Information
                
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 Patent Grant
                     
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 6435818
                     
                
             
         
    
    
        
            
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Patent Number
                    6,435,818
                 
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Date Filed
                    Wednesday, August 30, 200025 years ago
                 
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Date Issued
                    Tuesday, August 20, 200223 years ago
                 
            
         
     
    
        
            
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Inventors
        
                 
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Original Assignees
        
                 
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Examiners
            
                    - Lopez; F. Daniel
 
                    - Woo; Richard
 
            
                    
                 
            
         
     
    
        
            
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CPC
        
                 
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US Classifications
        
                            Field of Search
        
                US
 
                    - 415 119
 
                    - 415 206
 
                    - 415 203
 
                    - 415 200
 
                    - 415 2131
 
                    - 415 2141
 
                    - 417 42314
 
                    - 417 42315
 
                    - 417 312
 
                    
                 
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International Classifications
        
                 
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        Abstract
A blower housing having a casing with a resilient bottom piece and a rigid top piece assembling with the bottom piece to define an interior of the casing is provided. The bottom piece of the blower housing directly abuts a blower mounting surface. The top piece supports a blower motor. The bottom piece is constructed from a vibration dampening material. The top piece is constructed from a rigid material. The vibration absorbing material attenuates noise and other vibrations transmitted from the blower motor and impeller of the blower housing to the blower mounting surface and other associated structures.             
         
        
            
                    Description
  
    
      
        BACKGROUND OF THE INVENTION
      
    
    
      
        (1) Field of the Invention
      
    
    
      
        The invention relates to blowers for high efficiency furnaces for drawing combustion gases into the furnace and propelling the products of combustion into the exhaust pipe to be vented to atmosphere. More specifically, the invention relates to the construction of the blower housing.
      
    
    
      
        (2) Description of the Related Art
      
    
    
      
        Blowers to which the present invention is directed are common in the art. The blower is used on high efficiency furnaces (e.g. 90%) to draw combustion air into the furnace from outside the home. Generally, these blowers are located downstream of a combustion chamber or combustion tubes in the furnace, depending upon the style of furnace. Combustion air is drawn into the combustion chamber or combustion tubes, mixed with fuel, and ignited to generate heat for the furnace. The exhaust gases are then drawn into the suction of the blower and discharged from the blower to an exhaust pipe that vents to outside atmosphere.
      
    
    
      
        
          FIG. 1
        
         shows a blower 
        
          
            20
          
        
         of the prior art arranged on a blower mounting surface 
        
          
            21
          
        
         of a furnace 
        
          
            22
          
        
        . The blower 
        
          
            20
          
        
         includes a blower motor (
        
          
            47
          
        
        ) and a blower housing 
        
          
            24
          
        
        . In 
        
          FIG. 1A
        
        , the blower motor has been removed from its center mount 
        
          
            26
          
        
         on top of the blower housing 
        
          
            24
          
        
         to show greater detail of the blower housing 
        
          
            24
          
        
        . The blower housing 
        
          
            24
          
        
         has a side wall 
        
          
            28
          
        
         extending between a top piece 
        
          
            30
          
        
         and a bottom piece 
        
          
            32
          
        
        . Locator surfaces 
        
          
            33
          
        
        A,
        
          
            33
          
        
        B are provided on the top and bottom pieces 
        
          
            30
          
        
        ,
        
          
            32
          
        
         to align the top and bottom pieces 
        
          
            30
          
        
        ,
        
          
            32
          
        
        . The locator surfaces 
        
          
            33
          
        
        A,
        
          
            33
          
        
        B also form a seal between the top and bottom pieces 
        
          
            30
          
        
        ,
        
          
            32
          
        
         to contain exhaust gases within the blower housing 
        
          
            24
          
        
        . The top piece 
        
          
            30
          
        
         is molded with the center mount 
        
          
            26
          
        
         recessed to receive the blower motor (not shown). The side wall 
        
          
            28
          
        
        , top piece 
        
          
            30
          
        
        , and bottom piece 
        
          
            32
          
        
         form a volute 
        
          
            34
          
        
         for the blower housing 
        
          
            24
          
        
        . When the blower 
        
          
            20
          
        
         is energized, an impeller (not shown), operably connected to a shaft of the blower motor (not shown), rotates in the volute 
        
          
            34
          
        
         to draw exhaust gases through an inlet hole 
        
          
            35
          
        
         in the center of the bottom piece 
        
          
            32
          
        
         and to compress gases in the volute 
        
          
            34
          
        
        . The pressurized exhaust gases are directed into a discharge pipe 
        
          
            36
          
        
         that extends outward and away from the blower 
        
          
            20
          
        
         and the furnace 
        
          
            22
          
        
        . Mounting feet 
        
          
            38
          
        
         for attaching the blower 
        
          
            20
          
        
         to the blower mounting surface 
        
          
            21
          
        
         of the furnace 
        
          
            22
          
        
         are provided on the side wall 
        
          
            28
          
        
         of the blower housing 
        
          
            24
          
        
        .
      
