Patent Description:
The present technology relates to a blower for generating a pressure differential. In an example, the blower may be used in a positive airway pressure (PAP) device used for the delivery of respiratory therapy to a patient. Examples of such therapies are Continuous Positive Airway Pressure (CPAP) treatment, Non-Invasive Positive Pressure Ventilation (NIPPV), and Variable Positive Airway Pressure (VPAP). The therapy is used for treatment of various respiratory conditions including Sleep Disordered Breathing (SDB) and more particularly Obstructive Sleep Apnea (OSA). However, the blower may be used in other applications (e.g., vacuum applications (medical or otherwise)).

A need has developed in the art for blower designs that are quieter and more compact. The present technology provides alternative arrangements of blowers that consider this need.

An aspect of the disclosed technology relates to a blower including a volute separated into a high speed airpath region and a low speed airpath region.

Another aspect of the disclosed technology relates to a blower including a stationary component structured to support the whole motor and driver assemblies and provide one or more additional functions such as shielding to prevent blade pass tone, bearing tube for bearing retainment and alignment, assist in defining the volute, correct alignment and positioning of the stator assembly, protect or separate the motor from the airpath, and/or central aperture for the shaft or rotor.

Another aspect of the disclosed technology relates to a blower housing including a housing part that provides the inlet and an inlet tube portion aligned with the inlet that is overmolded to the housing part.

Another aspect of the disclosed technology relates to a blower housing including a housing part including a shield to prevent electromagnetic interference of a printed circuit board assembly supported within the housing.

Another aspect of the disclosed technology relates to a seal positioned between the housing and the stationary component of the blower to provide a seal along the volute. In an example, the seal may include structure to support a printed circuit board assembly within the housing and guide wires from the printed circuit board assembly to external the blower.

Another aspect of the disclosed technology relates to a blower in which the stationary component and a stator assembly of the motor are overmolded with one another.

Another aspect of the disclosed technology relates to a blower including a housing including an inlet and an outlet, a stationary component provided to the housing, an impeller positioned between the inlet of the housing and the stationary component, and a motor adapted to drive the impeller. The housing and the stationary component cooperate to define a volute that directs air towards the outlet. The housing includes a separating wall constructed and arranged to divide the volute into a high speed airpath region and a low speed airpath region.

Another aspect of the disclosed technology relates to a blower including a housing including an inlet and an outlet, a stationary component provided to the housing, an impeller positioned between the inlet of the housing and the stationary component, and a motor adapted to drive the impeller. The housing and the stationary component cooperate to define a volute that directs air towards the outlet. The volute includes a high speed airpath region and a low speed airpath region that is radially offset from the high speed airpath region.

Another aspect of the disclosed technology relates to a blower including a housing including an inlet and an outlet, a stationary component provided to the housing, an impeller positioned between the inlet of the housing and the stationary component, and a motor adapted to drive the impeller. The housing and the stationary component cooperate to define a volute that directs air towards the outlet. The volute includes at least one step that extends radially outwardly from the impeller.

Another aspect of the disclosed technology relates to a PAP device including a casing adapted to fit on top of the patient's head in use and a blower provided within the casing. The blower includes an outlet that is angled, curved, and/or oriented towards a lower wall of the casing.

Another aspect of the disclosed technology relates to a blower including a housing including an inlet and an outlet, a motor including a stator assembly, a magnet, and a shaft adapted to cooperatively drive an impeller, and a stationary component provided to the housing. The stationary component may be configured to support the stator assembly of the motor. The stationary component may include a bearing tube adapted to retain one or more bearings. The magnet may be located on a magnet support adapted to align the magnet with the stator assembly. The magnet support may further include a hub that engages with the shaft of the motor to facilitate rotation of the shaft.

Other aspects, features, and advantages of this technology will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of this technology.

The accompanying drawings facilitate an understanding of the various examples of this technology. In such drawings:.

The following description is provided in relation to several examples (some of which are illustrated, some of which may not) which may share common characteristics and features. It is to be understood that one or more features of any one example may be combinable with one or more features of the other examples. In addition, any single feature or combination of features in any of the examples may constitute additional examples.

Aspects of the technology will be described herein in its application to non-invasive ventilation (NIVV) treatment apparatus (e.g., positive airway pressure (PAP) devices), such as CPAP, but it is to be understood that aspects of the technology may have application to other fields of application where blowers are used, e.g., in both positive pressure and negative pressure applications.

In this specification, the words "air pump" and "blower" may be used interchangeably. The term "air" may be taken to include breathable gases, for example air with supplemental oxygen. It is also acknowledged that the blowers described herein may be designed to pump fluids other than air.

Also, each blower example below is described as including a single stage design. However, it should be appreciated that examples of the technology may be applied to multiple stage designs, e.g., two, three, four, or more stages. <CIT> discloses a blower assembly comprising a rotor magnet rotatable with the stator bore.

Further examples of blowers and aspects related to the present technology are disclosed in PCT Application No. <CIT>.

<FIG> illustrate a single stage, centrifugal blower <NUM> according to an example of the technology. As described below, the blower <NUM> provides an arrangement that is relatively small, compact, and lightweight. In an example, the blower may be structured to provide pressurized air in the range of <NUM>-<NUM> cmH<NUM>O, e.g., <NUM>-<NUM> cmH<NUM>O, such as <NUM> cmH<NUM>O, <NUM> cmH<NUM>O and/or <NUM> cmH<NUM>O.

