Patent Description:
Various household appliances utilize fans to circulate air within the appliance for purposes including heating, cooling, drying and the like. The fan is generally mounted to the appliance frame. Further, the air outlet of the fan is generally connected to an air duct or other air distribution channel within the appliance.

When the fan is in operation, the forces generated cause the fan to vibrate. These vibrations are then translated through the fan connections to the appliance frame and air duct, causing those elements to vibrate as well. The cumulative vibration of all of these components results in an undesirable amount of noise, which many consumers find aggravating.

<CIT> provides a draught fan assembly of a dust extraction device. The assembly comprises a front buffer sleeve, an axial flow fan component and a rear buffer sleeve, wherein the front buffer sleeve, the axial flow fan component and the rear buffer sleeve are connected in sequence, the front buffer sleeve is arranged at the air inlet end of the axial flow fan component, the rear buffer sleeve is arranged at the air outlet end of the axial flow fan component, and a cross ventilation type cavity which is sealed all around is defined by the front buffer sleeve, the axial flow fan component and the rear buffer sleeve together. The utility model further provides a dust extraction device provided with the axial flow fan. Due to the adoption of the axial flow fan, dust carrying capacity in unit working time can be improved, and dust extraction efficiency can be improved. Furthermore, the axial flow fan has the advantages of being low in noise, low in energy consumption and low in cost.

<CIT> provides a ventilation system which comprises a fan mounted in a flat oval sectioned casing which may be connected at either end to duct of the same cross section using flanges. The casing may be a double walled construction with an inner wall and outer wall sandwiching a noise reducing acoustic material. The walls may be perforated and may be produced from helical strips of material. The fan may be suspended from a frame inside the casing by springs.

Accordingly, an assembly to mount the fan within the appliance which absorbs the vibration of the fan and supports the fan itself is desirable.

According to the invention, there is provided a fan assembly as defined by independent claim <NUM>.

In order to aid understanding of this disclosure, several terms are defined below. The defined terms are understood to have meanings commonly recognized by persons of ordinary skill in the arts relevant to the present invention. The terms "includes" and "including" are intended to be inclusive in a manner similar to the term "comprising. " Similarly, the term "or" is generally intended to be inclusive (i.e., "A or B" is intended to mean "A or B or both"). The terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

Turning to the figures, <FIG> illustrates a perspective view of an exemplary appliance (e.g., a refrigerator appliance <NUM>). Although the fan mounting assembly described herein is explained in the context of an exemplary refrigerator appliance, it is to be understood that the fan mounting assembly may be employed in any appliance utilizing a fan, such as, for example, a dryer, freezer, air conditioner, heater, electric fireplace, or the like.

Refrigerator appliance <NUM> includes a cabinet <NUM>. As shown, cabinet <NUM> generally extends between a top <NUM> and a bottom <NUM> along a vertical direction V, between a first side <NUM> and a second side <NUM> along a lateral direction L, and between a front side <NUM> and a rear side <NUM> along a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another and form an orthogonal direction system.

As shown, cabinet <NUM> generally defines one or more insulated chambers for receipt of food items for storage. In particular, cabinet <NUM> defines a fresh food chamber <NUM> proximal to top <NUM> of cabinet <NUM> and a freezer chamber <NUM> arranged proximal to bottom <NUM> of cabinet <NUM>. Freezer chamber <NUM> is spaced apart from fresh food chamber <NUM> along the vertical direction V. It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular appliance configuration.

According to the illustrated embodiment, various storage components are mounted within fresh food chamber <NUM> to facilitate storage of food items therein as will be understood by those skilled in the art. In particular, the storage components include bins, drawers, and shelves (not pictured) that are mounted within fresh food chamber <NUM>. Bins, drawers, and shelves are positioned to receive of food items (e.g., beverages, solid food items, etc.) and may assist with organizing such food items. As an example, drawers can receive fresh food items (e.g., vegetables, fruits, or cheeses) and increase the useful life of such fresh food items.