    
    
      
        
          FIG. 1B
        
         shows the blower 
        
          
            20
          
        
         arranged on the blower mounting surface 
        
          
            21
          
        
         in the furnace 
        
          
            22
          
        
        . The blower housing 
        
          
            24
          
        
         is positioned to allow the impeller (not shown) to draw exhaust gases directly from the combustion chamber or combustion tubes (not shown) into the blower housing 
        
          
            24
          
        
        . The discharge pipe 
        
          
            36
          
        
         is coupled to an exhaust pipe 
        
          
            39
          
        
         using a gasket 
        
          
            40
          
        
         to vent the exhaust gases to atmosphere. The top piece 
        
          
            30
          
        
         is attached to the blower mounting surface 
        
          
            21
          
        
         using mechanical fasteners 
        
          
            41
          
        
         through holes 
        
          
            42
          
        
         on the mounting feet 
        
          
            38
          
        
        . The mechanical fasteners 
        
          
            41
          
        
         have a screw head driving end 
        
          
            43
          
        
         and an opposite driven end 
        
          
            44
          
        
         spaced from the driving end 
        
          
            43
          
        
         by a shaft 
        
          
            45
          
        
        . The screw head driving end 
        
          
            43
          
        
         engages a seating surface 
        
          
            46
          
        
         on the mounting foot 
        
          
            38
          
        
         and holds the top piece 
        
          
            30
          
        
         onto the blower mounting surface 
        
          
            21
          
        
        . The bottom piece 
        
          
            32
          
        
         is preferably held in position between the top piece 
        
          
            30
          
        
         and the blower mounting surface 
        
          
            21
          
        
         by compression from the mechanical fasteners 
        
          
            41
          
        
        .
      
    
    
      
        Typically, the impeller rotates at a high rate of speed to generate sufficient air flow into the combustion chamber and combustion tubes and to draw the exhaust gases out into the exhaust pipe 
        
          
            39
          
        
        . As shown in 
        
          FIG. 1B
        
        , the blower motor 
        
          
            47
          
        
         is positioned directly atop of the blower housing 
        
          
            24
          
        
         and the shaft (not shown) of the blower motor 
        
          
            47
          
        
         is directly coupled to the impeller (not shown) in the blower housing 
        
          
            24
          
        
        . The high speed rotation of the impeller and the motor 
        
          
            47
          
        
         tends to create noise and other vibrations that are transferred directly into the blower housing 
        
          
            24
          
        
        . As shown in 
        
          FIG. 1B
        
        , the blower 
        
          
            20
          
        
         is directly mounted onto the blower mounting surface 
        
          
            21
          
        
         of the furnace 
        
          
            22
          
        
        . Therefore, noise and vibrations are transmitted directly to the blower mounting surface 
        
          
            21
          
        
         in the furnace 
        
          
            22
          
        
        . This vibration results in unwanted noise being transmitted into the associated structures of the furnace 
        
          
            22
          
        
         such as ducting where the noise can be transmitted throughout the house. The vibration also contributes to decreased life span of the blower 
        
          
            20
          
        
        .
      
    
    
      
        In the prior art to combat these problems, the installation of the blower housing onto the furnace mounting surface generally involved installing cushioning mounts 
        
          
            48
          
        
         and other vibration absorbing gaskets between the blower housing 
        
          
            24
          
        
         and the blower mounting surface 
        
          
            21
          
        
        .
      
    
    
      
        What is needed to overcome the disadvantages of the prior art is to form a blower housing which has sound dampening qualities integrally formed in the housing to reduce noise and vibration transmitted from the motor and impeller into the blower mounting surface. Such a blower housing would have the vibration absorbing material integrally formed in the housing so that gaskets and other additional cushioning devices are not needed. Moreover, such a blower housing would be sufficiently sturdy to withstand high temperature exhaust gases passing through it.
      
    
    
      
        SUMMARY OF THE INVENTION
      
    
    
      
        In order to overcome the disadvantages of the prior art, the blower of the present invention includes a blower housing having a resilient bottom piece and a rigid top piece covering over the bottom piece to enclose an interior of the blower housing. The bottom piece of the blower housing directly abuts the exterior mounting surface of the furnace. The top piece of the blower housing supports the blower motor.
      
    
    
      
        The bottom piece of the blower housing may be made from a vibration dampening material. Materials such as sanoprene and viram are suitable for dampening and attenuating vibrations and withstanding the heat from the products of combustion. The top piece of the blower housing may be made from a material such as polypropylene to provide a rigid foundation for the blower motor and for material compatibility the bottom piece.
      
    
    
      
        The top piece of the blower housing includes an annular lower support portion for supporting the blower motor and an annular upper portion extending above and around the lower portion. The upper portion of the top piece of the blower housing has an outer peripheral edge and at least one lug extending outward beyond outer peripheral edge. The bottom piece of the blower housing has a flange that aligns with the lug of the top piece when the blower housing is assembled. The flange interlocks with the lug to detachably engage the top piece to the bottom piece. The top piece, side wall and bottom piece form a volute for the blower housing.
      
    
    
      
        The lug on the top piece has a lug hole to receive a mechanical fastener. The flange on the bottom piece preferably has a flange hole that receives the mechanical fastener therethrough when the mechanical fastener joins the top piece to the blower mounting surface of the furnace. The mechanical fastener preferably attaches the blower housing to a blower mounting surface of the furnace such that the blower housing is positioned between a blower motor and exterior mounting surface of the furnace. The mechanical fastener has a driven end and a driving end. The driven end is inserted into the blower mounting surface of the furnace and the driving end is located above the lug on the upper portion of the top piece.
      