As illustrated, the blower <NUM> includes a housing <NUM> (e.g., constructed of metal or plastic, e.g., polycarbonate) with first and second housing parts <NUM>, <NUM>, a stationary component <NUM> (also referred to as a motor-driver support, a stator component, or an intermediate housing part (e.g., constructed of metal or plastic)), a hub <NUM> that provides an arm <NUM> for magnet support and magnetic flux path, a motor <NUM> positioned within the stationary component <NUM> and adapted to drive a rotatable shaft or rotor <NUM>, and an impeller <NUM> (e.g., constructed of plastic such as polycarbonate) provided on one side of the stationary component and coupled to an end portion of the rotor <NUM>. The motor <NUM> includes stator assembly <NUM>, magnet <NUM>, and rotor <NUM> as discussed in more detail below.

In an example, a dynamic balancing process may be applied to the rotating masses to minimize noise and vibration during operation. This may be accomplished, for example, by mass removal from two planes, e.g., one plane being at the impeller and another plane being at the hub provided to the rotor. Another way to accomplish this would be to add mass in either of those planes.

In the illustrated example, the first housing part <NUM> provides both an inlet <NUM> and an outlet <NUM>. The blower is operable to draw a supply of gas into the housing through the inlet and provide a pressurized flow of gas at the outlet. The blower is generally cylindrical with the inlet aligned with an axis of the blower and the outlet structured to direct gas exiting the blower in a generally tangential direction.

In the illustrated example, the outlet <NUM> is in the form of an outlet tube that extends outwardly from the first housing part <NUM>. The shape, size, and/or orientation of the outlet tube may have alternative configurations to modify flow, pressure, etc..

For example, <FIG> shows three different configurations of the outlet tube <NUM>(<NUM>), <NUM>(<NUM>), <NUM>(<NUM>) in overlapping relation. <FIG> show the three different configurations in <FIG> isolated from one another, and <FIG> shows an alternative configuration of the outlet tube <NUM>(<NUM>) not shown in <FIG>.

In each example, the outlet tube diverges from an inlet end <NUM> of the tube (i.e., the end connected to the main body of the first housing part <NUM>) to an outlet end <NUM> of the tube. That is, the inlet end <NUM> defines an internal diameter that is smaller or narrower (e.g., by one or more millimeters) than an internal diameter defined by the outlet end <NUM>. This divergent arrangement decreases the air flow rate so as to provide increased pressure at the outlet end <NUM> of the tube. Preferably, the divergence of the outlet tube is gradual (i.e., the diameter to the tube does not increase significantly from the inlet end to the outlet end) so as to minimize air turbulence in the tube which may impede pressure and flow.

<FIG> show exemplary dimensions of the different configurations of the outlet tube. Although specific dimensions are provided, it should be understood that these dimensions are merely exemplary and other dimensions are possible, e.g., depending on application.

For example, in <FIG>, the outlet tube <NUM>(<NUM>) includes a generally straight orientation with respect to horizontal. In this example, angle d1 at the top of the inlet end <NUM> is about <NUM>° and angle d2 at the bottom of the inlet end <NUM> is about -<NUM>° which defines an average (center line) of about <NUM>° and a difference (divergence) of about <NUM>°. Angle d3 at the top of the outlet end <NUM> is about <NUM>° and angle d4 at the bottom of the outlet end <NUM> is about -<NUM>° which defines an average (center line) of about <NUM>° and a difference (divergence) of about <NUM>°. In this example, the minimum slider draft angle for molding may be about <NUM>°.

In <FIG>, the outlet tube <NUM>(<NUM>) includes an angled orientation with respect to horizontal. In this example, angle d1 at the top of the inlet end <NUM> is about <NUM>° and angle d2 at the bottom of the inlet end <NUM> is about <NUM>° which defines an average (center line) of about <NUM>° and a difference (divergence) of about <NUM>°. Angle d3 at the top of the outlet end <NUM> is about <NUM>° and angle d4 at the bottom of the outlet end <NUM> is about <NUM>° which defines an average (center line) of about <NUM>° and a difference (divergence) of about <NUM>°. In this example, the minimum slider draft angle for molding may be about <NUM>°.

In <FIG>, the outlet tube <NUM>(<NUM>) is curved along its length (e.g., banana-shaped or slight concave shape). In this example, angle d1 at the top of the inlet end <NUM> is about <NUM>° and angle d2 at the bottom of the inlet end <NUM> is about -<NUM>° which defines an average (center line) of about <NUM>° and a difference (divergence) of about <NUM>°. Angle d3 at the top of the outlet end <NUM> is about <NUM>° and angle d4 at the bottom of the outlet end <NUM> is about <NUM>° which defines an average (center line) of about <NUM>° and a difference (divergence) of about <NUM>°. In this example, the minimum slider draft angle for molding may be about <NUM>°.