One or more refrigerator doors 120are rotatably hinged to an edge of cabinet <NUM> for selectively accessing insulated fresh food chamber <NUM> and extending across at least a portion of fresh food chamber <NUM>. In addition, a freezer door <NUM> is rotatably hinged below refrigerator doors <NUM> for selectively accessing insulated freezer chamber <NUM> and extending across at least a portion of freezer chamber <NUM>. Refrigerator doors <NUM> and freezer door <NUM> are each shown in the closed position in <FIG> (i.e., a first closed position corresponding to doors <NUM>, and a second closed position corresponding to door <NUM>).

Operation of the refrigerator appliance <NUM> can be generally controlled or regulated by a controller (not shown). In some embodiments, the controller is operably coupled to a user interface panel (e.g., mounted within fresh food chamber <NUM>) or various other components of refrigerator appliance <NUM>. In some embodiments, the user interface panel provides selections for user manipulation of the operation of refrigerator appliance <NUM>. As an example, the user interface panel may provide for selections of temperature settings or specific modes of operation. In response to one or more input signals (e.g., from user manipulation of the user interface panel or one or more sensor signals), the controller may operate various components of the refrigerator appliance <NUM> according to the current mode of operation.

The controller may include a memory and one or more microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of refrigerator appliance <NUM>. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In some embodiments, the processor executes programming instructions stored in memory. For certain embodiments, the instructions include a software package configured to operate appliance <NUM>. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, the controller may be constructed without using a microprocessor (e.g., using a combination of discrete analog or digital logic circuitry-such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.

The controller, or portions thereof, may be positioned in a variety of locations throughout refrigerator appliance <NUM>. In example embodiments, the controller is located within the user interface panel. In other embodiments, the controller may be positioned at any suitable location within refrigerator appliance <NUM>, such as for example within cabinet <NUM>, doors <NUM> or <NUM>, etc. Input/output ("I/O") signals may be routed between the controller and various operational components of refrigerator appliance <NUM>. For example, the user interface panel may be operably coupled to the controller via one or more signal lines or shared communication busses.

Turning to <FIG>, a cut away view of certain components of a sealed cooling system <NUM> for refrigerator appliance <NUM> is provided. As may be seen in <FIG>, refrigerator appliance <NUM> includes a sealed cooling system <NUM> for executing a vapor compression cycle for cooling air within refrigerator appliance <NUM> (e.g., within fresh food chamber <NUM> and freezer chamber <NUM>). Sealed cooling system <NUM> includes a compressor, a condenser, an expansion device (not shown), and an evaporator <NUM> connected in fluid series and charged with a refrigerant. As will be understood by those skilled in the art, sealed cooling system <NUM> may include additional or fewer components. For example, sealed cooling system <NUM> may include multiple discrete evaporators positioned in separate locations within cabinet <NUM>.

Within sealed cooling system <NUM>, gaseous refrigerant flows into the compressor, which operates to increase the pressure of the refrigerant. This compression of the refrigerant raises its temperature, which is lowered by passing the gaseous refrigerant through the condenser. Within the condenser, heat exchange (e.g., with ambient air) takes place so as to cool the refrigerant and cause the refrigerant to condense to a liquid state.