    
    
      
        In another aspect of the present invention, the blower housing is provided with an improved seal between the top and bottom pieces. Preferably, the blower housing includes a bottom piece having a disk shaped bottom portion with an outer perimeter border. The bottom piece has an upstanding annular wall extending outward from the bottom disk around the outer perimeter border. The upstanding annular wall has an interior surface that forms a portion of the volute for the blower housing and an exterior surface surrounding the interior surface. The upstanding wall has an annular end axially opposite the bottom disk portion that extends between the exterior and interior surfaces of the upstanding wall. The annular end has an annular lip axially spaced from the annular end.
      
    
    
      
        The top piece fits over the bottom piece to enclose the volute and form a casing for the blower. The top piece has a lower portion recessed into the top piece and extending into the casing. The lower portion receives the blower motor. The top piece has an upper portion which extends around and above the lower portion. The upper portion has a primary groove and an outer peripheral edge surrounding the primary groove. The primary groove has an annular outer side wall and an annular inner side wall spaced apart by an annular groove wall. The groove wall preferably has a secondary groove intermediate the coterminous edges of the groove wall and inner and outer side walls. The inner side wall of the primary groove abuts the interior surface of the upstanding wall of the bottom piece and the annular lip of the bottom piece is received in the secondary groove when the casing is assembled.
      
    
    
      
        The inner side wall of the primary groove preferably has an annular rib extending outward from the side wall into the primary groove. The interior surface of the upstanding annular wall preferably has an annular notch on its interior surface. In this arrangement, the annular notch receives the annular rib in the primary groove when the bottom piece is fully assembly with the top piece. This construction provides a positive indicator of sealing between the top and bottom pieces when the blower housing is assembled.
      
    
    
      
        To provide further structural integrity to the top and bottom pieces when the casing is assembled, the lug on the top piece is preferably provided with a depending leg. The depending leg extends downward and away from the outer peripheral edge of the top piece and is received in the flange hole.
      
    
    
      
        The blower housing of the present invention may be installed on a furnace without the use of sound absorbing or other vibration dampening devices. The two piece assembly of the blower housing facilitates assembly of the blower housing and installation of the blower housing onto the furnace mounting surface.
      
    
  
  
    
      
        BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
      
    
    
      
        Further objects and features of the invention are revealed in the following detailed description of the preferred embodiment of the invention and in the drawings wherein:
      
    
    
      
        
          FIG. 1
        
         is an exploded, perspective view of a blower of the prior art;
      
    
    
      
        
          FIG. 1B
        
         is a side view of the blower of the prior art installed on a mounting structure of a furnace;
      
    
    
      
        
          FIG. 2
        
         is a side view of a blower of the present invention installed on the mounting structure of the furnace;
      
    
    
      
        
          FIG. 3
        
         is a perspective view of a blower housing of the blower of 
        
          FIG. 2
        
        ;
      
    
    
      
        
          FIG. 4
        
         is a top, perspective view of a top piece of the blower housing of 
        
          FIG. 3
        
        ;
      
    
    
      
        
          FIG. 5
        
         is a bottom, perspective view of the top piece of 
        
          FIG. 4
        
        ;
      
    
    
      
        
          FIG. 6
        
         is a top, perspective view of a bottom piece of the blower housing of 
        
          FIG. 3
        
        ;
      
    
    
      
        
          FIG. 7
        
         is a bottom, perspective view of the bottom piece of 
        
          FIG. 6
        
        ;
      
    
    
      
        
          FIG. 8
        
         is a cross-sectional view of the top piece installed with the bottom piece to form the blower housing of 
        
          FIG. 3
        
        ; and
      
    
    
      
        
          FIG. 9
        
         is a cross-sectional view of the top piece installed with the bottom piece to form the blower housing of FIG. 
        
          
            3
          
        
        .
      
    
  
  
    
      
        Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
      
    
    
      
        DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
      
    
    
      
        
          FIG. 2
        
         shows the blower of the present invention installed in a furnace. The blower 
        
          
            50
          
        
         includes a blower motor 
        
          
            52
          
        
         and a blower housing 
        
          
            54
          
        
        . The blower housing 
        
          
            54
          
        
         has an annular upstanding wall 
        
          
            56
          
        
         extending between a top piece 
        
          
            58
          
        
         and bottom piece 
        
          
            60
          
        
        . The bottom piece 
        
          
            60
          
        
         is mounted on a blower mounting surface 
        
          
            21
          
        
         in the furnace 
        
          
            22
          
        
        , or the furnace bonnet, using mechanical fasteners 
        
          
            41
          
        
        . The driving end 
        
          
            43
          
        
         of each of the fasteners 
        
          
            41
          
        
         seats against the top most portion of top piece 
        
          
            58
          
        
         and the driven end 
        
          
            44
          
        
         is installed in the blower mounting surface 
        
          
            21
          
        
         on the furnace 
        
          
            22
          
        
        . In the arrangement shown in 
        
          FIG. 2
        
        , the bottom piece 
        
          
            60
          
        
         is preferably held in position between the top piece 
        
          
            58
          
        
         and the blower mounting surface 
        
          
            21
          
        
         by compression from the mechanical fasteners 
        
          
            41
          
        
        .
      
