Blower assembly with motor integrated into the impeller fan and blower housing constructions

Abstract

A blower comprises a blower housing, a fan, a motor and a support member. The blower housing has an air outlet opening. The fan is within the blower housing, the fan is adapted for rotation about a fan axis. The motor has a stator and a rotor. The rotor is rotatably coupled to the stator for rotation about the fan axis. The rotor and fan are coupled such that the fan rotates with the rotor. The support member is connected between the stator of the motor and the blower housing and extends generally radially from the fan axis. The support member supports both the motor and the fan.

What is claimed is: 
     
         1 . A blower comprising:
 a blower housing having an air outlet opening;   a fan within the blower housing, the fan being adapted for rotation about a fan axis, the fan comprising a first set of impeller blades and a second set of impeller blades, the first set of impeller blades being spaced axially from the second set of impeller blades;   a motor having a stator and a rotor, the rotor being rotatably coupled to the stator for rotation about the fan axis, the rotor and fan being coupled such that the fan rotates with the rotor; and   a support member connected between the stator of the motor and the blower housing and extending generally radially from the fan axis, the support member supporting both the motor and the fan, the support member being between the first set of impeller blades and the second set of impeller blades.   
     
     
         2 . A blower as set forth in  claim 1  wherein the rotor includes an outer diameter and an axial length, the axial length extending along an axial extent of the fan axis, the axial length of the rotor being not more than approximately one-half of the outer diameter of the rotor. 
     
     
         3 . A blower as set forth in  claim 2  wherein the axial length of the rotor is not more than approximately one-quarter of the outer diameter of the rotor. 
     
     
         4 . A blower as set forth in  claim 2  wherein the support member does not extend axially beyond the axial extent of the fan axis. 
     
     
         5 . A blower as set forth in  claim 1  comprising a single bearing, the bearing transmitting load between the rotor and the stator and transmitting load between the fan and the blower housing. 
     
     
         6 . A blower as set forth in  claim 5  wherein the motor comprises an axial flux motor. 
     
     
         7 . A blower as set forth in  claim 1  wherein the support member comprises a wall extending radially outward from adjacent the stator to adjacent the blower housing. 
     
     
         8 . A blower as set forth in  claim 7  wherein the wall circumscribes the stator. 
     
     
         9 . A blower as set forth in  claim 1  wherein the support member comprises a fin-shaped mount extending radially from an arcuate portion of the outer periphery of the stator. 
     
     
         10 . A blower as set forth in  claim 1  wherein the fan extends along a fan axial extent of the fan axis, and wherein the motor is generally axially centered in the fan axial extent of the fan axis. 
     
     
         11 . A blower as set forth in  claim 1  wherein the rotor of the motor comprises a plurality of magnets arranged to form a magnet ring, each of the plurality of magnets having an inner edge and an outer edge, the inner edges of the magnets combining to generally define an inner circumference and an inner diameter of the magnet ring, the outer edges of the magnets combining to generally define an outer circumference and an outer diameter of the magnet ring, the outer diameter of the magnet ring being not more than approximately 1.2 times the inner diameter. 
     
     
         12 . A blower comprising:
 a blower housing having an air outlet opening;   a fan within the blower housing, the fan being adapted for rotation about a fan axis;   a motor having a stator and a rotor, the rotor being rotatably coupled to the stator for rotation about the fan axis, the rotor and fan being coupled such that the fan rotates with the rotor; and   a support member connected between the stator of the motor and the blower housing and extending generally radially from the fan axis, the support member supporting both the motor and the fan.   
     
     
         13 . A blower as set forth in  claim 12  wherein the rotor includes an outer diameter and an axial length, the axial length extending along an axial extent of the fan axis, the axial length of the rotor being not more than approximately one-half of the outer diameter of the rotor. 
     
     
         14 . A blower as set forth in  claim 12  wherein the axial length of the rotor is not more than approximately one-quarter of the outer diameter of the rotor. 
     
     
         15 . A blower as set forth in  claim 12  wherein the support member does not extend axially beyond the axial extent of the fan axis. 
     
     
         16 . A blower as set forth in  claim 12  comprising a single bearing, the bearing transmitting load between the rotor and the stator and transmitting load between the fan and the blower housing. 
     
     
         17 . A blower as set forth in  claim 16  wherein the motor comprises an axial flux motor. 
     
     
         18 . A blower as set forth in  claim 12  wherein the support member comprises a wall extending radially outward from adjacent the stator to adjacent the blower housing. 
     
     
         19 . A blower as set forth in  claim 18  wherein the wall circumscribes the stator. 
     
     
         20 . A blower as set forth in  claim 12  wherein the support member comprises a fin-shaped mount extending radially from an arcuate portion of the outer periphery of the stator. 
     
     
         21 . A blower as set forth in  claim 12  wherein the fan extends along a fan axial extent of the fan axis, and wherein the motor is generally axially centered in the fan axial extent of the fan axis. 
     
     
         22 . A blower as set forth in  claim 12  wherein the rotor of the motor comprises a plurality of magnets arranged to form a magnet ring, each of the plurality of magnets having an inner edge and an outer edge, the inner edges of the magnets combining to generally define an inner circumference and an inner diameter of the magnet ring, the outer edges of the magnets combining to generally define an outer circumference and an outer diameter of the magnet ring, the outer diameter of the magnet ring being not more than approximately 1.2 times the inner diameter. 
     
     
         23 . A blower comprising:
 a blower housing having an air outlet opening;   a fan within the blower housing, the fan being adapted for rotation about a fan axis;   an axial flux motor having a stator and a rotor, the rotor being rotatably coupled to the stator for rotation about the fan axis, the rotor and fan being coupled such that the fan rotates with the rotor; and   a support structure operatively connecting the stator of the motor to the blower housing.   
     
     
         24 . A blower as set forth in  claim 23  comprising a single bearing, the bearing transmitting load between the rotor and the stator and transmitting load between the fan and the blower housing. 
     
     
         25 . A blower as set forth in  claim 23  wherein the fan is integrally connected to the rotor. 
     
     
         26 . A blower comprising:
 a blower housing having an air outlet opening;   a fan within the blower housing, the fan being adapted for rotation about a fan axis, the fan extending along a fan axial extent of the fan axis; and   a motor having a stator and a rotor, the rotor being rotatably coupled to the stator for rotation about the fan axis, the rotor and fan being coupled such that the fan rotates with the rotor, the rotor including an outer diameter and an axial length, the axial length extending along a rotor axial extent of the fan axis, the axial length of the rotor being not more than approximately one-half of the outer diameter of the rotor, the motor being generally axially centered in the fan axial extent of the fan axis.