  158 ′ are welded onto the bottom wall  1512  of the housing  151 . In certain embodiments, the two or more sleeve members  157 ′ are formed of an elastic material. As assembled, the motor  110  is tightly positioned in the space. 
     In yet another embodiment, as shown in  FIGS. 6A-6C , the mounting means comprises one Ω-shaped clamp  157 ″ and two screws  1581 ″ to securely mount the motor  110  on nuts  158 ″ on the bottom wall  1512  of the housing  151 . The Ω-shaped clamp  157 ″ is formed of a rigid material such as plastic or metal. As assembled, the motor  110  is tightly positioned between the Ω-shaped clamp  157 ″ and the bottom wall  1512  of the housing  151 . In addition, in order to reduce vibrations and noises, one or more elastic cushions  1571 ″ placed between the Ω-shaped clamp  157 ″ and the motor  110 . 
     In addition, in certain embodiments, as shown in  FIGS. 5A and 6A , an elastic pad  155  is placed between the motor  110  and the bottom wall  1512  of the housing  151  for reducing the noises that may be generated due to the metal contact of the motor  110  with the bottom wall  1512  of the housing  151 . Further, a gasket member  156  may be placed between the motor  110  and the cover  159 . In certain embodiments, the gasket member  156  is placed between the bracket  121  mounted on the front end of the motor  110  and the cover  159 . More preferably, the gasket member  156  is placed between the opposite side of the base  122  of the bracket  121  mounted on the front end of the motor  110  and the cover  159 . 
     According to the embodiments of the invention, as shown in  FIGS. 4A, 5A and 6A , the motor  110  is securely mounted in the housing  151  without a foam plastic block. 
     Referring back to  FIGS. 2A and 2B , the adjustable member  130  has a spindle  131  having one end  1331  passing through the window  1513  of the housing  151  and connected to the second end portion  1272  of the connector  127  of the transmission mechanism  120  through coupling members  128 , which in turn, is mounted on the bottom wall  1512  of the housing  151  with a plate  154 . The other end  1332  of the spindle  131  is engaged with an activation element  135 . 
     As assembled, the actuator  100  is positioned inside the tubes  1301 - 1303  and the housing  151  of a lifting column, as shown in  FIG. 1 . In operation, the motor rotates in one direction, the rotation of the output worm shaft  112  drives the worm wheel  123  to rotate, which in turn, drives the spindle  131  to rotate accordingly, thereby causing the activation element  135  to extend, which drives the tubes  1301 - 1303  in a extending movement so as to lift an instrument, furniture or an object in which the lifting column is incorporated. Otherwise, when the motor rotates in the other direction, it drives the worm wheel  123  to rotate reversely, which in turn, drives the spindle  131  to rotate reversely, thereby causing the activation element  135  to retract, which drives the tubes  1301 - 1303  in a retracting movement so as to lower the instrument, furniture or the object in which the lifting column is incorporated. 
     Referring to  FIGS. 7, 8A and 8B , the actuator  100 ′ is shown according to another embodiment of the invention. In this embodiment, the actuator  100 ′ is structurally similar to the actuator  100  as shown in  FIG. 2A , except that the mounting means is in accordance with that shown in  FIGS. 5A-5C , and the transmission mechanism  120 ′ is shown in  FIGS. 8A and 8B . 
     As shown in  FIGS. 8A and 8B , the transmission mechanism  120 ′ includes a bracket  121  mounted onto the front end of the motor  110 . The bracket  121  has a base  122 , and a fixing pin  1221  extending from the base  122  along a direction perpendicularly to the worm shaft  112  of the motor  110 . 
     The transmission mechanism  120 ′ also includes a worm wheel  123 ′ having a first side  1231 ′, an opposite, second side  1232 ′, a recess  124 ′ defined in the second side  1232 ′, and limiting structures  1223 ′ spaced-apart formed on walls of the recess  124 ′. The worm wheel  123 ′ is attached onto the base  122  through the fixing pin  1221  on the first side  1231 ′, and is mechanically meshing with the worm shaft  112  of the motor  110 . 
     The transmission mechanism  120 ′ further includes a gasket  125 ′ having flanges  1251 ′ radially protruded from a perimeter  1252 ′ of the gasket  125 , placed in the recess  124 ′ of the worm wheel  123 ′ such that each limiting structure  1223 ′ is tightly positioned between two adjacent flanges  1251 ′. 
     In addition, the transmission mechanism  120 ′ includes a connector  127 ′ having a first end portion  1271 ′ and a second end portion  1272 ′ extending oppositely from the first end portion  1271 ′. The first end portion  1271 ′ is formed with engaging posts  1271 ′, and placed in the recess  124 ′ of the worm wheel  123 ′ such that each engaging post  1271 ′ is tightly positioned between two adjacent flanges  1251 ′ and between two adjacent limiting structures  1223 ′. As such, each flange  1251 ′ of the gasket  125  is tightly positioned between a respective limiting structure  1223 ′ and a respective engaging post  1271 ′. 
     In addition to the above description, it should be appreciated that other embodiments of the mounting means, such as those shown in  FIGS. 4A-4D and 6A-6C , can also utilized in the actuator  100 ′. 
     Furthermore, other types of the mounting means, such us, springs placed between the side walls of the housing and the motor to secure the motor in the housing, and screws to mount the motor to the bottom (or top), or the side walls of the housing, etc., can also be utilized in the invention. 
     The foregoing description of the exemplary embodiments of the invention has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching. 
     The embodiments were chosen and described in order to explain the principles of the invention and their practical application so as to activate others skilled in the art to utilize the invention and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its spirit and scope. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description and the exemplary embodiments described therein.