The expansion device (e.g., a valve, capillary tube, or other restriction device) receives liquid refrigerant from the condenser. From the expansion device, the liquid refrigerant enters evaporator <NUM>. In some embodiments, such as the embodiment of <FIG>, evaporator <NUM> is positioned within freezer chamber <NUM>. Upon exiting the expansion device and entering evaporator <NUM>, the liquid refrigerant drops in pressure and vaporizes. Due to the pressure drop and phase change of the refrigerant, evaporator <NUM> is cool relative to freezer and fresh food chambers <NUM> and <NUM> of refrigerator appliance <NUM>. As such, cooled air is produced and refrigerates freezer and fresh food chambers <NUM> and <NUM> of refrigerator appliance <NUM>. Thus, evaporator <NUM> acts as a heat exchanger that transfers heat from air passing over evaporator <NUM> to refrigerant flowing through evaporator <NUM>. In some embodiments, a fan assembly <NUM> is provided adjacent to evaporator <NUM>. For instance, fan assembly <NUM> may be provided within freezer chamber <NUM> to motivate air across evaporator <NUM> and into the freezer and fresh food chambers <NUM> and <NUM> in a forced convection airflow. Additionally or alternatively, air may flow between freezer and chamber <NUM> and fresh food chamber <NUM> via a natural convection airflow (i.e., according to the difference in density between relatively cold air and relatively hot air). In other embodiments, fan assembly <NUM> may be dedicated to a particular application, such as cooling of an ice box (not pictured). In such embodiments, fan assembly <NUM> may be situated in proximity to evaporator <NUM> in order to draw cooled air created by operation of evaporator <NUM>. However, unlike most fans employed in a closed cooling system of a refrigerator, operation of fan assembly <NUM>, in this embodiment, may be operated independently of evaporator <NUM>. That is, this embodiment of fan assembly <NUM> may be turned on to provide cooling air to the ice box while evaporator <NUM> remains idle. Likewise, heat exchange through operation of evaporator <NUM> may occur without running fan assembly <NUM> in this embodiment.

Although refrigerators, and many appliances on the market, employ a fan to circulate air, the fan is commonly connected to directly or indirectly to the appliance frame. Additionally, the fans of these appliances are often further connected to the appliance at the fan outlet, which typically attaches to the inlet of an air duct or other air distribution channel using physical (e.g., screws, nuts and bolts, rivets) or adhesive methods of connection. Because the fan is physically restrained in such situations, operation of the fan results in significant vibration, which is then translated through the mounting and fan outlet connections to other components of the appliance. Each of these sources of vibration results in noise, the cumulative effect being a frequent source of complaints from consumers.

Fan assembly <NUM>, an embodiment of which is shown in the exploded view of <FIG> and the assembled view of <FIG>, addresses this problem by eliminating the need for direct contact between the fan and the appliance and providing a vibration-isolating buffer between the fan and appliance where necessary. In particular, fan assembly <NUM> includes fan <NUM> and mount <NUM> connected via elastomeric band <NUM>. Mount <NUM>, in turn, may be connected or integral to an air distribution channel for circulating air within appliance <NUM>. Once connected, elastomeric band <NUM> supports fan <NUM>, eliminating the need for a direct connection between fan <NUM> and appliance <NUM> for the purpose of mounting. Further, elastomeric band <NUM> enables fluid communication between fan <NUM> and mount <NUM> (and therefore to the air distribution channel) while preventing direct contact between the two, permitting elastomeric band <NUM> to absorb a large portion of the energy generated by the vibration of fan <NUM>.

Turning next to the individual components of fan assembly <NUM>, <FIG> depict an embodiment of fan <NUM>. It should be appreciated that fan <NUM> may be any suitable type, size, and configuration for circulating air through the system. For example, fan <NUM> could be an axial fan, or each fresh food and freezer chamber <NUM> and <NUM> could have a dedicated fan for urging cooling airflow into the respective chambers. Fan <NUM> includes a housing <NUM> forming the exterior of fan <NUM> and providing protection for its internal components. Housing <NUM> further includes a housing outlet <NUM> constituting the portion of housing <NUM> that guides air flow generated by fan <NUM> out of fan <NUM>. Housing outlet <NUM> is shaped such that it forms a first opening <NUM> through which air flow is discharged from fan <NUM>.

At least one fan retaining member <NUM> is connected to housing outlet <NUM>. Each of the one or more fan retaining members <NUM> extends away from first opening <NUM> and at least partially in a direction that is parallel to the plane of first opening <NUM>. In other words, in some embodiments, one or more fan retaining members <NUM> may be parallel to first opening <NUM>, whereas in other embodiments, one or more fan retaining members <NUM> may extend away from first opening <NUM> at angle, so long as the angle is not perpendicular to the plane of first opening <NUM>. As shown in <FIG>, in some embodiments, fan retaining member <NUM> may be a rectangular flange. However, the flange may be of any desired shape or size, so long as it includes one or more flange corners <NUM>. Flange corners <NUM> need not be sharp corners, but may be rounded or otherwise curved or segmented as desired.

