Low part count blower-motor assembly in common housing

Abstract

A low part count blower-motor assembly in a two-part housing which defines fluid inlet and discharge openings for the blower but which is otherwise sealed when assembled. An integrated tubular stator subassembly is fixedly attached to one of the housing parts and projects axially toward the fluid inlet opening. An integrated motor rotor subassembly is also disposed within the housing for rotation about the stator subassembly in coaxial relationship therewith, a part of the rotor subassembly being disposed axially between the stator and the inlet opening in spaced relationship with the opening. A shaft is journaled in the central opening of the tubular stator subassembly and projects axially there from toward the inlet opening and a fluid impeller mounted on the projecting end portion of the shaft receives fluid from the inlet opening. The impeller is also fixedly attached to the part of the rotor which resides between the stator and inlet opening.

1 . A low part count blower-motor assembly in a common housing comprising a two-part housing which defines fluid inlet and discharge openings for the blower but which is otherwise sealed when assembled, an integrated tubular stator subassembly fixedly attached to one of the housing parts and projecting axially toward the fluid inlet opening, an integrated motor rotor subassembly disposed within the housing for rotation about the stator subassembly in coaxial relationship therewith, a part of the rotor subassembly being disposed axially between the stator and the inlet opening in spaced relationship with the opening, a shaft journaled in the central opening of the tubular stator subassembly and projecting axially from the opening toward the inlet opening, and a fluid impeller mounted on the projecting end portion of the shat to receive fluid from the inlet opening, said impeller also being fixedly attached to said part of the rotor residing between the stator and the inlet opening.  
   
   
       2 . A low part count blower-motor assembly in a common housing as set forth in  claim 1  wherein openings are provided respectively for communication between the interior of the stator subassembly and the upstream and downstream sides of the impeller, a flow of cooling fluid through the stator subassembly thus being provided.  
   
   
       3 . A low part count blower-motor assembly in a common housing as set forth in  claim 2  wherein a flow regulating device is provided for at least one of said stator openings whereby to control cooling of the motor.  
   
   
       4 . A low part count blower-motor assembly in a common housing as set forth in  claim 3  wherein the fluid is air, and wherein the flow regulating device is a plug in the associated opening and having an air flow passageway of predetermined area for controlling air flow through the stator.  
   
   
       5 . A low part count blower-motor assembly in a common housing as set forth in  claim 1  wherein the stator subassembly is overmolded in a plastic injection molding process to provide a unitary subassembly.  
   
   
       6 . A low part count blower-motor assembly in a common housing as set forth in  claim 1  wherein the rotor subassembly is overmolded in a plastic injection molding process to provide a unitary subassembly.  
   
   
       7 . A low part count blower-motor assembly in a common housing as set forth in  claim 1  wherein both the stator and rotor subassemblies are overmolded in plastic injection molding operations to provide unitary subassemblies.  
   
   
       8 . A low part count blower-motor assembly in a common housing as set forth in  claim 1  wherein the impeller is ultrasonically welded to the rotor part residing between the stator and the inlet opening.  
   
   
       9 . A low part count blower-motor assembly in a common housing as set forth in  claim 1  wherein the rotor and impeller are integrally molded simultaneously.  
   
   
       10 . A low part count blower-motor assembly in a common housing as set forth in  claim 1  wherein the housing parts are adapted for snap-fit interengagement.  
   
   
       11 . A blower-motor assembly wherein at least the motor bearings and shaft are located in the blower housing in such a manner that no significant pressure drop occurs across the bearings, the motor including fluid flow passageways which divert a portion of the main fluid flow stream generated by the blower into one of said passageways through the motor and then out another of said passageways to rejoin the main fluid flow stream whereby to cool the motor.  
   
   
       12 . A blower-motor assembly in a common housing which defines inlet and discharge openings for the blower but which is otherwise sealed, an annular stator fixedly attached to the housing and a rotor carried by the stator for rotation thereabout and in turn driving a fluid impeller, a shaft mounted within axially spaced bearings in the central opening of the tubular stator, inlet and discharge openings in the stator arranged to divert a portion of the main fluid stream generated by the impeller through the stator and thereby cooling the motor.  
   
   
       13 . A blower-motor assembly as set forth in  claim 12  wherein the fluid flow passageways are arranged to draw fluid from the downstream side of the blower and discharge the cooling air to the upstream side of the blower.  
   
   
       14 . A blower motor assembly as set forth in  claim 12  wherein the fluid flow passageways are arranged to draw fluid from the downstream side of the blower and discharge the cooling air to the upstream side of the blower but sub impeller for blower.  
   
   
       15 . A blower-motor assembly as set forth in  claim 14  wherein both the stator and rotor are of overmolded plastic construction.