CA2208463C - Combined heater and pump - Google Patents
Combined heater and pump Download PDFInfo
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- CA2208463C CA2208463C CA002208463A CA2208463A CA2208463C CA 2208463 C CA2208463 C CA 2208463C CA 002208463 A CA002208463 A CA 002208463A CA 2208463 A CA2208463 A CA 2208463A CA 2208463 C CA2208463 C CA 2208463C
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- heater
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Abstract
A compact combined heater and pump is disclosed. There is a pump housing forming an internal pump chamber, the housing having both an inlet and an outlet and an opening therethrough. A drive shaft is rotatably mounted in the opening and is driven by a motor located outside the chamber. An impeller is mounted on the drive shaft within the housing and a heater is sandwiched in the chamber between the motor and impeller. Rotation of the shaft can draw liquid in from the inlet, past the heater and through the outlet. A cooling fan attached to the shaft for rotation therewith draws cooling air over control circuitry and then forces the air over the motor.
Description
COINED FIEATER AND pLlMp PCIYU59~/16679 Field Of Iavexstion The present invention relates to pumps and more particularly to a compact pump and heater for a spa or the like.
Description Ot The Art It is often desirable to provide large whirlpool tubs within a relatively confined area. This is particularly true where a whirlpool system is to replace a conventional tub and must fit within an existing tub alcove. Complicating matters, a whirlpool. tub must share alcove space with "hidden" whirlpool system components such as a pump, pump motor, a heating unit, control circuitry, and additional plumbing to direct crater to ansl fzom the pump unit, heating unit, and tub.
It is also desirable to configure a whirlpool system so that all of the hidden components are located in a single area of the alcove. proximate placement of components permits all components to more easily be serviced from a single port anal limits the amount of plumbing required to route water.
U.S. patent No. 4,594,50D describes one relatively economical and serviceable pump/heating configuration wherein a pump element and a heating element are included in a single unit. Unfortunately, this design is not much smaller than the two housings it replaces.
Another problem is that during operation both the motor and control circuitry generate heat. If the heat is not dissipated properly,, ~.t can drive: the operating temperature of both the motor ar~.d control circuitry outside the ideal range and eventually damage or destroy the motor and/or circuitry.
By placing the motor and control circuitry within a single confined space the overheating problem is exacerbated as heat is i:rapped near the motor and circuitry.
Furthermore, placing the heating unit in the same confined area as the motor and control circuitry would be thought to exacerbate the overheating problem.
U.S. patens:, 5,006,743 dEacribes a well known fan unit which rotates with a motor shaft to cool the motor aauring operation. While a motor fan may sufficiently cool the motor, it roes little to dissipate control circuitry heat.
Therefore, it would be a:~dvani:ageous to have a whirlpool system including a pump unit, heatinca unit, motor and control circuitry that together require minimal space. In addition, it would be desirable to have such a system that includes both a motor and control circuitry coc:rlir7g mechanism.
Summary Of They Invention The present invention l:5rovides a pump for pumping and heating a liquid, the pump being drivable by a motor, the pump comprising: a pump housing having an internal pump chamber, a liquid inlet into the chamber, a chamber base wall, and a radial outlet, the lr~ase wall having an opening therethrough; a drive shaft rotatably mounted in the ofrening, the sh~rft being suitable to be attached to a motor located outside the chamber; an impeller mounted on the drive shaft to rotate therewith in the chamber, the impeller mor.mted such that the outlet is between the impeller and the base wall; and a heater sa:rndwiched in the chamber between the base wall and impeller; whereby upon operatic~r~ of the pump <~nd connection of the pump to a liquid supply, rotation of the shaft can draw liquid in from the inlet, past the heater and through the outlet.