As noted above, the outlet tube <NUM>(<NUM>) of <FIG> includes a general curved shape, in which the outlet tube is bent or arcuate along its length and the radius of curvature changes along the length. For example, the curvature at the inlet end may be very slight so as to prevent noise and turbulence, and the curvature increases along the length with the maximum curvature provided at the outlet end. The slight bend or no bend at the inlet end of the outlet tube may reduce air turbulence created between the interface of the outlet tube and the pump volute. The reduced turbulence may directly lead to a reduction in pressure drop in the region and a reduction in flow loss, which in turn may lead to improved pumping characteristics of the blower and/or reduced vibration and noise.

Also, the curved outlet tube <NUM>(<NUM>) may enable the angle on the air flow exiting the blower to be substantially parallel to the curved surface on the top of the patient's head, when the blower is adapted to be mounted on the crown or in front of the crown of the patients head in use (e.g., see examples below).

<FIG> shows another view of the outlet tube <NUM>(<NUM>) of <FIG> provided to the first housing part <NUM>.

<FIG> shows an alternative example of outlet tube <NUM>(<NUM>) in which angle d1 at the top of the inlet end <NUM> is about -<NUM>° and angle d2 at the bottom of the inlet end <NUM> is about <NUM>° which defines an average (center line) of about <NUM>° and a difference (divergence) of about <NUM>°. Angle d3 at the top of the outlet end <NUM> is about <NUM>° and angle d4 at the bottom of the outlet end <NUM> is about <NUM>° which defines an average (center line) of about <NUM>° and a difference (divergence) of about <NUM>°. In this example, the minimum slider draft angle for molding may be about <NUM>°.

As best shown in <FIG>, the outlet tube <NUM>(<NUM>) and <NUM>(<NUM>) is bent or curved with respect to horizontal, i.e., generally upwardly as viewed in <FIG>. When the blower <NUM> is mounted within the casing <NUM> of a PAP device <NUM> adapted to fit on top of the patient's head in use (e.g., with the inlet <NUM> oriented downwardly towards the patient's head in use as shown in <FIG>), the outlet <NUM>(<NUM>), <NUM>(<NUM>) is oriented such that it is bent or curved downwardly towards the patient's head, so as to better follow the contour of the patient's head in use and direct the outlet flow at a suitable angle in use.

In an alternative arrangement, the outlet tube may be bent or curved in the opposite direction to that shown in <FIG>. This arrangement allows the blower to be mounted within the casing <NUM> of the PAP device <NUM> with the inlet <NUM> oriented upwardly away from the patient's head in use and with the outlet tube <NUM>(<NUM>) curved or bent downwardly to follow the contours of the patient's head as shown in <FIG>.

The blower may be supported within the casing of the PAP device in any suitable manner, e.g., blower supported by a lower wall of the casing, blower suspended from an upper wall of the casing, blower suspension system as described in <CIT>.

As shown in <FIG> and <FIG>, the first and second housing parts <NUM>, <NUM> may provide a joint <NUM> (e.g., tongue and groove arrangement or a welded connection) to facilitate alignment and connection.

Alternatively, the first and second housing parts may be connected by a mechanical interlock type arrangement, e.g., snap-fit or snap-lock arrangement. For example, as shown in <FIG>, the first housing part <NUM> may include tab members <NUM> each having an opening <NUM> adapted to receive or interlock with a corresponding protrusion provided to the second housing part. As illustrated, the opening <NUM> has an inverted "mickey mouse ear" type shape (i.e., having an arc shape with two opposing semi-circular protrusions at the end opposite the arc), which increases the resiliency of the tab member <NUM> and prevents accidental breakage. However, it should be appreciated that the opening may have other suitable shapes. The shape is preferably designed to eliminate sharp corners that result in high stress points.

As best shown in <FIG> and <FIG>, the first housing part <NUM> cooperates with the stationary component <NUM> to define a volute <NUM> that directs air towards the outlet. As illustrated, the first housing part <NUM> includes a cylindrical, separating wall or baffle <NUM> that separates the volute <NUM> into two regions, i.e., a high speed airpath region <NUM>(<NUM>) and a low speed airpath region <NUM>(<NUM>). In the illustrated example, the low speed airpath region <NUM>(<NUM>) is radially offset from the high speed airpath region <NUM>(<NUM>). The separating wall <NUM> extends from a position adjacent the top of the impeller <NUM> to a position at or beyond the bottom of the impeller <NUM>. The separating wall extends generally parallel to a central axis of the blower, i.e., general vertical orientation as shown in <FIG>. In use, the separating wall <NUM> separates the high speed airpath region <NUM>(<NUM>) from the low speed airpath region <NUM>(<NUM>) so as to minimize air turbulence at relatively high speeds. That is, the separating wall reduces noise and airpath disruption.

At flows other than the ideal design flow, conventional volutes cause asymmetrical flow patterns in and around the impeller. These asymmetrical flow patterns cause pulsating pressure and acoustic noise, as the impeller rotates within the volute. In the example of the present technology, the separating or dividing wall allows asymmetrical flow patterns in the low speed airpath region, while encouraging the high speed airpath region to remain relatively symmetrical in and around the impeller, hence minimizing the pressure pulsations and/or acoustic noise.

Also, the cylindrical configuration of the separating wall or baffle <NUM> which separates the volute radially provides a relatively small package or compact arrangement (e.g., compared to a volute that may separate the volute axially). This arrangement allows more available motor space.