Turning our attention now to mount <NUM>, embodiments of which are depicted in <FIG>. Mount <NUM> is used to connect fan assembly <NUM> to an air duct or other air distribution channel within appliance <NUM>. Mount <NUM> includes a frame <NUM>, which defines the shape of mount <NUM>. Frame <NUM> further defines a second opening <NUM> through which the air flow discharged from fan <NUM> may enter. In the embodiment of <FIG>, frame <NUM> is rectangular with rounded corners.

Mount <NUM> may be attached to an air duct or other air distribution channel in any myriad ways known to one of ordinary skill. For example, as shown in the embodiment of <FIG>, mount <NUM> may include flexible clamps141 with a lip <NUM> on the distal end of the clamp <NUM>. The clamp <NUM> may be attached to or integrated with frame <NUM>. The distal end of clamp <NUM> may flex over an air duct lip (not pictured) and, upon clearing the air duct lip, return to its original position, the lip <NUM> of clamp <NUM> preventing movement of mount <NUM> away from the air duct due to corresponding air duct lip.

Similarly, other embodiments of mount <NUM> may include arcuate flanges <NUM> that extend perpendicular to frame <NUM> in the direction of the air flow. As shown in the embodiment of <FIG>, flanges <NUM> may include mount holes <NUM> centered along the length of flanges <NUM> that permit connection to an air duct. These mount holes <NUM> may be accompanied by recesses <NUM> in flanges <NUM> on the interior surface of flanges <NUM> extending between mount holes <NUM> and the outer edge of flanges <NUM> and utilized in the molding process to create holes <NUM>, eliminating the need for a cam mechanism in the mold and lowering the cost of tooling. The exterior surface of flanges <NUM> may further include ridges, which provide thickness to flanges <NUM> for a mounting screw head to seat against (not pictured).

Alternatively, in other embodiments, frame <NUM> itself may include a number of holes or gaps (not pictured), through which screws, bolts, or other known methods of connection are used to directly attach mount <NUM> to an air duct. Further embodiments may include flanges of any number of shapes or sizes that extend perpendicular to the direction of air flow and away from second opening <NUM>, which are attached on either or both of mount <NUM> and an air duct, through which the connection is made. As will be apparent to the skilled artisan, combinations of any of these methods of connection may also be employed consistent with the current invention. Indeed, in certain embodiments, mount <NUM> may be integral to an air duct or other air distribution channel, serving as an inlet end of that element of appliance <NUM> and therefore not requiring any mechanical connection.

In certain embodiments, one or more mount retaining members(not shown) may be connected to frame <NUM>. In these embodiments, each of the one or more mount retaining members extends away from second opening <NUM> and at least partially in a direction that is parallel to the plane of second opening <NUM>. In other words, in some embodiments, one or more mount retaining members may be parallel to second opening <NUM>, whereas in other embodiments, one or more mount retaining members may extend away from second opening <NUM> at an angle, so long as the angle is not perpendicular to the plane of second opening <NUM>.

Fan assembly <NUM> further includes an elastomeric band <NUM> for connecting fan <NUM> to mount <NUM>. As used herein, the term elastomeric refers to flexible natural or synthetic rubber or rubber-like materials that are able to resume their original shape following removal of a deforming force. <FIG>, and <FIG> show an exemplary elastomeric band made of silicone rubber. However, alternative solid, non-foam elastomeric materials, may be used including, but not limited to, EPDM, nitrile, Viton®, Neoprene®, butyl, and natural rubber, and other materials with similar properties and characteristics, as would be understood by the skilled artisan.