The present invention further provides a pump for pumping and heating a liquid, the pump being drivable by a mator, the pump comprising: a pump housing having an internal pump chamber, a fluid inlet into the chamber, a chamber base wall, and a radial outlet, the base wall having an opening therethrough; a drive shaft rotatably mounted in the opening, the shaft being suitable to be attached to a motor located outside the chamber, the drive shaft being an armature of a motor; an impeller mounted on the drive shaft to rotate therewith in the chamber; a heater sandwiched in thE~ chamber between the base wall and impeller; whereby upon operation of the pump and connection of the pump to a liquid supply, rotation of the shaft can draw liquid in from thee inlE;t, past the heater and through the outlet; the 2a motor is enclosed in a motor housing having at least one air intake, and there is a circuit housing p~~sitioned adjacent the motor housing near the intake;
control circuitry for the motor and pump is positioned within the circuit housing; the circuit housing includinca a chimney chute at a first end that communicates with the intake and an intake hole at a second end opposite the first end; and the motor includes a fan within the motor housing that forces air through the intake hole, over the control circuitry, through the chimne~~r <:hute and intake, and over the motor.
The presE:nt invention also provides a motor unit comprising: a motor positioned within a motor housing, the motor being controlled by a control circuitry, the motor housing having at least one air intake; the control circuitry located in a separate chamber from the rnotor in a position adjacent and upstream the intake;
and a fan connected to the nootor, the fan forcing cooling air to traverse an air path over the control circuitry, thrc:nugh the intake, and then over the motor.
The present invention furthermore provides a pump comprising: an internal chamber definecl by a pump chamber wall; an insert that has been ultrasonically driven through the chamber ~,nrall so that an extension of the insert extends into the chamber; and an O-ring positioned at a seam between the insert and the chamber wall for providing a seal.
Description Ot The Art It is often desirable to provide large whirlpool tubs within a relatively confined area. This is particularly true where a whirlpool system is to replace a conventional tub and must fit within an existing tub alcove. Complicating matters, a whirlpool. tub must share alcove space with "hidden" whirlpool system components such as a pump, pump motor, a heating unit, control circuitry, and additional plumbing to direct crater to ansl fzom the pump unit, heating unit, and tub.
It is also desirable to configure a whirlpool system so that all of the hidden components are located in a single area of the alcove. proximate placement of components permits all components to more easily be serviced from a single port anal limits the amount of plumbing required to route water.
U.S. patent No. 4,594,50D describes one relatively economical and serviceable pump/heating configuration wherein a pump element and a heating element are included in a single unit. Unfortunately, this design is not much smaller than the two housings it replaces.
Another problem is that during operation both the motor and control circuitry generate heat. If the heat is not dissipated properly,, ~.t can drive: the operating temperature of both the motor ar~.d control circuitry outside the ideal range and eventually damage or destroy the motor and/or circuitry.
By placing the motor and control circuitry within a single confined space the overheating problem is exacerbated as heat is i:rapped near the motor and circuitry.
Furthermore, placing the heating unit in the same confined area as the motor and control circuitry would be thought to exacerbate the overheating problem.
U.S. patens:, 5,006,743 dEacribes a well known fan unit which rotates with a motor shaft to cool the motor aauring operation. While a motor fan may sufficiently cool the motor, it roes little to dissipate control circuitry heat.
Therefore, it would be a:~dvani:ageous to have a whirlpool system including a pump unit, heatinca unit, motor and control circuitry that together require minimal space. In addition, it would be desirable to have such a system that includes both a motor and control circuitry coc:rlir7g mechanism.
Summary Of They Invention The present invention l:5rovides a pump for pumping and heating a liquid, the pump being drivable by a motor, the pump comprising: a pump housing having an internal pump chamber, a liquid inlet into the chamber, a chamber base wall, and a radial outlet, the lr~ase wall having an opening therethrough; a drive shaft rotatably mounted in the ofrening, the sh~rft being suitable to be attached to a motor located outside the chamber; an impeller mounted on the drive shaft to rotate therewith in the chamber, the impeller mor.mted such that the outlet is between the impeller and the base wall; and a heater sa:rndwiched in the chamber between the base wall and impeller; whereby upon operatic~r~ of the pump <~nd connection of the pump to a liquid supply, rotation of the shaft can draw liquid in from the inlet, past the heater and through the outlet.