    
    
      
        As shown in 
        
          FIG. 2
        
        , the blower 
        
          
            50
          
        
         is mounted on a blower mounting surface 
        
          
            21
          
        
         on the furnace 
        
          
            22
          
        
         where the blower housing 
        
          
            54
          
        
         is positioned to allow the impeller (not shown) to draw exhaust gases directly from the combustion chamber or combustion tubes (not shown) into the blower housing 
        
          
            54
          
        
        . A discharge pipe 
        
          
            61
          
        
         is coupled to an exhaust pipe 
        
          
            62
          
        
         using a gasket 
        
          
            64
          
        
         to vent the exhaust gases to atmosphere.
      
    
    
      
        
          FIG. 3
        
         shows a perspective view of the blower housing 
        
          
            54
          
        
         with top piece assembled on the bottom piece 
        
          
            60
          
        
        . The top piece 
        
          
            58
          
        
         covers over the bottom piece 
        
          
            60
          
        
         to tightly enclose the blower housing 
        
          
            54
          
        
         and prevent exhaust gases from leaking from the blower housing 
        
          
            54
          
        
         during operation. The top piece 
        
          
            58
          
        
         has a lower portion 
        
          
            66
          
        
         that is recessed into the top piece 
        
          
            58
          
        
         and extends into the blower housing casing 
        
          
            54
          
        
        . The diameter of the recessed lower portion 
        
          
            66
          
        
         is sized to accommodate the blower motor 
        
          
            52
          
        
        . The lower portion 
        
          
            66
          
        
         has mounting fittings 
        
          
            68
          
        
         for securing the blower motor to the top piece 
        
          
            58
          
        
        . The lower portion 
        
          
            66
          
        
         may also have screw fittings 
        
          
            70
          
        
         for securing the motor to the top piece 
        
          
            58
          
        
        . At the center of the lower portion 
        
          
            66
          
        
        , a through hole 
        
          
            72
          
        
         is provided to allow a shaft (not shown) from the blower motor to pass into the interior of the blower housing 
        
          
            54
          
        
         to be coupled with the impeller (not shown). The top piece 
        
          
            58
          
        
         has an upper portion 
        
          
            74
          
        
         which extends around and above the lower portion 
        
          
            66
          
        
         and includes a seating surface 
        
          
            76
          
        
         for the mechanical fasteners 
        
          
            41
          
        
        .
      
    
    
      
        
          FIGS. 4 and 5
        
         provide greater detail of the top piece 
        
          
            58
          
        
        . The upper portion 
        
          
            74
          
        
         of the top piece 
        
          
            58
          
        
         has an outer peripheral edge 
        
          
            78
          
        
         and lugs 
        
          
            80
          
        
         extending radially outward beyond the outer peripheral edge 
        
          
            78
          
        
        . The lugs 
        
          
            80
          
        
         preferably have arcuate lug holes 
        
          
            82
          
        
         formed therein to allow minor positioning of the blower housing 
        
          
            54
          
        
         on the blower mounting surface 
        
          
            21
          
        
         of the furnace 
        
          
            22
          
        
         when the blower 
        
          
            50
          
        
         is installed on the furnace 
        
          
            22
          
        
        . Preferably, each of the lugs 
        
          
            80
          
        
         has a depending leg 
        
          
            84
          
        
         extending downward and away from the outer peripheral edge 
        
          
            78
          
        
         of the top piece 
        
          
            58
          
        
        . Each leg 
        
          
            84
          
        
         preferably has an exterior surface 
        
          
            86
          
        
         and an arcuate interior surface 
        
          
            88
          
        
         which gives each leg 
        
          
            84
          
        
         a generally concave aspect when it is installed on the blower housing 
        
          
            54
          
        
        . The arcuate interior surface 
        
          
            88
          
        
         of the depending leg 
        
          
            84
          
        
         preferably has a circumferential guide portion 
        
          
            90
          
        
         that conforms to the upstanding annular wall 
        
          
            56
          
        
         on the bottom piece 
        
          
            60
          
        
        . The circumferential guide portion 
        
          
            90
          
        
         on the depending leg 
        
          
            84
          
        
         supports and aligns the top piece 
        
          
            58
          
        
         with the bottom piece 
        
          
            60
          
        
         during operation. The depending leg 
        
          
            84
          
        
         bears some of the weight of the blower motor when the blower 
        
          
            50
          
        
         is installed on the blower mounting surface 
        
          
            21
          
        
         of the furnace 
        
          
            22
          
        
        .
      
    
    
      
        As shown in 
        
          FIG. 5
        
        , an annular locating groove 
        
          
            92
          
        
         is provided around the upper portion 
        
          
            74
          
        
         radially inward of the outer peripheral edge 
        
          
            78
          
        
        . The annular locating groove 
        
          
            92
          
        
         is positioned a sufficient distance away from the outer peripheral edge 
        
          
            78
          
        
        , lug hole 
        
          
            82
          
        
        , and depending leg 
        
          
            84
          
        
         to so as not to interfere with the seal between the top piece 
        
          
            58
          
        
         and bottom piece 
        
          
            60
          
        
         when the blower housing 
        
          
            54
          
        
         is assembled. Greater detail of the annular locating groove 
        
          
            92
          
        
         and seal between the top and bottom pieces 
        
          
            58
          
        
        ,
        
          
            60
          
        
         will be discussed later with reference to FIG. 
        
          
            8
          
        
        .
      