As shown in the embodiment of <FIG>, elastomeric band <NUM> includes an interior surface <NUM> and an exterior surface <NUM> such that a pathway is formed through elastomeric band <NUM>, allowing the passage of air. At one end of this pathway, elastomeric band <NUM> includes air inlet end <NUM>. At least a portion of housing outlet <NUM> and each of the one or more fan retaining members <NUM> (e.g., the flange shown in the embodiment of <FIG>) are inserted into air inlet end <NUM>. At the other end of the pathway through elastomeric band <NUM> is air outlet end <NUM>. At least a portion of mount <NUM> and each of the mount retaining members <NUM> (if any) are inserted into air outlet end <NUM>.

The manner of physically combining fan <NUM> and mount <NUM> with elastomeric band <NUM> depends upon the geometry of these components at the point of connection. For example, in the embodiment of <FIG>, elastomeric band <NUM> further includes four first slots <NUM> positioned in each of the corners of the rectangular (in cross-section) elastomeric band <NUM>. Each of the first slots <NUM> is a gap in elastomeric band <NUM> providing an opening that extends between interior surface <NUM> and exterior surface <NUM>. The positioning of first slots <NUM> corresponds to the position of flange corners <NUM> on the flange of fan <NUM>. The relative size of the flange of fan <NUM> and elastomeric band <NUM> is such that when housing outlet <NUM> is inserted into air inlet end <NUM>, at least a portion of flange corners <NUM> extend through first slots <NUM>. This manner of attachment prevents movement of fan <NUM> relative to first slots <NUM>.

Similarly elastomeric band <NUM> may include, as shown in the embodiment of <FIG>, four second slots <NUM> positioned in each of the corners of the rectangular elastomeric band <NUM> for stabilizing the position of mount <NUM>. Each of the second slots <NUM> is a gap in elastomeric band <NUM> providing an opening that extends between interior surface <NUM> and exterior surface <NUM>. The positioning of second slots <NUM> corresponds to the position of the corners the rectangular mount <NUM>. Additionally, each of second slots <NUM> is located between the one or more first slots <NUM> and air outlet end <NUM>. The relative size of mount <NUM> and elastomeric band <NUM> is such that when mount <NUM> is inserted into air outlet end <NUM>, at least a portion of frame142 of mount <NUM> extends through second slots <NUM>. In this way, movement of mount <NUM> relative to second slots <NUM>.

Although the combination of fan <NUM>, elastomeric band <NUM>, and mount <NUM> is described above in the context of the exemplary embodiment of <FIG>, one of ordinary skill will recognize that the invention is not limited to this embodiment, but rather is applicable to a wide array of embodiments in which one or more first slots <NUM> and one or more second slots <NUM> of elastomeric band <NUM> impede the movement of fan <NUM> and mount <NUM>, respectively. As alternative exemplary embodiments, the flange of fan <NUM> may be, for example, triangular or octagonal or numerous additional shapes. In such cases, flange corners <NUM> may be fitted into the corresponding number of slots on elastomeric band <NUM>. Further, the number of flange corners <NUM> and first slots <NUM> need not be equal. In other embodiments outside the scope of the claimed invention, fan <NUM> may lack a flange, but instead include one or more protrusions connected to housing outlet <NUM> that extend outward and away from first opening <NUM>. For each of these protrusions, a corresponding first slot <NUM> may be present on elastomeric band <NUM> and located in a position that corresponds to the position of the protrusion on housing outlet <NUM>. It should further be recognized that, although the disclosure generally refers to first slots <NUM> and second slots <NUM> as "slots," this term may reasonably be interpreted as any hole or gap capable of receiving a flange corner <NUM> and portions of mount <NUM>.

Similarly, mount <NUM> is not limited to the embodiment of <FIG>, in which at least portions of frame <NUM> extend through second slots <NUM>, but may likewise include a mount retaining members, such as flange with flange corners or protrusions, that are connected to frame <NUM> and that engage with second slots <NUM> in the same manners that fan <NUM> may connect with elastomeric band <NUM>, as explained above.