Also, the first housing part <NUM> provides a stepped configuration, which adjusts the volume of the volute <NUM> (i.e., the low speed airpath region <NUM>(<NUM>)) around the perimeter of the blower. Specifically, the low speed airpath region includes an expanding volume as it extends towards the outlet, i.e., volute volume larger at the outlet and smaller away from the outlet.

As described in greater detail below, the stationary component mechanically supports the whole motor and driver assemblies as well as provides one or more additional functions such as (i) shielding to prevent blade pass tone, (ii) bearing tube for bearing retainment and alignment, (iii) assists in defining the volute, (iv) correct alignment and positioning of the stator assembly, (v) protects or separates the motor from the airpath, and/or (vi) central aperture for the shaft or rotor <NUM>.

As shown in <FIG> and <FIG>, the stationary component <NUM> includes a tube portion or bearing tube portion <NUM>, a shield portion <NUM> provided to one end of the tube portion, and a downwardly and outwardly extending end portion <NUM> extending from the shield. In the illustrated example, the stationary component is integrally molded as a one-piece structure. However, the stationary component may be constructed in other suitable manners.

The interior surface of the tube portion <NUM> is structured to retain and align the bearings <NUM>, <NUM> that rotatably support the shaft <NUM>. In the illustrated example, the tube portion <NUM> is structured such that upper and lower ends of the tube portion are adapted to support bearings of the same size. However, a tube portion structured to support mixed bearing sizes may be used. As illustrated, the upper end of the tube portion includes a flange <NUM> that provides a stop for the bearing <NUM> at the upper end. The flange <NUM> also defines a central aperture <NUM> for the shaft or rotor <NUM> to pass through for engagement with the impeller <NUM>. A hub <NUM> for the magnet support <NUM> provides a stop for the bearing <NUM> at the lower end of the tube portion. Further examples of tube portions are disclosed in <CIT>, and <CIT>. For assembly, the ball bearings are inserted in the bearing housings <NUM>, <NUM> and pushed in and over a projection within the bearing housings to lock the ball bearings within the bearing housings. A spring <NUM> is positioned between the two bearings <NUM>, <NUM> to maintain the bearings in the correct alignment.

The outer edge of the shield portion <NUM> substantially aligns with or extends radially beyond the outer edge of the impeller <NUM>. The edge of the shield portion <NUM> cooperates with the separating wall <NUM> to define a narrow gap <NUM> between the high speed airpath region <NUM>(<NUM>) and the low speed airpath region <NUM>(<NUM>). However, in an alternative example, the outer edge of the shield portion <NUM> may not extend as far as the outer edge of the impeller <NUM>. The shield portion <NUM> assists in preventing blade pass tonal noise when the impeller is rotating as it provides a barrier between spinning impeller blades and the fixed stator end portion <NUM>.

The end portion <NUM> cooperates with the first housing part <NUM> to define the volute <NUM>. The inner edge of the end portion may include an angled surface <NUM>. Alternatively, such surface <NUM> may include a curved profile. As illustrated, the free end of the end portion includes a tab <NUM> adapted to engage within a respective slot <NUM> provided in the first housing part <NUM> to align and retain the stationary component within the housing. Also, the downward section <NUM>(<NUM>) of the end portion is adapted to engage the stator assembly of the motor <NUM> as described below. A seal may be provided between the tab <NUM> and the slot <NUM> to facilitate a seal for the volute. The seal also provides a spring force to keep the tab and slot engaged.

<FIG> and <FIG> illustrate a blower including a stationary component according to an alternative example. The remaining components of the blower are substantially similar to that described above and indicated with similar reference numerals. In this example, the downwardly and outwardly extending end portion <NUM> of the stationary component <NUM> includes multiple steps <NUM>, e.g., two steps. However, any suitable number of steps may be provided, e.g., <NUM>, <NUM>, <NUM>, or more steps. The inner edge of each step may include a curved profile.

The motor <NUM> includes a magnet <NUM>, a shaft <NUM> and a stator assembly <NUM> including windings that generate the electromagnetic field to cause spinning movement of the shaft <NUM> via the magnet <NUM>. The magnet <NUM> is coupled to the shaft <NUM> by a magnet support <NUM> which includes a hub <NUM> engaged with the shaft <NUM> and an arm <NUM> to support the magnet <NUM>. The arm <NUM> of the magnet support <NUM> extends radially outwards and then vertically upwards to surround the bearing tube portion <NUM> of the stationary component <NUM>. The arm <NUM> of the magnet support <NUM> facilitates alignment of the magnet <NUM> with the stator assembly <NUM>. The magnet support <NUM> is rotated to enable rotation of the shaft <NUM> and the impeller <NUM> attached the shaft due to the interaction of the magnet <NUM> and the stator assembly <NUM>. This arrangement provides an internal rotor with a cup-like configuration. As shown in <FIG>, the shaft <NUM> may be magnetically biased downwardly toward the second housing part <NUM> (as indicated by the arrow). However, an axial force may be provided by a bearing preload, e.g., a spring <NUM> between outer races of the bearings <NUM>, <NUM> as shown in <FIG>.

