Source: http://www.google.com/patents/US6439862?dq=7069184
Timestamp: 2014-03-13 17:30:18
Document Index: 9691939

Matched Legal Cases: ['arts 32', 'arts 32', 'arts 34', 'arts 32', 'arts 32', 'arts 32', 'arts 32', 'arts 32']

Patent US6439862 - Fan with improved electric motor and mounting - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA household fan with motor and motor housing for shielding the motor. The electric motor is preferably a four-pole permanent-split capacitor motor with a narrow profile enabling it to fit within a narrow box fan, the motor having a stator including a core of stacked laminations. A first outermost lamination...http://www.google.com/patents/US6439862?utm_source=gb-gplus-sharePatent US6439862 - Fan with improved electric motor and mountingAdvanced Patent SearchPublication numberUS6439862 B2Publication typeGrantApplication numberUS 09/850,450Publication dateAug 27, 2002Filing dateMay 7, 2001Priority dateOct 20, 1998Fee statusPaidAlso published asUS6227822, US20010018027Publication number09850450, 850450, US 6439862 B2, US 6439862B2, US-B2-6439862, US6439862 B2, US6439862B2InventorsYung ChenOriginal AssigneeLakewood Engineering And Manufacturing Co.Export CitationBiBTeX, EndNote, RefManPatent Citations (31), Non-Patent Citations (11), Referenced by (6), Classifications (34), Legal Events (5) External Links: USPTO, USPTO Assignment, EspacenetFan with improved electric motor and mountingUS 6439862 B2Abstract A household fan with motor and motor housing for shielding the motor. The electric motor is preferably a four-pole permanent-split capacitor motor with a narrow profile enabling it to fit within a narrow box fan, the motor having a stator including a core of stacked laminations. A first outermost lamination defines a first supporting surface, and a second outermost lamination defines a second supporting surface on which the front and rear casings are supported. Copper windings are wound about the core. A rotor has an output shaft which passes through a central region of the core. The front and rear casings are generally dome-shaped. Each casing has a circumferential side wall and a vented end wall. The front casing has a recessed area around the opening for the output shaft such that a portion of the bladed propeller assembly protrudes within the recessed area, allowing for a narrow profile design. Radially extending legs allow for mounting on parallel brackets along a rear grill of the fan.
What is claimed is: 1. An electric motor assembly for driving a bladed propeller of a portable fan assembly, comprising;
a motor drive assembly having a rotor with an output shaft and a stator of stacked laminations and wire windings; a front casing formed of cast aluminum and a rear casing formed of cast aluminum, said front and rear casings each having an outer casing wall, said outer casing wall of said rear casing being positioned radially outward of the windings at a distance configured to provide a space for wiring to pass between the outer wall and the windings, and at least one body portion extending radially outward of one of the outer casing walls, then al least one body portion being configured to provide a mounting bracket with at least a pair of mounting holes for securing the motor in a fan body said pair of mounting holes being aligned along an axis of a mounting surface that resides radially outward of said outer casing walls; slots formed in the laminations, each said slot having a transverse aperture dimensioned to provide a passageway for said windings passing between a first side of the laminations and a second side of the laminations, said windings being compressed in a manner such that the height of the windings passing beyond an outer surface of the laminations is no more than ⅝ inch and the overall height of the motor assembly as measured from the outer casing wall of the front casing to the outer casing wall of the rear casing is configured for use in a narrow body fan. 2. The rotor assembly of claim 1; wherein,
said windings bend radially outward to provide an obtuse inner angle between said laminations and an extent of the windings. 3. The motor assembly of claim 2; wherein,
said bend of the windings provides an outer portion of the windings formed into an extended position beyond an outer edge of the stator slots. 4. The motor assembly of claim 3; wherein,
said outer portion of the windings extends at least 2 millimeters beyond an outer edge of the stator slots. 5. The motor assembly of claim 1; wherein,
a plurality of said stator slots have a generally flat outer edge portion. 6. The motor assembly of claim 1, wherein;
said transverse apertures of the stator slots have a generally flat inner edge portion at a radially outward region of the stator. 7. The motor assembly of claim 1, wherein,
said pair of mounting holes are each aligned along an axis that resides radially outward of said outer casing walls. 8. The motor assembly of claim 7, wherein;
a second pair of holes are located on said mounting bracket, said second pair of holes being aligned along a second axis residing radially outward of said casing walls. 9. The motor assembly of claim 2; wherein,
said bend is formed adjacent to said first side of the laminations. 10. The motor assembly of claim 2; wherein,
said bend of the windings being adapted to direct windings radially outward provides an obtuse inner angle of the windings relative to said laminations. 11. The motor assembly of claim 2; wherein,
said bend of the windings is adapted to position an outer portion of the windings in an extended position at least 2 millimeters beyond an outer edge of the stator slots. 12. An electric motor assembly for driving a bladed propeller of a portable fan assembly, comprising;