    
    
      
        
          FIGS. 6 and 7
        
         provide detail of the bottom piece 
        
          
            60
          
        
         of the blower housing 
        
          
            54
          
        
        . The bottom piece 
        
          
            60
          
        
         has a bottom disk portion 
        
          
            94
          
        
         with a center inlet hole 
        
          
            95
          
        
         that allows the blower 
        
          
            50
          
        
         to draw exhaust gases into the housing 
        
          
            54
          
        
         during blower operation. The bottom disk portion 
        
          
            94
          
        
         has an outer perimeter border 
        
          
            96
          
        
         and the upstanding annular wall 
        
          
            56
          
        
         extends outward and away from the outer perimeter border 
        
          
            96
          
        
        . The underside of the bottom disk portion 
        
          
            94
          
        
         of the blower housing 
        
          
            54
          
        
         is generally flat so that it may be mounted flush against the blower mounting surface 
        
          
            21
          
        
         of the furnace 
        
          
            22
          
        
        . The upstanding annular wall 
        
          
            56
          
        
         has an interior surface 
        
          
            98
          
        
         which defines a portion of a volute 
        
          
            100
          
        
         of the blower housing 
        
          
            54
          
        
         and an exterior surface 
        
          
            102
          
        
         that surrounds the interior surface 
        
          
            98
          
        
        . The discharge pipe 
        
          
            61
          
        
         extends outward and away from the annular wall 
        
          
            56
          
        
         and communicates with the volute 
        
          
            100
          
        
         to direct pressurized exhaust gases from the blower housing 
        
          
            54
          
        
        . The discharge pipe 
        
          
            61
          
        
         may have a boss end 
        
          
            105
          
        
         to allow connection to the exhaust pipe 
        
          
            62
          
        
        , as required. Preferably, the bottom disk portion 
        
          
            94
          
        
        , the upstanding wall 
        
          
            56
          
        
        , and the discharge pipe 
        
          
            61
          
        
         are formed monolithically.
      
    
    
      
        The bottom piece 
        
          
            58
          
        
         is provided with a plurality of mounting flanges 
        
          
            106
          
        
         circumferentially spaced around the outer perimeter border 
        
          
            96
          
        
         of the bottom disk portion 
        
          
            94
          
        
        . Each of the mounting flanges 
        
          
            106
          
        
         extends radially outward from the outer perimeter border 
        
          
            96
          
        
         and has a flange hole 
        
          
            108
          
        
         therethrough. Each of the mounting flanges 
        
          
            106
          
        
         preferably aligns with a corresponding lug 
        
          
            80
          
        
         on the top piece 
        
          
            58
          
        
        . The alignment of the lugs 
        
          
            80
          
        
         and flanges 
        
          
            106
          
        
         may be such that the top piece 
        
          
            58
          
        
         and bottom piece 
        
          
            60
          
        
         are assembled in only one orientation. Similar to the lug hole 
        
          
            82
          
        
        , the flange hole 
        
          
            108
          
        
         is also preferably arcuate to allow minor adjustment of the blower 
        
          
            50
          
        
         when the blower 
        
          
            50
          
        
         is mounted on the blower mounting surface 
        
          
            21
          
        
         of the furnace 
        
          
            22
          
        
        . To maximize the diameter of the upstanding annular wall 
        
          
            56
          
        
        , an inner edge 
        
          
            110
          
        
         of the flange hole 
        
          
            108
          
        
         may be formed flush with the exterior surface 
        
          
            102
          
        
         of the upstanding annular wall 
        
          
            56
          
        
        .
      
    
    
      
        Preferably, the flange hole 
        
          
            108
          
        
         is also formed to receive the depending leg 
        
          
            84
          
        
         of the top piece 
        
          
            58
          
        
         when the blower 
        
          
            50
          
        
         is assembled. As shown in 
        
          FIG. 9
        
        , the flange hole 
        
          
            108
          
        
         preferably has a step recess 
        
          
            112
          
        
         which is shaped to receive the depending leg 
        
          
            84
          
        
         from the lug 
        
          
            80
          
        
         of the top piece 
        
          
            58
          
        
         and a through hole 
        
          
            113
          
        
        . The through hole 
        
          
            113
          
        
         allows the mechanical fastener to be directed from the lug 
        
          
            80
          
        
         and lug hole 
        
          
            82
          
        
         on the top piece 
        
          
            58
          
        
         to the blower mounting surface 
        
          
            21
          
        
         on the furnace 
        
          
            22
          
        
         when the blower 
        
          
            50
          
        
         is secured to the blower mounting surface 
        
          
            21
          
        
         on the furnace 
        
          
            22
          
        
        . The step recess 
        
          
            112
          
        
         positively aligns the depending leg 
        
          
            84
          
        
         and captures a bottom portion of the circumferential guide portion 
        
          
            90
          
        
         of the depending leg 
        
          
            84
          
        
         so that the top piece 
        
          
            58
          
        
         and bottom piece 
        
          
            60
          
        
         remain positively engaged during operation of the blower 
        
          
            50
          
        
        . It is preferred that the bottom piece 
        
          
            60
          
        
         be held in position by the compressive forces exerted by the mechanical fastener 
        
          
            40
          
        
         on the top piece 
        
          
            58
          
        
        . The step recess 
        
          
            112
          
        
         bears some of this compressive force and stabilizes the position of the bottom piece 
        
          
            60
          
        
         adjacent the blower mounting surface 
        
          
            21
          
        
         of the furnace 
        
          
            22
          
        
        .
      
    
    
      
        Details of the attachment between the top and bottom pieces are best shown in FIG. 
        