The stator assembly <NUM> includes a stator core or electromagnetic core <NUM> (e.g., including a plurality of laminations stacked on top of one another) on which stator coils or windings <NUM> are wound. First and second insulators <NUM>(<NUM>), <NUM>(<NUM>) (also referred to as slot insulators or slot liners) are provided on opposing sides of the stator core <NUM> to insulate the stator core <NUM> from the stator coils <NUM>. Further details of such insulators are disclosed in <CIT>.

As illustrated, the exterior surface of the stator assembly <NUM> (i.e., exterior surface of the stator core <NUM>) may be supported and retained by the stationary component <NUM> (i.e., the downward section <NUM>(<NUM>) of the end portion <NUM>). The stationary component provides correct alignment and positioning of the stator assembly. Also, the downward section <NUM>(<NUM>) engaging the stator core <NUM> is exposed to the flow of gas, which allows forced-convection cooling of the stator core as gas flows through the housing in use. In addition, this arrangement may assist in heating the gas or patient air.

A printed circuit board assembly (PCBA) <NUM> is mounted to the lower surface of the housing <NUM>. In an example, the PCBA is a pulse-width modulation (PWM) controller to control the motor. The PCBA <NUM> may contain one or more sensors or control chips <NUM>(<NUM>), <NUM>(<NUM>) to assist in controlling the spinning movement of the shaft and hence the load, e.g., impeller. For example, the PCBA may include a Hall sensor to sense the position of shaft or a thermal sensor. Alternatively, the blower may use a sensorless, brushless DC motor control.

In an example, the PCBA is provided within the blower to commutate the motor, control the motor speed to be constant (even with varying flow load as the patient breathes), and/or provide over-temperature and over-speed safety cut-outs. The PCBA includes a motor commutation circuit. With the application of power and an input command, this circuit causes the rotor to turn. This circuitry may be integral or remote from the motor.

The blower can be completely driven by hardware and not software reliant. The speeds may be set manually by the patient. In an example, the blower may be adapted to produce a maximum pressure of <NUM> cmH<NUM>O or preferably <NUM> cmH<NUM>O at <NUM> feet (i.e., <NUM> feet being standard cabin pressure for jet aircraft). However, other pressures such as <NUM> cmH<NUM>O or <NUM> cmH<NUM>O or less are also within the scope of the technology. The light and compact arrangement of the blower is adapted for travel and able to operate up to <NUM> ft.

The blower may be powered by batteries, or a switch mode power supply. Where batteries are used, there is a tendency for the voltage to reduce as the battery is discharged. If the blower is driven with fixed PWM, this would result in a reduction of speed and hence pressure as the battery discharges. Alternatively, speed control can be used to keep the pressure relatively constant as the battery discharges.

In the illustrated example, the impeller <NUM> includes a plurality of continuously curved or straight blades <NUM> sandwiched between a pair of disk-like shrouds <NUM>, <NUM>. The lower shroud <NUM> incorporates the hub or bushing that is adapted to receive the shaft <NUM>. Also, the impeller includes a tapered configuration wherein the blades taper towards the outer edge. Further details of impellers are disclosed in <CIT>.

Air enters the blower <NUM> at the inlet <NUM> and passes into the impeller <NUM> where it is accelerated tangentially and directed radially outward. Air then flows into the high speed airpath region <NUM>(<NUM>) of the volute <NUM>, and then through the gap <NUM> into the low speed airpath region <NUM>(<NUM>) of the volute <NUM>. Air is directed along the volute towards the tangential outlet <NUM>, which volute has an increasing volume.

The blower provides a relatively flat, compact, and lightweight arrangement. For example, the blower may weight less than <NUM> grams, e.g., <NUM> grams. In an example, the blower may be structured to provide pressurized air in the range of <NUM>-<NUM> cmH<NUM>O, such as <NUM>-<NUM> cmH<NUM>O, e.g., up to <NUM> cmH<NUM>O at <NUM> rpm.

The blower may be used for CPAP and/or ventilator applications. In an example, the blower may be incorporated into the patient interface, headgear, or carried by the patient, examples of which are disclosed in <CIT>.

For example, <FIG> illustrates a PAP system <NUM> including a patient interface including a sealing arrangement <NUM> adapted to form a seal with the patient's nose and/or mouth and headgear <NUM> to support the sealing arrangement in position on the patient's head. As illustrated, the blower <NUM> may be supported by the patient interface on the patient's head and in communication with the patient interface.

<FIG> illustrates an alternative arrangement in which headgear connectors <NUM> are provided to respective sides of the blower <NUM>. The headgear connectors <NUM> are adapted to attach to respective headgear straps <NUM> for supporting the blower on top of the patient's head in use.

<FIG> illustrate another example of a blower <NUM> for an integrated CPAP system incorporating a patient interface and a head/body worn PAP device or flow generator (e.g., see <FIG> described below). In an example, the blower may be structured to provide pressurized air in the range of <NUM>-<NUM> cmH<NUM>O, e.g., <NUM>-<NUM> cmH<NUM>O, such as <NUM> cmH<NUM>O, <NUM> cmH<NUM>O and/or <NUM> cmH<NUM>O. In an example, the blower may provide fixed pressure settings (e.g., <NUM> cmH<NUM>O, <NUM> cmH<NUM>O and/or <NUM> cmH<NUM>O) adjustable by the user. The blower may be powered by a power cord assembly or by a battery (e.g., charger pack for battery provided as accessory).