a motor drive assembly having a rotor with an output shaft and a stator of stacked laminations and wire windings; slots formed in the laminations, each said slot having a transverse aperture dimensioned to provide a passageway for said windings passing between a first side of the laminations and a second side of the laminations, at least one bolt hole aperture passing through said laminations a front casing positioned to cover at least a portion of the first side of said laminations, and a rear casing positioned to cover at least a portion of the second side of said laminations, said front casing body secured to said rear casing by at least one fastener passing through the bolt hole aperture of the laminations, wherein an outer casing wall of said rear casing is positioned radially outward of the windings at a distance configured to provide a space such that motor wiring passes only between the outer wall and the windings; and said front casing having an outer sidewall with an indented region extending radially inward toward the windings and configured to provide a recess at least partially surrounding said fastener. 13. The motor assembly of claim 12, wherein;
said front casing sidewall has a generally circular periphery, and said indented region having a recess extending radially inward of said periphery. 14. The motor assembly of claim 13; wherein;
said rear casing having at least one boss depending from a lower surface of the front casing, said boss being partially received into said bolt hole aperture of the laminations. 15. The motor assembly of claim 12, wherein;
said stacked laminations is generally square having comer areas radially outward from said stator slots, a bolt hole aperture being in each said comer area, and a fastener passing through the bolt hole aperture, said fastener being secured to the front casing and said rear casing, at least a portion of the fastener residing within said indented area and being recessed below a major extent of an end wall of the front casing. 16. The motor assembly of claim 14, wherein;
said front casing has at least two indented regions, each providing an area surrounding a fastener, and said rear casing having at least two bosses, each extending into an aligned bolt hole aperture and dimensioned to receive a portion of a fastener. 17. The motor assembly of claim 12, wherein;
said front casing and the rear casing are formed of cast aluminum. 18. An electric motor assembly for driving a bladed propeller of a portable fan assembly, comprising;
a motor drive assembly having a rotor with an output shaft and a stator of stacked laminations and wire windings; slots formed in the laminations, each said slot having a transverse aperture dimensioned to provide a passageway for said windings passing between a first side of the laminations and a second side of the laminations; a front casing formed of cast aluminum and a rear casing formed of cast aluminum, said front and rear casings each having an outer casing wall, said outer casing wall of said rear casing being positioned radially outward of the windings at a distance configured to provide a space for wiring to pass between the outer wall and the windings, and at least one body portion extending radially outward of one of the outer casing walls, then at least one body portion being configured to provide a mounting bracket with at least a pair of mounting holes for securing the motor in a fan body; the front casing outer wall comprising a generally circular geometry, indented regions extending radially inward of said generally circular geometry, and a recess configured to receive at least a portion of a fastener securing the front casing into engagement with said stacked laminations, each said indented region being in linear alignment with an aperture in said laminations configured to receive a portion of a fastener extending from said front casing, and wherein said rear casing receives a portion of said fastener to fasten the front casing to the rear casing by a threaded fastener passing from said indented regions through the aperture in said laminations and passing into the rear casing; and said pair of mounting holes are each aligned along an axis of a mounting surface that resides radially outward of said,outer casing walls. 19. The motor assembly of claim 18, wherein;
said pair of mounting holes are each aligned along an axis that resides radially outward of said outer casing walls. 20. The motor assembly of claim 18, wherein;
a second pair of holes are located on at least one body portion extending radially outward of an outer casing wall, said second pair of holes being aligned along a second axis of a second mounting surface residing radially outward of said casing walls. 21. An electric 4-pole permanent split capacitor motor assembly for driving a fan blade, comprising;
a front casing at least partially defining a front chamber, and a rear casing at least partially defining a rear chamber; a motor drive assembly having a rotor with an output shaft and a stator of stacked laminations and wire windings, slots being formed in the laminations, and each said slot having a transverse aperture dimensioned to provide a passageway for said windings passing through the laminations, said windings having a portion residing in said front chamber and having a portion residing in said rear chamber; said rear chamber having a sidewall area positioned at a distance radially outward of an region of said windings, the distance being adapted to provide a space for electrical wires to pass radially outward of the windings and between the windings and the sidewall; said rotor having a metal core with an electronic resistance value providing a peak torque output of drive assembly, at least an outer portion of said rotor having an outer coating of matrix material, said matrix material being adapted to increase said resistance value of the rotor to thereby reduce said peak torque output of said drive assembly. 22. The electric motor of claim 21, wherein;
said windings extending into said front chamber to an average front maximum height beyond said laminations, and said windings extend into the rear chamber to an average rear maximum height beyond said laminations, at least one of said front or rear maximum height being less than about 0.625 inch. 23. The electric motor of claim 21, wherein;
