Information
-
Patent Grant
-
6736615
-
Patent Number
6,736,615
-
Date Filed
Friday, November 8, 200221 years ago
-
Date Issued
Tuesday, May 18, 200420 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Yu; Justine R.
- Solak; Timothy P.
Agents
- Renner, Kenner, Greive, Bobak, Taylor & Weber
-
CPC
-
US Classifications
Field of Search
US
- 310 239
- 310 90
- 417 4231
- 417 4232
- 417 42315
- 417 42314
- 417 42312
-
International Classifications
- F04B1700
- H01R3938
- H02K516
-
Abstract
A fan/motor assembly having an integrated brush support and bearing retainer is disclosed. The fan/motor assembly includes a rotatable shaft, a working air fan coupled to the shaft, and a motor bracket and baffle assembly interposed between the working air fan and the motor assembly. The motor bracket and baffle assembly retains a bearing which rotatably receives the shaft and provides integral brush boxes for the motor assembly.
Description
TECHNICAL FIELD
The present invention is directed generally to fan/motor assemblies having a rotatable shaft. In particular, the present invention is directed a fan/motor assembly which has a fan end bracket that carries a brush mechanism and also retains a bearing assembly.
BACKGROUND ART
It is well known that wet/dry vacuum cleaners such as those known as utility vacs and carpet extractors, operate in an environment in which the debris, which is extracted from the surface being cleaned, is laden in a mixture of air and water. In order to prevent the moisture laden air from entering the vacuum generating motor, bypass motors are typically used in these operations. As is known to those skilled in the art, a bypass motor/fan assembly is one which the working air, generated by a working air fan, never passes through the motor and is totally isolated from the motor. The motor itself may have a separate motor cooling air fan which draws cooling air over the motor armature and field. Accordingly, the working air and the motor cooling air take totally separate paths, and do not mix—except possibly in an exhaust area. While both the motor cooling fan and the working fan operate on the same motor shaft, in a bypass motor, the chambers for the working air and motor cooling air are separate and distinct from each other such that moisture laden air never enters the motor assembly.
Bypass motors have a working air fan at an end of the motor/fan shaft, with the fan rotating within an enclosure which is sometimes called a shroud. The shroud may be a separately manufactured part or it may be an integral part of the vacuum assembly. In any event, the enclosure, along with a fan end bracket, defines a chamber within which the fan operates. One portion of the fan enclosure is provided with an air intake, with a circumference or periphery of the enclosure defined by a single outlet tube or a plurality of spaced apart exhaust apertures. The intake aperture communicates with a vacuum chamber and the cleaning device, while the exhaust apertures communicate with the ambient air. Typically, the enclosure simply defines the chamber in which the fan rotates and accordingly, that chamber becomes pressurized such that the air therein eventually finds its way to an exhaust port.
Assembly of these fan motor assemblies includes many different parts. Typically, the motor housing includes a slot or section that holds a pair of motor brushes which are placed in contact with the commutator of the motor assembly. Each motor brush is slidably contained within a tube, wherein the tube is secured to the motor housing by a strap secured with fasteners. Known fan end bracket assemblies position and orient the motor shaft with an inserted press-fit motor bearing. Retaining the bearing in this manner is problematic in that the bearing may loosen from the end bracket and cause damage to the motor. Although it is known to provide integrated brush box support with the motor housing, it is not known to use a retainer with the brush boxes to retain the motor bearing.
Therefore, there is a need in the art for a motor/fan assembly with an integrated brush support and bearing retainer which reduces the number of parts and thus the number of manufacturing operations.
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide a fan/motor assembly with integrated brush support and bearing retainer.
Another object of the present invention, which shall become apparent as the detailed description proceeds, is achieved by a fan motor assembly having an integrated brush support and bearing retainer comprising: a motor assembly having a rotatable shaft; a working air fan coupled to the shaft; and a motor bracket and baffle assembly interposed between the working air fan and the motor assembly, the motor bracket and baffle assembly retaining a bearing which rotatably receives the shaft.