As best shown in <FIG>, the blower <NUM> includes a housing <NUM> with first and second housing parts <NUM>, <NUM>, a stationary component <NUM> overmolded with a stator assembly <NUM>, magnet <NUM> coupled to the shaft <NUM> by magnet support <NUM>, impeller <NUM> coupled to an end portion of the shaft <NUM>, and PCBA <NUM> for motor control.

In an example, as best shown in <FIG>, <FIG>, <FIG>, and <FIG>, a chimney or inlet tube portion <NUM> is provided to the inlet <NUM> of the first housing part <NUM>. The chimney <NUM> (e.g., constructed of TPU alloy, e.g., TPE, or other suitable material) may be overmolded to the first housing part <NUM>. However, the chimney may be coupled to the first housing part <NUM> in other suitable manners, e.g., mechanical interlock.

The chimney <NUM> includes a base <NUM>(<NUM>) that extends along the upper wall of the first housing part <NUM> and a tube portion <NUM>(<NUM>) aligned with the inlet <NUM>. Such chimney may help to dampen vibrations when the blower is mounted within the casing of the PAP device.

In an example, as best shown in <FIG> and <FIG>, a shield or plate <NUM> is provided to the second housing part <NUM>. The shield <NUM> may be adhered to the bottom wall of the second housing part <NUM>, e.g., by an adhesive disk <NUM>(<NUM>) as shown in <FIG>. However, the shield may be coupled to the second housing part <NUM> in other suitable manners.

As shown in <FIG>, the shield <NUM> (e.g., constructed of stainless steel) is positioned along the second housing part <NUM> which is adjacent the PCBA <NUM> to prevent electromagnetic interference (EMI) of the PCBA <NUM>.

In an example, the stationary component <NUM> (e.g., constructed of liquid crystal polymer (LCP)) may be integrated with a stator assembly <NUM> (e.g., including insulators constructed of liquid crystal polymer (LCP)), e.g., by overmolding, to form a one-piece overmolded stationary assembly <NUM>. Such overmolded assembly may provide better shock and vibration performance, more compact (e.g., less axial height), better strength and tolerance of harsh environments, and/or lower cost.

<FIG> shows an example of the stator assembly <NUM> (including a core <NUM>, windings <NUM>, and insulators <NUM> (e.g., see <FIG>) as described above) and a stationary component <NUM> (including a bearing tube portion <NUM>, shield portion <NUM>, and downwardly and outwardly extending end portion <NUM> (e.g., see <FIG>) as described above). The stationary component <NUM> is shown in the opposite orientation to that shown in <FIG> and <FIG>, i.e., the end closest to the second housing part <NUM> facing upwards. Thus, the stator assembly is inserted into the stationary component from the bottom or lower end. <FIG> shows the stationary component <NUM> and stator assembly <NUM> overmolded with one another to establish the one-piece overmolded stationary assembly <NUM>. <FIG> and <FIG> are exemplary cross-sectional views of the one-piece overmolded stationary assembly <NUM>.

<FIG> show various views of the shaft <NUM> (e.g., constructed of stainless steel), magnet support <NUM> (e.g., constructed of stainless steel), and magnet <NUM> as described above. Such assembled components establish a shaft assembly or rotor assembly <NUM> which is assembled to the overmolded stationary assembly <NUM>.

<FIG> show various views of the assembly of the shaft assembly <NUM> to the overmolded stationary assembly <NUM>. As illustrated, the interior surface of the tube portion <NUM> is structured to retain and align the bearings <NUM>, <NUM> that rotatably support the shaft <NUM>. A spring <NUM> (e.g., crest to crest or wave spring constructed of stainless steel) is positioned between the two bearings <NUM>, <NUM> to maintain the bearings in the correct alignment. In an example, as shown in <FIG> and <FIG>, the bearing <NUM> positioned closest to the impeller may be initially press-fit into the tube portion <NUM> (i.e., press-fit outer race of the bearing to the tube portion) before installing the other bearing, spring, and shaft assembly.

Also, a retaining ring <NUM> (e.g., snap ring constructed of beryllium copper (BeCu) or other suitable material) is provided to the shaft <NUM> to retain the shaft assembly <NUM> to the overmolded stationary assembly <NUM>. As best shown in <FIG>, the shaft <NUM> includes a groove <NUM>(<NUM>) to engage the ring <NUM>.

<FIG> show the impeller <NUM> assembled to the assembly of the shaft assembly <NUM> and overmolded stationary assembly <NUM>. In an example, as shown in <FIG>, the spacing d between the impeller <NUM> and the shield portion <NUM> of the overmolded stationary assembly <NUM> may be about <NUM> to <NUM>, e.g., about <NUM>.

In an example, as shown in <FIG> and <FIG>, a seal <NUM> (e.g., constructed of silicone rubber or other suitable material) is provided to the overmolded stationary assembly <NUM> to (i) provide a seal along the volute (i.e., stator airpath seal), (ii), support the PCBA <NUM>, and (iii) provide a wire grommet for guiding wires from the PCBA to external the blower.

