Abstract:
A blower assembly having a blower housing, an impeller fan within the blower housing, the impeller fan being adapted for rotation about an axis and having a plurality of impeller blades and having an axial length, a motor having a stator and a rotor, the motor having an axial length, the rotor being configured to rotate relative to the stator for rotation about the axis, the rotor and the impeller fan being coupled so that the impeller fan rotates with the rotor about the axis, wherein a ratio of the axial length of the motor to the axial length of the impeller fan is less than 0.3, and a motor support bracket operatively securing the stator to one of the first and second side walls of the blower housing.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application 61/674,087 that was filed Jul. 20, 2012 and is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    A disadvantage with a standard furnace air handler is the lack of energy savings that is now currently expected by customers. Consequently, there are applications where a high efficiency motor is required or an ultra-high efficiency motor is requested by customers. Furthermore, the noise and sound can be too high to be acceptable to the consumer who currently owns a standard furnace air handler. This may include a high efficiency distribution blower (“HEB”). Another disadvantage with current designs is that the electronics associated with a motor can restrict air flow because the inlet space is not fully open. 
         [0003]    The present invention is directed to overcoming one or more of the problems set forth above. 
       SUMMARY OF INVENTION 
       [0004]    In one aspect of the invention, a blower assembly is disclosed. The blower assembly includes a blower housing having a first air inlet opening in a first side wall and a second air inlet opening in a second side wall, an impeller fan within the blower housing, the impeller fan being adapted for rotation about an axis and having a plurality of impeller blades and having an axial length, a motor having a stator and a rotor, the motor having an axial length, the rotor being configured to rotate relative to the stator for rotation about the axis, the rotor and the impeller fan being coupled so that the impeller fan rotates with the rotor about the axis, wherein a ratio of the axial length of the motor, without extensions, to the axial length of the impeller fan is less than 0.3, and a motor support bracket operatively securing the stator to one of the first and second side walls of the blower housing. 
         [0005]    In still another aspect of the invention, a blower assembly is disclosed. The blower assembly includes a blower housing having a first air inlet opening in a first side wall and a second air inlet opening in a second side wall, an impeller fan within the blower housing, the impeller fan being adapted for rotation about an axis and having a plurality of impeller blades and having an axial length, a motor having a stator and a rotor, the motor having a frame, having a width, in the form of a geometric shape and having an air directing surface to direct air generally radially outwardly towards the impeller fan, wherein a ratio of the width of the frame, to the axial length of the impeller fan is less than 0.3, and a motor support bracket operatively securing the stator to one of the first and second side walls of the blower housing. 
         [0006]    In another aspect of the invention, a blower assembly is disclosed. The blower assembly includes a blower housing having a first side wall and a second side wall with an air inlet opening in the first side wall, an impeller fan within the blower housing, the impeller fan being adapted for rotation about an axis and having a plurality of impeller blades and having an axial length, a motor having a stator and a rotor, the motor having an axial length, the rotor being configured to rotate relative to the stator for rotation about the axis, the rotor and the impeller fan being coupled so that the impeller fan rotates with the rotor about the axis, wherein a ratio of the axial length of the motor, without extensions, to the axial length of the impeller fan is less than 0.3, and a motor support bracket operatively securing the stator to one of the first and second side walls of the blower housing. 
         [0007]    In still yet another aspect of the invention, a blower assembly is disclosed. The blower assembly includes a blower housing having a first air inlet opening in a first side wall and a second air inlet opening in a second side wall, an impeller fan within the blower housing, the impeller fan being adapted for rotation about an axis and having a plurality of impeller blades and having an axial length, a pancake motor having a stator and a rotor, the motor having an axial length, the rotor being configured to rotate relative to the stator for rotation about the axis, wherein a ratio of the axial length of the motor, without extensions, to the axial length of the impeller fan is less than 0.3, a motor support bracket operatively securing the stator to one of the first and second side walls of the blower housing, a stationary plate that is attached to the stator, a drive plate that is operatively attached to the rotor and the impeller fan, and a bearing mechanism located between the stationary plate and the drive plate that allows rotatable movement for the drive plate in relationship to the stationary plate so that the rotor and the impeller fan are coupled so that the impeller fan rotates with the rotor about the axis. 