          
            8
          
        
        . The upstanding annular wall 
        
          
            56
          
        
         of the bottom piece 
        
          
            60
          
        
         has an upper section 
        
          
            114
          
        
         that cooperates with the annular groove 
        
          
            92
          
        
         in the upper portion 
        
          
            74
          
        
         of the top piece 
        
          
            58
          
        
        . The upper section 
        
          
            114
          
        
         includes an annular end 
        
          
            116
          
        
         that extends between the interior and exterior surfaces 
        
          
            98
          
        
        ,
        
          
            102
          
        
         of the upstanding wall 
        
          
            56
          
        
        . The annular end 
        
          
            116
          
        
         has a lip 
        
          
            118
          
        
         extending axially outward from the bottom disk portion 
        
          
            94
          
        
         intermediate the coterminous edges of the annular end 
        
          
            116
          
        
         and the interior and exterior surfaces 
        
          
            98
          
        
        ,
        
          
            102
          
        
         of the upstanding annular wall 
        
          
            56
          
        
        . Preferably, the annular lip 
        
          
            118
          
        
         has a triangular shaped cross section to allow a locking-type fit between the top and bottom pieces 
        
          
            58
          
        
        ,
        
          
            60
          
        
        . The upper section 
        
          
            114
          
        
         also includes an annular notch 
        
          
            120
          
        
         extending around the interior surface 
        
          
            98
          
        
         of the upstanding wall 
        
          
            56
          
        
        .
      
    
    
      
        The annular groove 
        
          
            92
          
        
         formed in the upper portion 
        
          
            74
          
        
         of the top piece 
        
          
            58
          
        
         includes a primary groove 
        
          
            122
          
        
         and a secondary groove 
        
          
            124
          
        
        . The primary groove 
        
          
            122
          
        
         includes an annular inner side wall 
        
          
            126
          
        
         and an annular outer side wall 
        
          
            128
          
        
         spaced apart from the annular inner side wall 
        
          
            126
          
        
         by an annular groove wall 
        
          
            130
          
        
        . When the top piece 
        
          
            58
          
        
         is installed on the bottom piece 
        
          
            60
          
        
        , the annular inner side wall 
        
          
            126
          
        
         abuts the interior surface 
        
          
            98
          
        
         of the upstanding annular wall 
        
          
            56
          
        
        , and the annular outer side wall 
        
          
            128
          
        
         faces the exterior surface 
        
          
            102
          
        
         of the upstanding annular wall 
        
          
            56
          
        
        . The annular outer side wall 
        
          
            128
          
        
         may be formed with a lead-in taper 
        
          
            132
          
        
         to allow the top and bottom pieces 
        
          
            58
          
        
        ,
        
          
            60
          
        
         to more easily fit together.
      
    
    
      
        The primary groove 
        
          
            122
          
        
         also includes an annular rib 
        
          
            134
          
        
         axially spaced below the annular groove wall 
        
          
            130
          
        
        . The annular rib 
        
          
            134
          
        
         cooperates with the annular notch 
        
          
            120
          
        
         in the upstanding annular wall 
        
          
            56
          
        
         of the bottom piece 
        
          
            58
          
        
         to form a first sealing area 
        
          
            136
          
        
         for the blower housing 
        
          
            54
          
        
        . When the top piece 
        
          
            58
          
        
         is fully installed on the bottom piece 
        
          
            60
          
        
        , the top piece 
        
          
            58
          
        
         will snap fit onto the bottom piece 
        
          
            60
          
        
         as the annular rib 
        
          
            134
          
        
         slides across the interior surface 
        
          
            98
          
        
         of the upstanding annular wall 
        
          
            56
          
        
         and into the annular notch 
        
          
            120
          
        
        . The rib 
        
          
            134
          
        
         and notch 
        
          
            120
          
        
         provide a positive lock indication for a blower assembly operator when assembling the blower housing 
        
          
            54
          
        
         during manufacture.
      
    
    
      
        The secondary groove 
        
          
            124
          
        
         in the annular groove 
        
          
            92
          
        
         on the upper portion 
        
          
            74
          
        
         of the top piece 
        
          
            58
          
        
         is formed internal to primary groove 
        
          
            122
          
        
        . The secondary groove 
        
          
            124
          
        
         is formed intermediate the coterminous edges of the annular groove wall 
        
          
            130
          
        
         and inner and outer side walls 
        
          
            126
          
        
        ,
        
          
            128
          
        
        . The secondary groove 
        
          
            124
          
        
         has a triangular shaped cross section that matches the geometry of the annular lip 
        
          
            118
          
        
         on the upstanding wall 
        
          
            56
          
        
         of the bottom piece 
        
          
            60
          
        
        . The secondary groove 
        
          
            124
          
        
         provides a secondary sealing area 
        
          
            138
          
        
         for the blower housing.
      
    
    
      
        In assembling the blower housing 
        
          
            54
          
        
         into the arrangement shown in 
        
          FIG. 3
        
        , the top piece 
        
          
            58
          
        
         may be installed with the bottom piece 
        
          
            60
          
        
         to create the blower housing 
        
          
            54
          
        
         of the present invention. The upper section 
        
          
            114
          
        
         of the annular wall 
        
          
            56
          
        
         of the bottom piece 
        
          
            60
          
        
         may be inserted into the annular groove 
        
          
            92
          
        
         on the underside of the top piece 
        
          
            58
          
        
         and positively locked in place to seal the blower housing 
        
          
            54
          
        
        .
      