As shown in <FIG>, the seal <NUM> includes a ring-shaped main body <NUM> with an integrated wire grommet <NUM> and integrated tab members <NUM>. In an example, the seal is integrally molded in one piece, e.g., constructed of silicone rubber or other suitable material.

As best shown in <FIG>, <FIG>, and <FIG>, the main body <NUM> includes a side wall portion <NUM>(<NUM>) and a bulbous end portion <NUM>(<NUM>) that are positioned between the first housing part <NUM> and the overmolded stationary assembly <NUM> to provide a seal along the volute <NUM> defined between such components.

The tab members <NUM> include support arms <NUM>(<NUM>) to support the PCBA <NUM>, e.g., see <FIG> and <FIG>. As shown in <FIG>, and <FIG>, the wire grommet <NUM> includes openings <NUM>(<NUM>) (e.g. four openings as illustrated, however more or less openings are possible depending on application) for routing or guiding wires <NUM> from the PCBA <NUM> to outside the blower.

As shown in <FIG>, the PCBA <NUM> is coupled to a satellite PCBA <NUM> by wires <NUM>, which satellite PCBA <NUM> is coupled to an overmolded power cord assembly <NUM>. A grommet <NUM> with a living hinge is provided to the satellite PCBA <NUM> to couple the wires <NUM> to the satellite PCBA <NUM>. The satellite PCBA <NUM> may provide additional elements to assist in controlling the motor. PCBA <NUM> provides a user adjustable interface to permit the selection of a speed corresponding with a given output pneumatic pressure; protects the PCBA <NUM> from energy surges that may manifest on the power lines; and/or allows for calibration adjustments, if needed, during final production processes.

<FIG> and <FIG> show installation of the seal <NUM> and PCBA <NUM> to the overmolded stationary assembly <NUM>, and the subsequent installation to the housing <NUM>.

As shown in <FIG>, the seal <NUM> is first installed to the overmolded stationary assembly <NUM>. As illustrated, the main body <NUM> of the seal <NUM> wraps around the outer edge of the assembly <NUM> and the wire grommet <NUM> and tab members <NUM> engage along an upwardly facing lip of the assembly <NUM> (as viewed in <FIG>).

The PCBA <NUM> is then installed to the seal <NUM>. As shown in <FIG> and <FIG>, the overmolded stationary assembly <NUM> includes a plurality of pin-type mounting protrusions <NUM>(<NUM>) (provided by the insulator <NUM> of the integrated stator assembly <NUM> described above) that are adapted to engage within corresponding holes provided in the PCBA <NUM>. The protrusions and holes are positioned to precisely position and align the PCBA <NUM> and its attendant components accurately with respect to the assembly <NUM> and its integrated stator assembly.

Also, the overmolded stationary assembly <NUM> includes a plurality of wires <NUM>(<NUM>) (provided by windings <NUM> of the integrated stator assembly <NUM> described above) that are adapted to extend through corresponding holes provided in the PCBA <NUM>.

Then, as shown in <FIG>, the arrangement is processed to form heads <NUM>(<NUM>) on the tips of one or more of the protrusions <NUM>(<NUM>), e.g., using heat staking. This forms the protrusions <NUM>(<NUM>) into rivets to securely mount the PCBA <NUM> to the assembly <NUM>.

Also, as shown in <FIG>, the ends of the wires <NUM>(<NUM>) are bent and connected, e.g., by soldering, to the PCBA <NUM>. A soldering surface <NUM>(<NUM>) (e.g., gold surface) may be provided around each wire opening of the PCBA to facilitate connection of wire to the PCBA.

<FIG> show assembly of the built stationary component/PCBA to the first housing part <NUM>, and <FIG> show the subsequent assembly of the second housing part <NUM> to the first housing part <NUM>. <FIG> and <FIG> are enlarged views showing positioning and support of the wire grommet <NUM> with respect to the first and second housing parts.

<FIG> show the blower <NUM> mounted within the casing <NUM> of a PAP device <NUM> according to an example of the disclosed technology. <FIG> show the casing with a removable cover or end wall removed, and <FIG> show the casing <NUM> with the cover <NUM>(<NUM>) installed.

As illustrated, the blower <NUM> is supported within the casing <NUM>. Insulators <NUM>(<NUM>), <NUM>(<NUM>) may be provided to respective ends of the blower to stably support the blower within the casing and absorb vibrations/noise from the blower in use.

The blower <NUM> is operable to draw a supply of air into its inlet <NUM> through one or more intake openings provided in the casing and provide a pressurized flow of air at an its outlet <NUM>. The blower outlet <NUM> is coupled to the outlet <NUM> of the casing <NUM> by a flexible tube member <NUM>.

As illustrated, the internal wall structure of the casing <NUM> is structured to support the satellite PCBA <NUM> and power cord assembly <NUM> associated with the PCBA <NUM> of the blower <NUM>.

<FIG> illustrates a blower <NUM> according to another example of the technology. In this example, a portion of the housing is formed of silicone which acts as a vibration isolator and outlet muffler in use.