Other aspects of the present invention are attained by a bottom motor bracket and baffle assembly interposed between a motor assembly having a shaft, and a fan assembly rotated by the shaft, the baffle assembly, comprising: a bracket for carrying the motor assembly; a bearing carried by the bracket, the bearing rotatably receiving the shaft; and a retainer secured to the bracket and holding the bearing in place.
These and other objects of the present invention, as well as the advantages thereof over existing prior art forms, which will become apparent from the description to follow, are accomplished by the improvements hereinafter described and claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
For a complete understanding of the objects, techniques and structure of the invention, reference should be made to the following detailed description and accompanying drawings, wherein:
FIG. 1
is an elevational view of a partially broken away of the fan/motor assembly according to the present invention;
FIG. 2
is top elevational view of a bottom motor bracket and baffle assembly according to the present invention;
FIG. 3
is a partial, cross-sectional view of the baffle assembly taken substantially along lines
3
—
3
of
FIG. 2
;
FIG. 3A
is partial, cross-sectional view of a cover plate used in the baffle assembly;
FIG. 4
is a partial, cross-sectional view of the baffle assembly taken substantially along lines
4
—
4
of
FIG. 2
;
FIG. 5
is a top elevational view of just the cover plate according to the present invention; and
FIG. 6
is a bottom elevational view of just a retainer used in the baffle assembly according to the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring now to the drawings and in particular to
FIG. 1
it can be seen that a fan/motor assembly within an integrated brush support and bearing retainer is designated generally by the numeral
10
. The fan/motor assembly
10
includes a motor assembly
12
which has an armature and a field assembly as is well known in the art and wherein the armature assembly includes a commutator
13
. Extending through the motor assembly
12
is a rotatable motor shaft
14
which carries a cooling fan
16
at one end. Interposed between the cooling fan
16
and the motor assembly is an end bracket
18
which carries a bearing that assists in the proper rotation of the motor shaft
14
. Disposed at the other end of the motor assembly
12
is a fan housing assembly designated generally by the numeral
20
. The fan housing assembly
20
includes a bottom motor bracket and baffle assembly designated generally by the numeral
30
and a top shroud
32
which mates with the baffle assembly. It will be appreciated that the top shroud
32
may be a stand alone manufactured piece or in the alternative it may be integral with the vacuum equipment to which the motor assembly
12
is coupled. In any event, a working air fan
34
is rotatable within the shroud
32
or vacuum equipment and is connected to the other end of the motor shaft
14
. The shroud
32
provides an inlet
36
to draw in working air which is then exhausted out an outlet
38
which is only partially shown in FIG.
1
. Although this embodiment describes a single outlet aperture for the working air, it will be appreciated that multiple apertures may be used.
Referring now to
FIGS. 2-4
it can be seen that the baffle assembly
30
includes a retainer designated generally by the numeral
40
and a bracket designated generally by the numeral
42
. The complete baffle assembly
30
is shown in
FIGS. 2-4
, while the bracket
42
is specifically shown in FIG.
5
and the retainer is shown specifically in FIG.
6
. Briefly, the retainer
40
and the bracket
42
are coupled to one another and are constructed so as to capture a bearing
43
therebetween. The bearing includes an outer race
44
which is held in place by the retainer
40
and the bracket
42
, and an inner race
45
which is secured to the rotating shaft
14
. Accordingly, this assembly only includes three parts and significantly reduces the time required for the assembling of the motor assembly
10
.
The baffle assembly
30
includes a cover plate
46
wherein the motor side of the cover plate
46
is shown in FIG.
2
and FIG.