said peak torque output of the drive assembly is reduced to a reduced value of approximately 1,000 revolutions per minute. 24. The electric motor of claim 21, wherein;
an outer side wall of said rear chamber is positioned radially outward of the windings in said rear chamber to provide an inner space for electrical wires to extend in a direction generally transverse to said output shaft. 25. An electric motor assembly for driving a bladed propeller of a portable fan assembly, comprising;
a motor drive assembly having a rotor with an output shaft and a stator of stacked laminations and wire windings; slots formed in the laminations, each said slot having a transverse aperture dimensioned to provide a passageway for said windings passing between a first side of the laminations and a second side of the laminations; a front casing formed of cast aluminum and a rear casing formed of cast aluminum, said front and rear casings each having an outer casing wall, at least a portion of the outer wall of said rear casing is positioned radially outward of the windings at a distance adapted to provide a space for wiring to pass between the outer wall and the windings; the front casing outer wall has a generally circular geometry, said front casing outer wall having indented regions extending radially inward of said generally circular geometry comprising a recess adapted to receive at least a portion of a fastener securing the front casing into engagement with said stacked laminations. 26. An electric motor assembly for driving a bladed propeller of a portable fan assembly, comprising;
a motor drive assembly having a rotor with an output shaft and a stator of stacked laminations and wire windings; slots formed in the laminations, each said slot having a transverse aperture dimensioned to provide a passageway for said windings passing between a first side of the laminations and a second side of the laminations; a front casing having an end-wall and positioned to cover at least a portion of the first side of said laminations, and a rear casing having an end-wall and positioned to cover at least a portion of the second side of said laminations; the end-wall of the front casing comprising a recessed portion having an inwardly directed passageway toward the rear end-wall and generally disposed in the center of the endwall to define a central opening wherein the output shaft of the motor drive assembly passes through the opening, and wherein the recessed portion exposes an adjacent segment of the output shaft. 27. The electric motor assembly of claim 26, further comprising at least one bolt hole aperture passing through said laminations.
28. The electric motor assembly of claim 27, wherein said front casing body is secured to said rear casing by at least one fastener passing through the bolt hole aperture of the laminations.
29. The electric motor assembly of claim 28, wherein the front casing outer wall comprising a generally circular geometry, indented regions extending radially inward of said generally circular geometry, and a recess configured to receive at least a portion of a fastener securing the front casing into engagement with said stacked laminations, each said indented region being in linear alignment with an aperture in said laminations configured to receive a portion of a fastener extending from said front casing, and wherein said rear casing receives a portion of said fastener to fasten the front casing to the rear casing by a threaded fastener passing from said indented regions through the aperture in said laminations and passing into the rear casing.
30. The electric motor assembly of claim 26, wherein the front and rear casing are cast aluminum.
RELATED APPLICATIONS This patent application is a continuation application claiming priority to U.S. patent application entitled, �Fan With Improved Electric Motor and Mounting,� application Ser. No. 09/175,635, filed Oct. 20, 1998, issued on May 8, 2001 as U.S. Pat. No. 6,227,822.
One type of electric motor which can be manufactured at lower cost is a four-pole permanent-split capacitor (PSC) motor. PSC motors incorporate a capacitor in series with an auxiliary: coil, the auxiliary coil being connected in parallel with a main coil. PSC motors can incorporate a less expensive type of laminations since a lower. grade steel may be used with a silicon content. Such laminations do not require heat treatment. However, there are many problems associated with providing a four-pole PSC motor in a narrow frame of a box fan. The primary problem is that the profile of the typical four-pole PSC motor is too thick to fit within the narrow box fan, due to the construction of the motor, the internal motor windings, and the casings used for such motors. Another main problem preventing manufacturers from placing a four-pole PSC motor in a narrow box fan is the difficulty of mounting the motor in the confined mounting space. Furthermore, the operating temperature of typical four-pole PSC motors places them in the UL Class B category.
Another problem with using a four-pole PSC motor in a narrow space within a fan is the relatively large thickness of such motors. The typical four-pole PSC motor has the bulk of its copper windings positioned on either of the sides of the laminations, thereby requiring additional thickness to them as compared to shaded pole motors. Further, by current UL standards, a clearance space of at least 2.4 millimeters (mm) is required between the copper windings and the cast metal outer casing of the motor. It would be advantageous, therefore, to develop a four-pole PSC motor that has a relatively reduced thickness, without compromising the volume of space required for the copper windings or violating:the UL standards of required clearance between the windings and the metal motor casing.