         [0008]    Still yet another aspect of the present invention is a method for utilizing a blower assembly is disclosed. The method includes utilizing a blower housing having a first air inlet opening in a first side wall and a second air inlet opening in a second side wall, utilizing an impeller fan within the blower housing, the impeller fan being adapted for rotation about an axis and having a plurality of impeller blades and having an axial length, utilizing a motor having a stator and a rotor, the motor having an axial length, the rotor being configured to rotate relative to the stator for rotation about the axis, the rotor and the impeller fan being coupled so that the impeller fan rotates with the rotor about the axis, wherein a ratio of the axial length of the motor, without extensions, to the axial length of the impeller fan is less than 0.3 with a motor support bracket operatively securing the stator to one of the first and second side walls of the blower housing. 
         [0009]    Yet another aspect of the present invention is a method of selling a motor to an assembler of a blower assembly is disclosed. The method includes providing a motor to an assembler of a blower assembly, wherein the motor includes a stator and a rotor, the motor having an axial length, the rotor being configured to rotate relative to the stator for rotation about the axis, the rotor and the impeller fan being coupled so that the impeller fan rotates with the rotor about the axis, wherein a ratio of the axial length of the motor, without extensions, to an axial length of an impeller fan utilized in a blower assembly is less than 0.3. 
         [0010]    These are merely some of the innumerable aspects of the present invention and should not be deemed an all-inclusive listing of the innumerable aspects associated with the present invention. These and other aspects will become apparent to those skilled in the art in light of the following disclosure and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0011]    For a better understanding of the present invention, reference may be made to the accompanying drawings in which: 
           [0012]      FIG. 1  is the perspective front side view of a blower assembly of the present invention revealing the outlet opening and first side wall; 
           [0013]      FIG. 2  is a perspective top view of the blower assembly of the present invention, shown in  FIG. 1 , without the top portion of the blower housing and a cutoff; 
           [0014]      FIG. 3  is schematic representation of the embodiment of the blower assembly of the present invention shown in  FIGS. 1 and 2 ; 
           [0015]      FIG. 4  is a perspective top view of the blower assembly of the present invention, shown in  FIG. 2 , that includes the top portion of the blower housing and a cutoff; 
           [0016]      FIG. 5  is an exploded side perspective view of a fan wheel with a series of mounting legs and attachment mechanisms, shown in  FIG. 1 ; and 
           [0017]      FIG. 6  is an isolated view of a single mounting leg having an attachment bracket on a first end portion for mounting on a mounting plate and an isolation mount attached to the second end portion of the single mount leg for attachment to a sidewall of a blower housing. 
       
    
    
       [0018]    Reference characters in the written specification indicate corresponding items shown throughout the drawing figures. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as to obscure the present invention. 
         [0020]    A typical construction of an air handler blower assembly is shown in a “Furnace Air Handler Blower Housing with an Enlarged Air Outlet Opening” found in U.S. Patent Publication No. 2011/0114073, U.S. patent application Ser. No. 12/178,161, filed Jul. 23, 2008, and published on May 19, 2011, which is incorporated herein by reference, in its entirety. Another illustrative example of an air handler blower assembly is shown in “Furnace Air Handler Blower Housing with an Enlarged Air Outlet Opening” found in U.S. Patent Publication No. 2009/0114205, U.S. patent application Ser. No. 11/935,726, filed Nov. 6, 2007, and published on May 7, 2009, which is incorporated herein by reference, in its entirety. 
         [0021]    Referring now to  FIG. 1  which is a front perspective view of a furnace air handler blower assembly of the present invention. The furnace of the invention is primarily constructed in the same manner as other known high efficiency furnaces. There is a blower assembly that is generally indicated by numeral  10 . The blower assembly  10  includes the impeller fan  12  that is contained with a blower housing  14 . The blower housing  14  has an outer wall  16  having a scroll-shaped length that extends from a first end edge  18  of the outer wall  16  to an opposite second end edge  20  of the outer wall  16 . The blower housing  14  includes a top portion  76  and a cutoff  78 . 