5
. The cover plate
46
provides an outlet tube
48
which forms a portion of the outlet
38
. A substantial periphery of the cover plate
46
is defined by a rim
50
. Extending from the motor side of the cover plate
46
are a plurality of radial support ribs
52
. These ribs provide structural strength to the cover plate primarily for the purpose of supporting the weight of the motor assembly
12
. An outer support ring
54
is connected to the radial support ribs
52
as is an inner support ring
56
which is concentric with the ring
54
. A pair of motor mounts
58
extend axially from the cover plate
46
and are positioned within the inner support ring
56
. Each motor mount
58
is provided with a mount hole
60
which receives a fastener to secure the motor assembly
12
to the cover plate
46
.
Referring now to
FIGS. 2
,
4
and
5
, more specific details of the bracket
42
are presented. In particular, the cover plate
46
has extending therefrom a pair of alignment posts
62
from which further extend a nub
64
. Also extending from the cover plate
46
are a pair of fastener posts
66
each of which has a fastener hole
68
. As best seen in
FIG. 5
, the posts
62
and
66
are positioned between the motor mounts
58
. Moreover, the alignment posts
62
are positioned diagonally with respect to one another as are the fastener posts
66
. In other words, the four posts
62
,
66
together form a rectangular shape such that one type of post has the different type of post on either side. And, as can best be seen in
FIG. 5
, the posts
62
and
66
are positioned between the inner support ring
56
and the outer support ring
54
.
Extending through the cover plate
46
at a central position between the motor mounts and the posts
62
and
66
is a bracket hole
70
. The bracket hole
70
is defined by a rim
72
as seen in
FIGS. 3A and 5
. Extending substantially perpendicularly from the rim
72
on the motor side of the cover plate is a ledge
74
from which axially extends a ledge wall
76
. Extending substantially perpendicularly from the ledge wall
76
is a step
78
that terminates at a bearing wall
80
which axially extends from the cover plate
46
. Although the step
78
and the bearing wall
80
are circular and are concentrically disposed around the bracket hole
70
, both the step
78
and the wall
80
may be discontinuous or interrupted with other structural features. A channel
84
is formed between the bearing wall
80
and the inner support ring
56
. As best seen in
FIG. 3
, the outer race
44
is supported by the step
78
in such a manner that the retainer
40
, when coupled to the bracket
42
secures the outer race
44
and allows the inner race
45
to freely rotate.
The retainer
40
, as best seen in
FIGS. 2-4
and
FIG. 6
, includes a frame
90
which has a retainer hole
92
extending therethrough. When the frame
90
is secured to the bracket
42
, the retainer hole
92
is aligned with the bracket hole
70
. The frame
90
includes a brush side
94
which faces the motor assembly
12
and a bearing side
96
which faces the cover plate
46
when assembled. Extending from a lateral edge of the brush side
94
are a pair of alignment tabs
98
which have corresponding alignment holes
100
. In a similar fashion, a pair of fastener tabs
102
extend from the brush side and they likewise provide a tab hole
104
therethrough. As best seen in
FIG. 2
, the alignment holes
100
and tab holes
104
are positionable and alignable over the alignment posts
62
and fastener posts
66
. In particular, the alignment holes
100
are aligned with and fit over the alignment post nubs
64
while tab holes
104
are aligned with the fastener holes
68
. A fastener
106
, which may be threaded or not, is insertable into each of the tab holes
104
and the fastener holes
68
for the purpose of securing the retainer
40
to the bracket
42
. It will further be appreciated that the alignment posts and nubs and the alignment tabs and fastener tabs may be reconfigured such that various alignment tab and hole configurations could be used. In other words, the retainer could be provided with the alignment posts and nubs while the bracket could be provided with corresponding openings to receive the nubs.
The bearing side
96
includes an outer race collar
110
which concentrically surrounds the retainer hole
92
. Extending down the collar
110
is a race flange
112
from which substantially perpendicularly extends a bearing support surface
114
. Extending substantially perpendicularly from the support surface
114
is a wall
116
which defines the retainer hole
92
and which extends to the brush side
94
.