The electric motor 10 is generally used to drive a cooling or air circulating household fan assembly 2. In the preferred embodiment, the electric motor 10 is a four-pole PSC motor. The motor 10 and housing 12 combination is particularly useful in the manufacture of a 3� inch box fan. Four-pole PSC electric motors have a substantially greater stack height than the shaded-pole motors which are normally used in the manufacture of � inch box fans. Therefore, conventional four-pole PSC motor/housing combinations are not compatible with 3� inch box fans. The present motor/housing combination can be utilized within a 3� inch box fan. The following features of the motor 10 and the motor housing 12 allow it to be fit within a 3� inch box fan.
Referring to FIG. 4, the motor's windings 20 have first and second parts 32, 34. The first parts 32 extend outwardly from the first and second outermost laminations 22, 26. The second parts 34 pass through the interior of the core 18. The first parts 32 bend as they emerge from the core of stacked laminations 18. The bend of the first and second parts 32, 34 forms a slot exit angle a between the first parts 32 and the first and second supporting surfaces 24 and 28, defined by the angle between the inner (closest to rotor) portion of the respective supporting surfaces 24 and 28, and the inner surface of first parts 32 as it leaves the slots 330. The slot exit angle α is generally greater than 90�. This bending of the first parts 32 allows the windings 20 to be maintained closer to the surface of the core 18, thus the overall thickness of the motor 10 is reduced. The dimensions of the outer circumference 420 and inner diameter 430 of the windings 20 are increased such that the height of the windings 20 between the front surface 24 of the laminations 18 and the front surface 400 of the windings 20, as well as the height of the windings between the rear surface 28 of laminations 18 and the rear surface 410 of the windings is about ⅝ inch or less. Thus, the motor has a narrower profile than typical PSC motors which have winding heights over � inch. The outer circumference 420 of the windings 20 extends at least 2.0 mm, and preferably about 3.0 mm to an area radially beyond the outer edge of the stator slots 330.
A first hub,74 is positioned within the first chamber 46 on the first interior surface 42 of the first casing 36. The first hub 74 stabilizes the output shaft 30 within the motor housing 12. The first hub 74 is centered about the longitudinal axis 40. The first hub 74 has a cylindrical side wall 76 that extends from the first interior surface 42 downwardly toward the stacked laminations 18. A sleeve 78 is fitted within the first hub 74 to further stabilize the output shaft 30.
The second circumferential side wall 86 further comprises an extended body portion for attachment to mounting surfaces of the fan, the extended body portion extending radially outward of the side wall of the rear casing and preferably comprised of a plurality of mounting brackets or legs 104. The mounting brackets 104 are integral with the second circumferential side wall 86 and spaced a distance from the second vented end wall 88. The spacing or offset helps allow the motor 10 to be used in a narrow box fan. Each mounting bracket or leg 104 has an opening or aperture 106 for receiving a fastening device. In one preferred embodiment, the extending body portion includes a rear surface which surrounds the apertures 106 and is aligned with the end wall of the rear casing 38. The fastening device attaches the motor 10 to a support bracket 150 within the fan frame 3. Normally, the space between the support brackets is lost because the motor housing lies completely in front of the support bracket. However, by offsetting the mounting brackets 104 the motor housing 12 extends between the support brackets and the motor housing 12 can be accommodated within a narrow box fan, such as a {fraction (3/4+L )} inch box fan. The mounting brackets or legs 104 are preferably positioned in pairs in such a way that a first line defined by and extending through the centers of the rear sides of the openings 106 of each of two primary legs or brackets 104 is parallel to a second line defined by and extending through the centers of the rear side of the openings 106 of the other two secondary legs or brackets 104, and the lines are adjacent and clear of the casing 38.
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CO., ILLINOISFree format text: RELEASE BY SECURED PARTY;ASSIGNOR:WELLS FARGO FOOTHILL, INC., AS ADMINISTRATIVE AGENT;REEL/FRAME:022793/0126Effective date: 20090608Mar 5, 2007ASAssignmentOwner name: WELLS FARGO FOOTHILL, INC., GEORGIAFree format text: SECURITY AGREEMENT;ASSIGNOR:LAKEWOOD ENGINEERING & MFG. CO.;REEL/FRAME:018961/0001Effective date: 20070222Feb 27, 2006FPAYFee paymentYear of fee payment: 4RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services©2012 Google