The present invention further provides a pump for pumping and heating a liquid, the pump being drivable by a mator, the pump comprising: a pump housing having an internal pump chamber, a fluid inlet into the chamber, a chamber base wall, and a radial outlet, the base wall having an opening therethrough; a drive shaft rotatably mounted in the opening, the shaft being suitable to be attached to a motor located outside the chamber, the drive shaft being an armature of a motor; an impeller mounted on the drive shaft to rotate therewith in the chamber; a heater sandwiched in thE~ chamber between the base wall and impeller; whereby upon operation of the pump and connection of the pump to a liquid supply, rotation of the shaft can draw liquid in from thee inlE;t, past the heater and through the outlet; the 2a motor is enclosed in a motor housing having at least one air intake, and there is a circuit housing p~~sitioned adjacent the motor housing near the intake;
control circuitry for the motor and pump is positioned within the circuit housing; the circuit housing includinca a chimney chute at a first end that communicates with the intake and an intake hole at a second end opposite the first end; and the motor includes a fan within the motor housing that forces air through the intake hole, over the control circuitry, through the chimne~~r <:hute and intake, and over the motor.
The presE:nt invention also provides a motor unit comprising: a motor positioned within a motor housing, the motor being controlled by a control circuitry, the motor housing having at least one air intake; the control circuitry located in a separate chamber from the rnotor in a position adjacent and upstream the intake;
and a fan connected to the nootor, the fan forcing cooling air to traverse an air path over the control circuitry, thrc:nugh the intake, and then over the motor.
The present invention furthermore provides a pump comprising: an internal chamber definecl by a pump chamber wall; an insert that has been ultrasonically driven through the chamber ~,nrall so that an extension of the insert extends into the chamber; and an O-ring positioned at a seam between the insert and the chamber wall for providing a seal.
In one embodiment the inlet opens into the chamber at a position opposite the side wall opening. In another embodiment, a ball bearing is included within the opening for receiving and supporting the drive shaft, a portion of the pump chamber may take the form of a volute fpz inczeasing water pressure prior to the outlet, and the heater is donut-shaped and surrounds the drive shaft.
Zn yet another embodiment, the pump includes an insert that is forced through the pump housing by ultzasonic vibrations, the insert having a sensing end extending into the pump chamber and a distal end located outside the pump chamber. An O-ring may be included at the junction between the insert and the pump housing for providing a seal. In addition, a sensor may be connected to the distal end of the insert and the ~.nsert may be thermally and electrically conductive. The sensor may be either a water temperature or water presence sensor.
Zn another embodiment, a gland is included outside the pump chamber on the pump chamber wall, the gland surrounding at least a portion of the insert and having an internal surface which opposes an external surface of the insert. The O-ring fits tightly between the internal and external surfaces.
Zn yet another embodiment the motor is enclosed in a motor housing having at least one aar intake and a circuit housing is positioned adjacent the motor housing CVO 96119672 ~ PCTIUS95/~6679 near the intake. ~'he control circuitry for the motor and pump are positioned within the circuitry housing. The circuitry housing includes a chimney chute at a first end that communicates with the intake and a.n intake hole at a second end opposite the first end. A fan is included within the motor housing that forc~a air through the intake hole, over the control circuitry, through the chimney chute and intake, and over the motor.
.., As will be apparent from the description belo~r,, the present invention allows a user to increase the volume of a whirlpool tub by minimizing the space required for certain hidden components of a whirlpool system. The user may provide a whirlpool tub having a comfortable size even in a relativel~r small alcove. In addition, even a small existing alcove need r~.ot be specially altered to receive a whirlpool system including components designed according to the present invention.
Furthermore, overheating problems involving the motor and control circuitry can be minimized even where all of the hidden components are located in a relatively small area.
The objects of the invention therefore include providing a heater/pump assembly of the above kind:
(a) which is inexpensive to produce;
(b) which. requires a minimal ampunt of space;
(c) wherein the system is designed to cool both motor and control circuitry;
(d) which provides a watertight ultrasonic insert for use with a ~.iquid pump; and (e) which is easy to service and maintain.
WO 96/19672 ' PCTIUS951i6679 The foregoing and other objects and advantages of the i,n~rention will appear from the following description.
In. the description, reference is made to the .
accompanying drawings which form a part hereof, arid in which there is shown by way of illustration preferred embodiments of the invention. Such embodiments do not represent the full scope of the invention. Reference is made therefore to the claims herein for interpreting the full. scope of the invention. .