As best seen in
FIGS. 2-4
, the brush side
94
provides a brush collar
120
from which perpendicularly extends a commutator wall
122
. When the motor assembly is secured to the motor mounts
58
, the commutator
13
rotatably fits within the commutator wall
122
. When the retainer
40
is secured to the bracket
42
, the bearing
43
is readily captured by the outer race collar
110
. The bearing support surface
114
and the step
78
together exert a compressive holding force on the outer race
44
while allowing the inner race
45
to freely rotate. Although the outer race collar
110
is a continuous member it could be interrupted with other structural features. The coaction and fit of the components
40
,
42
and
43
allow for a simple and cost efficient assembly process.
Extending from the brush side
94
are a pair of pads
124
from which axially extend a spring post
126
. Also extending from the brush side
94
are a pair of fingers
128
. Diametrically opposed to one another are a pair of brush boxes
130
that are integral with the frame
90
. As will be appreciated by those skilled in the art, the brush boxes
130
carry a carbon brush which is placed in contact with the commutator
13
. The brush boxes have a brush opening
132
for receiving the brush wherein the opening is defined by a pair of side walls
134
that are connected by a top
136
. A brush box bottom
138
is in the same plane as the brush side
94
and connects the other ends of the walls so as to warm a four-sided enclosure for retaining the brush. It will be appreciated that one of the sidewalls
134
provides a spring slot
140
. Extending axially from one corner of the brush box top
136
is a spring nub
142
.
In order to ensure electrical contact between the brushes and the commutator
13
, a spring
146
is employed to bias or assert a continuous force on the brush and make electrical contact with the commutator
13
. The spring
146
includes a coil
148
which has a brush end
150
and a bias end
152
. The coil
148
fits over the spring post
126
in such a manner that the bias end
152
is retained by a corresponding finger
128
. The brush end
150
of the spring is retained by the spring nub
142
until the brush is received within the brush opening
132
. Upon completion of the motor manufacturing operation, the brush end
150
is released from the spring nub
142
and provides the constant exertion of force against a back end of the brush so that the front end of the brush is contact with the commutator
13
.
Based upon the foregoing the advantages of the present invention are readily apparent. Primarily, the present invention allows for the efficient and quick assembly of a retainer to the bracket while also securing a bearing therebetween. This simplifies the manufacturing process and reduces the related scrap incurred by previous multiple part assemblies. Moreover, the retainer is constructed such as to fit quickly and easily over the posts of the bracket and to allow for receipt of fasteners for securing the bearing therebetween. The motor assembly can then be secured to the motor mounts while the motor brushes are easily installed. Accordingly, the assembly is reliable and cost efficient to manufacture.
Thus, it can be seen that the objects of the invention have been satisfied by the structure and its method for use presented above. While in accordance with the Patent Statutes, only the best mode and preferred embodiment has been presented and described in detail, it is to be understood that the invention is not limited thereto or thereby. Accordingly, for an appreciation of the true scope and breadth of the invention, reference should be made to the following claims.
Claims
- 1. A fan motor assembly having an integrated brush support and bearing retainer comprising:a motor assembly having a rotatable shaft; a working air fan coupled to said shaft; and a motor bracket and baffle assembly interposed between said working air fan and said motor assembly, said motor bracket and baffle assembly retaining a bearing which rotatably receives said shaft, said motor bracket and baffle assembly comprising a bracket, said motor assembly mounted to said bracket, and a retainer coupled to said bracket, said bracket and said retainer capturing said bearing therebetween, said retainer comprising a frame having a retainer hole therethrough which is alignable with said bracket hole, a pair of brush boxes extending from said frame and diametrically opposed to one another, a pair of spring posts extending from said frame, each said spring post in proximity to one of said corresponding brush boxes and wherein said fan motor assembly further comprises a spring carried by each said spring post.
- 2. The assembly according to claim 1, wherein said spring comprises:a coil having a brush end and a bias end; and said retainer further comprising a pair of fingers extending from said frame, each said finger retaining a bias end of said spring.