         [0022]    The blower housing  14  also includes a first side wall  32  and a second side wall  34 . Portions of the peripheries of the first side wall  32  and the second side wall  34  are connected to the opposite sides of the outer wall  16 . The first side wall  32  has a first straight edge portion  26  and the second side wall  34  has a second straight edge portion  28 . The first straight edge portion  26  and second straight edge portion  28  of the first side wall  32  and the second side wall  34 , respectively, are also positioned at opposite sides of an outlet opening  30 , which is preferably, but not necessarily, rectangular, of the blower housing  14  with the outer wall  16 , the first end edge  18  and the second end edge  20  defining the outlet opening  30 , which preferably, but not necessarily, have a rectangular configuration. The first side wall  32  includes a first circular aperture  36 , which is through the first side wall  32 . The second side wall  34  includes a second circular aperture  38 , shown in  FIG. 2 , which is through the second side wall  34 . The first circular aperture  36  and the second circular aperture  38  are coaxially aligned and function as the air inlet openings of the blower housing  14 . This dual inlet system for the blower assembly  10  is highly efficient. However, a single inlet or multiple inlets may be utilized. There is a first curved portion  22  extending between the first side wall  32  that includes a first circular aperture  36  and a second curved portion  24  extending between the second side wall  34  and the second circular aperture  38 . 
         [0023]    The motor  44  of the blower assembly  10  is preferably, but not necessarily, an axial flux motor, as shown in  FIG. 2 . Optimally, the motor  44  is a pancake motor. The outer edge  82  of the frame  52  for the motor  44  is preferably angled to allow a clear air flow path into the series of air flow impeller blades  13 , as shown in  FIG. 2 . However, with this present invention, any of a myriad of motors will suffice. The stator  46  of the motor  44  is attached to a stationary plate  80 , as shown in  FIG. 3  through a second series of attachment mechanisms  84 , e.g., nut and bolt combinations, through a series of openings  86 , as shown in  FIGS. 5 and 6 . There is a drive plate  68  that is attached to the impeller fan  12  to allow the rotor  62  to rotate the impeller fan  12 , as shown in  FIG. 3 . The drive plate  68  may optionally include a first connecting portion  69  and a second connecting portion  70  that are fixedly attached together by an attachment mechanism  71 , e.g., rivets, which connects the permanent magnets  72  for the rotor  62  that opposes the stator windings  48 . In this illustrative, but nonlimiting example, a bearing mechanism  66 , e.g., bearings, allows rotatable movement for the first connecting portion  69  in relationship to the stationary plate  80 . The second connecting portion  70  is attached to the impeller fan  12 . 
         [0024]    The blower assembly  10  is constructed in such a manner that allows for the wiring  58  associated with the stator  46  of the motor  44  to be run through to an electronic controller  60 , as shown in  FIG. 3 . In the illustrated, but nonlimiting, embodiment of the blower assembly  10 , the stator  46  has thirty-six (36) slots and eighteen (18) stator windings  48 . In the illustrated, but nonlimiting, embodiment, thirty (30) permanent magnets  72  are employed on the rotor  62 . 
         [0025]    As also shown in  FIG. 4 , the electronic controller  60  is preferably, but not necessarily, mounted to the blower housing  14  by a first series of attachment mechanisms  74 , e.g., nut and bolt combinations, preferably, but not necessarily, two (2). This increases efficiency by removing the electronics from the motor  44  in order to open fully the inlet space to provide improved air flow. The electronic controller  60  is not defined as being part of the motor  44  for determining the axial length of the motor  44 . 
         [0026]    Referring now to  FIG. 3 , the impeller fan  12  with the series of air flow impeller blades  13  are connected to the rotor  62  of the motor  44 . As shown in  FIG. 2 , the motor  44  can vary in position from the center of the blower  101  by a percentage of less than plus or minus thirty percent (30%) of the axial length of the impeller fan, indicated by reference number  106 , and preferably can vary in position from the center of the blower  101  by a percentage of less than plus or minus twenty percent (20%) and optimally preferably can vary in position from the center of the blower  101  by a percentage of less than plus or minus ten percent (10%). 