    
    
      
        The depending legs 
        
          
            84
          
        
         of the lug 
        
          
            80
          
        
         of the top piece 
        
          
            58
          
        
         may be inserted into the step recess 
        
          
            112
          
        
         formed in the flange hole 
        
          
            108
          
        
         such that the circumferential guide portion 
        
          
            90
          
        
         of the interior arcuate surface 
        
          
            88
          
        
         of the depending lug 
        
          
            84
          
        
         mounts flush against the exterior surface 
        
          
            102
          
        
         of the upstanding annular wall 
        
          
            56
          
        
         of the bottom piece 
        
          
            60
          
        
         and a bottom portion of the leg 
        
          
            84
          
        
         is nested within the recess 
        
          
            112
          
        
         of the flange hole 
        
          
            108
          
        
        . Preferably, the lengths of the depending legs 
        
          
            84
          
        
         are sized such that when the upper section 
        
          
            114
          
        
         of the annular wall 
        
          
            56
          
        
         is fully inserted into the annular groove 
        
          
            92
          
        
         in the top piece 
        
          
            58
          
        
        , the leg 
        
          
            84
          
        
         is captured by the flange hole 
        
          
            108
          
        
        . The lugs 
        
          
            80
          
        
         and matching flanges 
        
          
            106
          
        
         may have irregular angular placement along each of the respective top and bottom pieces 
        
          
            58
          
        
        ,
        
          
            60
          
        
         to provide a keying assembly for the blower housing 
        
          
            54
          
        
         such that the top and bottom pieces 
        
          
            58
          
        
        ,
        
          
            60
          
        
         may be assembled in only one orientation.
      
    
    
      
        Each of the top and bottom pieces 
        
          
            58
          
        
        ,
        
          
            60
          
        
         may be formed from materials that are capable of withstanding relatively high temperatures from the exhaust gases being expelled from the blower housing 
        
          
            54
          
        
        . To provide vibration dampening capability, the bottom piece may be made from viram or sanoprene. The top piece of the blower housing may be constructed from a polypropylene material that is sufficiently rigid and sturdy to prevent deformation under the weight of the blower motor during high temperature operation. Polypropylene is sufficiently rigid and does not require any stiffening panels as might be otherwise required should the entire blower housing itself be made from a rubber material. The polypropylene is also sufficiently rigid to prevent misalignment of the impeller during high temperature operation of the blower and furnace.
      
    
    
      
        Although the Figures shows the bottom piece formed with the upstanding wall and discharge pipe extending from the upstanding wall, the top piece may be formed with an upstanding wall and the discharge pipe extending from the upstanding similar to blower housing shown in FIG. 
        
          
            1
          
        
        A. Similarly, each of the top and bottom pieces may have a portion of the upstanding wall and a portion of the discharge pipe formed therein. The primary consideration for forming the bottom piece is to provide vibration dampening material between the motor and impeller and the blower mounting surface of the furnace. The bottom piece must also be constructed in such a way to resist deformation by the weight of the motor during high temperature operation so that the radial clearance between the impeller and the bottom piece is maintained.
      
    
    
      
        As is apparent to those skilled in the art, by locating the lugs 
        
          
            80
          
        
         on the upper portion 
        
          
            74
          
        
         of the blower housing 
        
          
            54
          
        
        , the diameter of the upstanding annular wall 
        
          
            56
          
        
         can be increased. By moving the driving end 
        
          
            42
          
        
         of the mechanical fastener 
        
          
            40
          
        
         above the lug 
        
          
            80
          
        
         on the top piece 
        
          
            58
          
        
        , the clearance between the screw head driving end 
        
          
            42
          
        
         and the upstanding annular wall 
        
          
            56
          
        
         of the blower housing 
        
          
            50
          
        
         can be eliminated. The mechanical fastener 
        
          
            40
          
        
         used to secure the blower housing to the blower mounting surface of the furnace may run directly down the exterior surface 
        
          
            102
          
        
         of the upstanding annular wall 
        
          
            56
          
        
         because there is sufficient clearance on the upper portion 
        
          
            74
          
        
         of the top piece 
        
          
            58
          
        
         for the screw head driving end 
        
          
            42
          
        
         of the mechanical fastener 
        
          
            40
          
        
        .
      
    
    
      
        Additionally, since the top piece 
        
          
            58
          
        
         snap fits with the bottom piece 
        
          
            60
          
        
         to create a sealed unit, the blower housing more effectively contains exhaust gases. By locating the lugs 
        
          
            80
          
        
         on the outer peripheral edge 
        
          
            78
          
        
         of the upper portion 
        
          
            74
          
        
         of the top piece 
        
          
            58
          
        
        , the upper portion 
        
          
            74
          
        
         of the top piece 
        
          
            58
          
        
         may flex inward such that the normally tapered outer side wall 
        
          
            128
          
        
         of the primary groove 
        
          
            122
          
        
         contacts the exterior surface 
        
          
            102
          
        
         of the upstanding wall 
        
          
            56
          
        
        . Thus, the combination of the primary seal 
        
          
            136
          
        
         and internal secondary seal 
        
          
            138
          
        
         provides improved sealing characteristics for the blower housing 
        
          
            54
          
        
         not found in the prior art.
      