Brief Description Of The Drawings Fig. 1 is an axial sectional view through a pump/heater unit embodying the present invention;
Fig. 2 is an exploded view of certain. of the components of the pump/heater unit of Fig. 1;
Fig. 3 is an end elevational view of the pump housing according to the invention;
Fig.-4 is a cross-sectional view taken along the line ~k-4 of Fig. 3;
Fig, 5 is a partial cross-sectional view of a motor including a separate circuit housing according to the present invention;
Fig. 6 is an enlarged view of the ultrasonic insert shown in Fig. 1; and Fig. 7 is an enlarged view of an ultrasonic insert.
Description Of The Preferred ~oda.metits Referring now to Fig. 1, a pumping arrangement embodying the present invention includes, as its main components, a motor 1Z and a pump/heater unit l~k which is mounted to the motor 22.
WO 96!19672 ~ ~C'f/US9~116679 The motor 12 is of any kr~.own construction and includes a motor housing l6 which is supported by means of a mounting arrangement 1B. In the following discussion, it will be assumed, unless otherwise indicated, that the motor housing 16 will be mounted on the mounting arrangement 18 in the illustrs.ted position, that is, vn a substantially horizontal surface of support. .The motor 12 includes a drive shaft 15 which extends from the mator housing 16 for rotatable motion about an axis of rotation 17.
Referring also to Fig. 2 the pump/heater unit 14 consists pra...marily of a pump housizig 20, a housing lid Z4, a heater 26, an impeller 28, and a seal spring 30.
Preferably, the pump housing 20, lid 24, heater 26, impeller 28, and spring 30 are arranged around the axis of rotation 1~.
Referring also to Figs. 3 and 4, the pump housing 20 includes a base wa~.l 32 having a substantially circu~.ar shape when viewed from an end elevational position and a cylindrical outer wall 33 which extends from the circumferential edge of the base wall 32 perpendicular to the axis of rotation 17 and in ~ direction away from the motor 12. ?he base wall 32 has an internal face 34 which faces the motor and an external face 35 facing in the opposite direction, A. hole 36, which is centered on the axis of rotation Z7, is provided in the base wall 32.
Preferably, a volute channel 38 is formed in the external facE~ 35.
Referring specifically to Fig. 3, in the preferred ,embodiment, the volute channel 38 begins at an angle F
WO 96/19672 PCTlUS95/16679 (approximately 45°) from vertical and wraps around the hole 36 (through approximately 225°) to a point at which it follows a tangent to a lateral edge of the internal face 34. The intez~nal rz and external r~ radii of the channel 3B are constant throughout the wrapping portion of the channel 38. The depth of the Channel 38 increases throughout its wrapping portion, being relatively narrow at an inlet end 4o and relativeJ.y deeper at an outlet end 42. - .
Referring also to Fig. 4, it can be seen that the Channel 3B is one depth at a cross section 44 near the inlet end 4o and a deeper depth at a different cross sectional area g6 near the outlet end 42. A heater aperture 51 is provided in the portion of the base wall 32 that does not form the volute 3B (i.e_ between the outlet 42 and the inlet 4o ends of the volute channel 38) .
Central and outer support cylinders 52, 53 extend from the base wall 32 tows.rd the motoz 12 and are centered on the centzal axis 17. The central cylinder 52 cir~umscxibes the hula 36, extending from the internal surface 34 of the base wall 32. Around a portion of the pump housing 2o where the volute channel 38 is relatively deep, the outer cylinder 53 extends from an external edge of the base wall 32. Where the volute channel 38 is relatively shallow, an additional support member 56 extends radially from the central cylinder 52 to support the outer cylinder 53. A recess 49 is provided on the external surface of the outer cylinder 53 along the cylinder's distal edge.
t WO 96119671 PCTlUS95116679 Referring still to Fig_ 4, both an annular nub 5s and an annular recess 6o are provided on the internal surface of the central cylinder 52. The nub 5e is loca.Zed approximately centrally within the cylinder, extends radially inwardly, and provides support for various sealing components as will be described in more detail below. Referring also to Fig. 1, the recess 6d is located on the edge of the i~nterzla~, surface of the cylinder 5Z f acing the motor 12 and provides support.. for a ball bearing 95 which is of a construction well-known in the art.