Additionally, in certain embodiments for which a cross-section of elastomeric band <NUM> maintains uniform dimensions along its entire length, it may be desirable that housing outlet <NUM> share substantially the same height, width, and shape as mount <NUM>, as is the case in the embodiment of <FIG>. This uniformity prevents the introduction of significant openings around the component with a smaller cross-sectional are, through which air flow generated by the fan might escape the system, decreasing efficiency and efficacy (e.g., if mount <NUM> is significantly smaller than housing outlet <NUM>, air outlet end <NUM> of elastomeric band <NUM> may direct air flow to areas outside of second opening <NUM>). Thus, in these embodiments, housing outlet <NUM> and mount <NUM> should be sized such that they maintain contact with interior surface <NUM> of elastomeric band <NUM> around their entire perimeters following their insertion into elastomeric band <NUM>.

The stabilization of fan <NUM> and mount <NUM> within first slots <NUM> and <NUM> respectively prevents direct contact between these components, preventing any direct translation of vibrations generated during operation of fan <NUM>. Moreover, as would be appreciated by those skilled in the art, the material characteristics of elastomeric band <NUM> provide the additional benefit of dampening indirect vibration from fan <NUM> through elastomeric band <NUM> by permitting deformation of the elastomeric band <NUM> and thus consuming the energy of the vibration. By virtue of its material characteristics, elastomeric band <NUM> then returns to its original form, essentially resetting the system. As will be further understood, the materials from which elastomeric band <NUM> are made, as previously described, have sufficient stiffness that elastomeric band <NUM> may support the weight of fan <NUM> once the two are joined as set forth above. As a result, it is not necessary to mount fan <NUM> to the frame or any other sub-component of appliance <NUM>. Thus, use of fan assembly <NUM> further eliminates vibration and noise that would otherwise be translated to and through appliance <NUM> as a consequence of such a connection.

Claim 1:
A fan assembly (<NUM>) for an appliance (<NUM>), the fan assembly (<NUM>) comprising:
a fan (<NUM>) for distributing air through an air flow path of the appliance (<NUM>), the fan (<NUM>) including;
a housing (<NUM>) including a housing outlet (<NUM>), wherein the housing outlet (<NUM>) forms a first opening (<NUM>) through which air is discharged from the fan (<NUM>);
at least one fan retaining member (<NUM>) connected to the housing outlet (<NUM>), wherein the at least one fan retaining member (<NUM>) extends away from the first opening (<NUM>);
a mount (<NUM>) including a frame (<NUM>) forming a second opening (<NUM>) which receives air discharged from the fan (<NUM>);
an elastomeric band (<NUM>) including;
an interior surface (<NUM>);
an exterior surface (<NUM>);
an air inlet end (<NUM>);
an air outlet end (<NUM>);
at least one first slot (<NUM>), each first slot (<NUM>) forming an opening between the interior surface (<NUM>) and the exterior surface (<NUM>) of the elastomeric band (<NUM>);
at least one second slot (<NUM>), wherein each second slot (<NUM>) is located between each first slot (<NUM>) and the air outlet end (<NUM>); and
the air inlet end (<NUM>) of the elastomeric band (<NUM>) extending around at least a portion of the housing outlet (<NUM>) and the air outlet end (<NUM>) of the elastomeric band (<NUM>) extending around at least a portion of the mount (<NUM>), at least a portion of each fan retaining member (<NUM>) extending through the at least one first slot (<NUM>) and at least a portion of the frame (<NUM>) extending through the at least one second slot (<NUM>), such that the elastomeric band (<NUM>) supports the fan (<NUM>) and prevents contact between the housing outlet (<NUM>) and the mount (<NUM>);
wherein the at least one fan retaining member (<NUM>) is a flange with one or more corners (<NUM>);
characterized in that each second slot (<NUM>) forms an opening between the interior surface (<NUM>) and the exterior surface (<NUM>) of the elastomeric band (<NUM>), and wherein each corner (<NUM>) of the flange extends through a separate first slot (<NUM>) of the elastomeric band (<NUM>).