    
    
      
        Although the description of the blower housing presented herein refers to a primary and secondary seals formed on respective portions of the top and bottom pieces, it should be noted that the location and combination of the components comprising the primary and secondary seals may reversed and positioned on the other of the top and bottom pieces of the blower housing.
      
    
    
      
        By constructing the bottom piece of the blower housing with a sound dampening material, excessive noise and vibration being transmitted by the blower motor and impeller is dampened and attenuated before reaching the blower mounting surface of the furnace. This prevents the noise from being transmitted into associated duct work throughout the house. The lower noise and vibrations increases the life of the blower.
      
    
    
      
        Various other changes to the preferred embodiment of the invention described above may be envisioned by those of ordinary skill in the art. However, those changes and modification should be considered as part of the invention which is limited only by the scope of the claims appended hereto and their legal equivalents.
      
    
  
             
            
                        Claims
        
                - 1. A gas moving system comprising:a gas chamber structure having an blower mounting surface; a blower motor; and a blower housing having a resilient bottom piece and a rigid top piece assembling with the bottom piece to define an interior of the blower housing, the interior of the blower housing having an impeller for moving gases, the bottom piece of the blower housing directly abutting the blower mounting surface of the gas chamber structure, the top piece supporting the blower motor.
 
                - 2. The gas moving system of claim 1, wherein:the bottom piece of the blower housing includes the volute and the discharge pipe.
 
                - 3. The gas moving system of claim 2, wherein:the volute and discharge pipe are monolithically formed with the bottom piece of the blower housing.
 
                - 4. The gas moving system of claim 1, wherein:the bottom piece is made from one of the group consisting of sanoprene, and viram, and the top piece is made from polypropylene.
 
                - 5. The gas moving system of claim 1, wherein:the bottom piece dampens vibration from the blower motor and impeller.
 
                - 6. The gas moving system of claim 5, wherein:the bottom piece limits the vibrations from being transmitted to the gas chamber structure.
 
                - 7. The gas moving system of claim 1, wherein:the top piece and bottom piece of the blower housing are keyed to allow assembly of the top and bottom pieces in a single configuration.
 
                - 8. The gas moving system of claim 1, wherein:one of the top piece and bottom piece has an annular groove and the other of the top piece and bottom piece has a matching sealing surface that cooperates with the groove, the annular groove receives the sealing surface when the top piece is assembled with the bottom piece to enclose the interior of the blower housing.
 
                - 9. The gas moving system of claim 1, wherein:one of the top piece and bottom piece has a lug located on its outer periphery and the other of the top piece and bottom piece has a matching flange located on its outer periphery, the flange and lug are adapted to detachably engage together when the top piece is installed on the bottom piece.
 
                - 10. The gas moving system of claim 1, wherein:the lug has a lug hole therethrough to receive a mechanical fastener, the mechanical fastener attaches the blower motor directly to the blower mounting surface of the gas chamber structure with the top and bottom pieces arranged between the blower mounting surface of the gas chamber and the blower motor.
 
                - 11. A blower housing comprising:a casing having a bottom piece with an upstanding wall and a discharge pipe and a top piece attaching to the bottom piece and covering over the upstanding wall to seal the casing, the bottom piece being made of a vibration absorbing material, the top piece being made of a rigid material.
 
                - 12. The blower housing of claim 11, wherein:the bottom piece is made from one of the group consisting of sanoprene and viram, and the top piece is made from polypropylene.
 
                - 13. The blower housing of claim 11, wherein:the top piece and bottom piece of the casing are keyed to allow assembly of the top and bottom pieces in a single configuration.
 
                - 14. The blower housing of claim 11, wherein:one of the top piece and bottom piece has a plurality of lugs located on its outer periphery and the other of the top piece and bottom piece has a plurality of matching flanges located on its outer periphery, each of the flanges has a hole therethrough that is adapted to receive its respective lug when the casing is assembled.
 
                - 15. The blower housing of claim 11 further comprising:an annular groove on the top piece being configured to receive a portion of the upstanding annular wall when the casing is assembled.
 
                - 16. A blower comprising:a casing having a resilient bottom piece and a rigid top piece assembling with the bottom piece to define an interior of the casing, the casing having a volute and a discharge pipe and the interior of the casing having a impeller to compress gas against the volute and direct the gas into the discharge pipe; and a motor being supported by the top piece and operably driving the impeller.
 
                - 17. The blower of claim 16 further comprising:an annular upstanding wall extending axially outward from the bottom piece of the casing, the annular upstanding wall having the discharge pipe extending outward therefrom.
 
                - 18. The blower of claim 16, wherein:the upstanding wall and the discharge pipe are monolithically formed with the bottom piece.
 
                - 19. The blower of claim 18, wherein:the bottom piece is made from one of the group consisting of rubber, sanoprene, and viram, and the top piece is made from polypropylene.
 
                - 20. The blower of claim 16, wherein:the bottom piece dampens vibration from the motor and impeller.
 
                - 21. The blower of claim 19, wherein:the top piece and bottom piece of the casing are keyed to allow assembly of the top and bottom pieces in a single configuration.
 
                - 22. The blower of claim 16, wherein:the casing has external lugs with lug holes therethrough on its outer periphery; and the top piece is connected directly to an external device by mechanical fasteners that pass through the lug holes whereby the bottom piece is positioned between the top piece and the external device.
 
        
                
                
                
                
                
                            US Referenced Citations (11)