The blower <NUM> includes a housing <NUM> with first and second housing parts <NUM>, <NUM>, a stationary component <NUM>, a motor positioned within the stationary component <NUM> and adapted to drive a rotatable shaft or rotor (not shown), a PCBA <NUM> for motor control, and an impeller <NUM> provided on one side of the stationary component <NUM> and adapted to be coupled to an end portion of the rotor. In addition, the blower includes an outer housing structure <NUM> communicated with the inlet <NUM> and structured to act as a muffler for incoming air.

In the illustrated example, the first housing part <NUM> provides the inlet <NUM> and the second housing part <NUM> provides the outlet <NUM>. The first housing part <NUM>, second housing part <NUM>, and stationary component <NUM> cooperate to define the volute <NUM> that directs air towards the outlet. Also, the first housing part <NUM> provides the separating wall <NUM> that separates the volute <NUM> into two regions, i.e., the high speed airpath region <NUM>(<NUM>) and the low speed airpath region <NUM>(<NUM>) as described above. The first and second housing parts <NUM>, <NUM> may provide a joint <NUM> (e.g., tongue and groove arrangement or a welded connection) to facilitate alignment and connection.

Moreover, the second housing part <NUM> (which provides an exterior portion, outer wall portion, or pressure side of the volute) is formed of an elastomer material, e.g., silicone or TPE. This arrangement allows the second housing part <NUM> to act as an air cushion in use, e.g., second housing part may at least partially inflate when pressurized in use. In use, the silicone second housing part <NUM> supports the first housing part <NUM>, stationary component <NUM>, motor, and impeller <NUM> in a flexible, vibration-isolated manner. Thus, vibrations and/or other movement generated by these components in use are substantially isolated, e.g., from the outer housing structure <NUM>. Moreover, the silicone second housing part <NUM> acts a muffler for air exiting the outlet <NUM> in use.

In the illustrated example, the stationary component <NUM> includes first and second parts <NUM>(<NUM>), <NUM>(<NUM>) that are coupled to one another, e.g., by a joint. The first and second parts cooperate to define a hollow interior adapted to support and maintain the motor and rotor in an operative position. Also, the first and second parts of the stationary component are structured to retain bearings <NUM>, <NUM> that rotatably support the rotor. For example, the first part <NUM>(<NUM>) may include a recess for supporting one bearing <NUM> and the second part <NUM>(<NUM>) may include a recess for supporting the other bearing <NUM>. The first and second parts may be structured to support bearings of the same or mixed bearing sizes. In addition, the first part provides an opening along its axis that allows the end portion of the rotor to pass therethrough for engagement with the impeller <NUM>.

The outer housing structure <NUM> includes a base <NUM> that extends around the exterior of the second housing part <NUM>, and a cover <NUM> that encloses the top of the blower including the inlet <NUM>. The base <NUM> provides an inlet <NUM> with an inlet chamber <NUM>(<NUM>) to reduce at least a portion of the noise produced by the blower and radiated from the air inlet. In addition, the cover <NUM> provides a small chamber <NUM>(<NUM>) upstream from the inlet chamber to muffle noise entering the inlet <NUM>.

In an example, isolating foam or gels may also be used in one or more portions of the blower to muffle noise and vibration.

In an example, the blower may be structured to provide pressurized air in the range of <NUM>-<NUM> cmH<NUM>O, about <NUM> rpm, and flow rate of about <NUM>-<NUM>/min.

In an example, as shown in <FIG>, H1 may be about <NUM>-<NUM> (e.g., less than <NUM>, <NUM>), H2 may be about <NUM>-<NUM> (e.g., less than <NUM>, <NUM>, <NUM>), W1 may be about <NUM>-<NUM> (e.g., less than <NUM>, <NUM>), W2 may be about <NUM>-<NUM> (e.g., less than <NUM>, <NUM>), and W3 may be about <NUM>-<NUM> (e.g., less than <NUM>, <NUM>, <NUM>). However, other suitable dimensions are possible.

Claim 1:
A blower (<NUM>; <NUM>), comprising:
a housing (<NUM>; <NUM>) including an inlet (<NUM>; <NUM>) and an outlet (<NUM>; <NUM>);
a motor (<NUM>; <NUM>) including a stator assembly (<NUM>; <NUM>), a magnet (<NUM>; <NUM>), and a shaft (<NUM>; <NUM>) adapted to cooperatively drive an impeller (<NUM>; <NUM>); and
a stationary component (<NUM>; <NUM>) provided to the housing (<NUM>; <NUM>), the stationary component configured to support the stator assembly (<NUM>; <NUM>) of the motor and including a bearing tube (<NUM>; <NUM>) adapted to retain and maintain alignment of one or more bearings (<NUM>, <NUM>; <NUM>, <NUM>),
characterized in that the magnet (<NUM>; <NUM>) is located on at least one arm (<NUM>; <NUM>) of a magnet support (<NUM>; <NUM>) adapted to align the magnet (<NUM>; <NUM>) with the stator assembly (<NUM>; <NUM>), the magnet support further including a hub (<NUM>; <NUM>) that engages with the shaft (<NUM>; <NUM>) of the motor to facilitate rotation of the shaft, and wherein the arm (<NUM>; <NUM>) extends radially outwards and then vertically to surround the bearing tube (<NUM>; <NUM>) and to facilitate the alignment of the magnet (<NUM>; <NUM>) with the stator assembly (<NUM>; <NUM>).