         [0027]    The stationary plate  80  is secured to the stator  46  of the motor  44  through a series of mounting legs  88  that are attached to the first side wall  32 , shown in  FIGS. 1 ,  3 ,  5  and  6 . There are preferably, but not necessarily, four (4). Preferably, the series of mounting legs  88  are pre-formed structures with reinforced sidewalls  90 . There are a series of isolation mounts  92  that are connected to the series mounting legs  88  that receive a third series of attachment mechanisms  94 , e.g., threaded bolts, e.g., preferably, but not necessarily, four (4). Optionally, a series of washers  96 , e.g., preferably, but not necessarily, four (4), can be located between the third series of attachment mechanisms  94  and the first side wall  32 , as shown in  FIG. 1 . The other end of the series of mounting legs  88  are attached to a corresponding series of attachment brackets  98 , which are preferably hinged, as shown in  FIG. 6 . Attachment is preferably, but not necessarily, through a wide variety of attachment means and mechanisms, that include spot welding. The series of mounting legs  88  are preferably, but not necessarily, pre-formed to eliminate belly bands, large stampings and die castings. 
         [0028]    There are a corresponding series of mounting plates  100  that receive a fourth series of attachment mechanisms  102 , e.g., threaded bolts, e.g., preferably, but not necessarily, two (2) that connect the attachment brackets  98  to the series of mounting plates  100 , as shown in  FIG. 6 . This design assists in minimizing cocking during assembly. The series of air flow impeller blades  13  can be any of a wide variety of shapes and dimensions with the preferred embodiment being a forward curve as shown in  FIG. 5 . 
         [0029]    The axial length of the motor  44  or thickness of the frame  52  of the motor  44  indicated by numeral  104  should be a ratio to the width of the impeller fan  12  indicated by numeral  106  less than 0.3, as shown in  FIG. 2 . Preferably this ratio is less than 0.26 and optimally this ratio is less than 0.211. As used herein and in the claims, the axial length of the motor  44  or thickness of the frame  52  of the motor  44  indicated by numeral  104  does not include any bearing journal extension, and does not include any portion of any axial extension, axial protrusion or other contrivance that is radially within a distance from the rotor axis of rotation of twenty percent of the radius of the impeller (i.e., the radial distance from the rotor axis of rotation to radially inner-most edges of the impeller blades), where air performance has a minimal impact. The frame  52  of the motor  44  has an air directing surface to direct air generally radially outwardly towards the impeller fan  12 . Therefore, any extensions, protrusions, or other augmentations to the frame  52  cannot be considered part of the axial length of the motor  44  or thickness of the frame  52  of the motor  44 . 
         [0030]    There are numerous potential ways to position the electronic controller  60  for the motor  44 , e.g., axial flux motor, as shown in  FIG. 3 . The motor  44  is shaftless to provide a compact design that eliminates shaft resonance that can be impacted by magnet cogging. Illustrative, but nonlimiting, examples of numerous other ways of mounting the electronic controller  60  and running the wiring  58  are found in International Application No. PCT/US2011/044702 for “Blower Assembly with Motor Integrated into the Impeller Fan and Blower Housing Constructions,” filed Jul. 20, 2011, claiming a priority of Jul. 20, 2010, which is incorporated by reference herein, in its entirety. An illustrative, but nonlimiting, example of an axial flux motor is found in International Application No. PCT/US2011/119574 for “Axial Flux Electric Machine and Methods of Assembling the Same,” filed Mar. 22, 2011, claiming a priority of Mar. 22, 2010, which is incorporated by reference herein, in its entirety. 
         [0031]    Furthermore, it should be understood that when introducing elements of the present invention in the claims or in the above description of the preferred embodiment of the invention, the terms “have,” “having,” “includes” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required.” Similarly, the term “portion” should be construed as meaning some or all of the item or element that it qualifies. 
         [0032]    Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims that follow.