- 3. A bottom motor bracket and baffle assembly interposed between a motor assembly having a shaft, and a fan assembly rotated by the shaft, the baffle assembly, comprising:a bracket for carrying the motor assembly; a bearing carried by said bracket, said bearing rotatably receiving the shaft; a retainer secured to said bracket and holding said bearing in place, said retainer comprising a frame, said frame having a retainer hole therethrough, and a pair of brush boxes extending from said frame and diametrically opposed to one another; a pair of spring posts extending axially from said frame; and a spring carried by each said spring post, each said spring having a brush end and a bias end, wherein each said brush box has extending therefrom a spring nub, said spring nub retaining said brush end.
- 4. The baffle assembly according to claim 3, wherein said bracket comprises:a cover plate, said cover plate having a bracket hole therethrough; and a bearing wall disposed about said bracket hole, said bearing positioned within said bearing wall and aligned with said bracket hole.
- 5. The baffle assembly according to claim 3, wherein said retainer comprises:a frame, said frame having a retainer hole therethrough; and an outer race collar disposed about said retainer hole, said bearing positioned within said outer race collar and aligned with said retainer hole.
- 6. The baffle according to claim 3,a cover plate, said cover plate having a bracket hole therethrough; and a bearing wall disposed about said bracket hole, said bearing positioned within said bearing wall and aligned with said bracket hole; a frame, said frame having a retainer hole therethrough; and an outer race collar disposed about said retainer hole, said bearing positioned within said outer race collar and aligned with said retainer hole; and wherein said bearing has an outer race and an inner race, said bearing wall and said outer race collar capturing said outer race.
- 7. The baffle assembly according to claim 3, wherein said bracket comprises:at least one alignment post, and at least one fastener post; and wherein said retainer comprises: a plurality of tabs, each said tab having a tab hole therethrough, said tab holes alignable with said at least one alignment post and said at least one fastener post.
- 8. The baffle assembly according to claim 7, further comprising:at least one fastener received through said tab hole to secure said retainer to said bracket.
- 9. The baffle assembly according to claim 3, wherein said retainer further comprises:a pair of fingers extending from said frame, each said finger retaining said bias end of said spring.
- 10. A fan motor assembly having an integrated brush support and bearing retainer comprising:a motor assembly having a rotatable shaft; a working air fan coupled to said shaft; and a motor bracket and baffle assembly interposed between said working air fan and said motor assembly, said motor bracket and baffle assembly retaining a bearing which rotatably receives said shaft, wherein said motor bracket and baffle assembly comprises a bracket, said motor assembly mounted to said bracket, and a retainer coupled to said bracket, said bracket and said retainer capturing said bearing therebetween, wherein said bracket has a cover plate with a bracket hole therethrough, said cover plate having a bearing wall extending axially therefrom and around said bracket hole, said bearing wall enclosing at least a portion of said bearing, wherein said retainer comprising a frame having a retainer hole therethrough which is alignable with bracket hole, and an outer race collar extending axially from said frame and around said retainer hole, said outer race collar enclosing at least a portion of said bearing; and said cover plate further comprising a step extending radially from said bearing wall toward said bracket hole, a ledge wall extending axially from said step, and a ledge extending radially from said ledge wall toward said bracket hole, wherein said bearing has an outer race and an inner race, and wherein said outer race is supported by said step.
- 11. The assembly according to claim 10, wherein said retainer further comprises:a race flange extending axially from said outer race collar, and a bearing support surface extending radially from said race flange, wherein said bearing support surface and said step hold said outer race when said retainer is coupled to said bracket.
- 12. The assembly according to claim 10, wherein said bracket has a plurality of alignment posts and said retainer has a plurality of alignment holes that are mateable with said alignment posts.
- 13. The assembly according to claim 12, wherein said bracket has a plurality of fastener posts with fastener holes, said retainer having tab holes alignable with said fastener holes for receiving fasteners to secure said retainer to said bracket.
US Referenced Citations (8)