Patent ID: 8032977

Claim:
A method for manufacturing an air moving device, comprising the steps of: forming an air moving device housing with at least two pieces and with a front side and a back side, for enclosing components of said air moving device, said air moving device housing having an air inlet port and an air outlet port, a thickness from front to back, and said housing having an air conveying chamber and a dust bag chamber; forming a compressible foam block assembly, said compressible foam block assembly occupying said air flow chamber and having a front to back thickness greater then the front to back thickness of said air conveying chamber, thus requiring compression to fit within said device housing, with said compressible foam block assembly defining an air path in said foam, and having an air inlet path and an air outlet path which are linked together by an air conveying chamber through said block assembly; forming a filter assembly with a particulate filter, said filter assembly configured to fill said filter chamber in said housing and operatively connected to said air path and a motor, forming a motor/fan engagement structure within said foam block assembly, with said motor/fan engagement structure configured for positioning a motor/fan assembly in said compressible foam block between said air inlet path and said air outlet path in said air conveying chamber of said block assembly; inserting a motor/fan assembly into said motor/fan engagement structure in said compressible foam block; attaching a power switch to said air moving device housing, and wiring said power switch to said motor/fan assembly within said block assembly; and installing a connection to a power source to said power switch and connecting said power switch to said motor/fan assembly; and placing said compressible foam block assembly within said air moving device housing so that said air inlet path of said block assembly accesses is operatively connected to said particulate filter and said air inlet port of said air moving device housing and placing said block assembly within said air moving device housing so that said air outlet path of said block assembly accesses is operatively connected to said outlet port of said air moving device housing.