Referring again to Figs. 1, 2, and 3, the pump housing 2o also includes an outlet channel 22 which extends radially from the pump housing 20. As best seen in Fig. 3, the outlet channel 22 is aligned with the outlet end 42 of the volute channel 38 so that liquid flowing in the volute channel 38 naturally proceed out the outlet channel 22. The pump kZOUSing 2o also includes four bolt holes 62 which are used to fasten the housing adjaoent a motor.
Referring now to Figs. 1 and 2, the housing lid 24 has an axially extending iz~.let nipple 64 which can be attached to an inlet pipe 66 in any known manner. The lid 24 includes a lid wall 68 having an internal surface 7o which farms an annular receiving shelf 72 centered on the ax~.s of rots.tion 17. The lid 24, like the pump housing 20, also has a cyliz~.drieal outer wall 74 which extends parallel to the axis of rotation 17. Outer wall 78 extends in the direction of the motor 12. The radii of bath the lid and housing cylindrical walls 33, 74 is a WO 96/19G~2 PCTIU695/I6679 identical so that when fastex~ed together, a tight seal carp be fcormed therebetween .
Referring to Figs. 1 and 4, a seal receiving channel 50 is provided on the distal edge of the housing outer wall 33 for receiving an elastomeric O-ring 76. When the lid 24 is installed on the pump housing 20, the elastomeric O-zing 76 is pressed between the distal ends of the outer walls 33, ~4 and forms a watertight seal therebetween_ ._ The outer walls 33, 74 together form a pumping chamber 7B which houses the heater 26, impeller 2B, and seal spring.30. The impeller 28 is of a known construction having inboard 65 az~d outboard 83 surfaces and includes an axial inlet eo extending away from the motor 13, a plurality of impeller vanes 82 and a plurality of substantially radially opening outlets 84_ The inlet 80 should be sized so that it fits between, and does not contact, the receiving shelf 72, so that it can freely rotate therein. The impeller 2B also includes a cylindrical shank 86 extending from a side opposite the ~.mpeller inlet 80. The shank 86 has a hollow notched bore 87 for receiving the end of the shaft 15, The distal end of the shaft 15 is threaded and the internal.
surface of the bore 87 is oppositelx threaded so that the shaft can be securely screwed to the end~of the shank B6.
An annular rubber cup gasket 89 ~.s sized so as to snugly fit within the hole 36 on the nub 5B: A~ceramic mating ring 91 fits v~rithin the cup gasket 89. An annular carbon seal ring 94 communicates with the mating ring 92.
wo ssn94~z pCf/U$951~6679 Referring to Figs. 1 and 2, the heater 26 is substantially donut-shaped having an inboard face B8 and an outboard face 9D. As best seen in Fig_ 2, a single mounting extension 92 extends fz~om the inboard face 8B
parallel to the axis of rotation 17_ Two electrical contacts 93 extend from the distal end of the mounting extension 92 'and are also parallel to the axis of rotation 17.
... The heater 26 includes an electrical resistance_~ire inside a stainless steel tube. Electrical i~.sulation surrounds the wire_ Aluminum is cast around the stainless steel tube. The aluminum cast is grounded. As the resistance wire and tube heat up, heat transfers to the aluminum and into water therearound. Importantly, the aluminum acts as an electrical current collector for the entire tub: This eliminates the need for separate current collectors in the tub or pump apparatus. In addition, the aluminum eliminates corrosion of the heating element.
~teferring to Fig. 1, the seal spring 3o is a standard helical spring having a diameter that is greater than. the diameter of the shank s6 so that Lhe shank 86 fits loosely therethrough. The diameter of the spring should be limited so that~it fits within the central support cylinder 52 and is supported by the annular nub S8.
When the pump housing 2o is insta~.led on the end of the motor housing 16, the recess 49 on the distal edge of the outer support cylinder 53 receives an adjacent edge of the motor housing 1G. The drive shaft 15 extends WO 96!19672 PCT/US95/16679 through the central cylinder 52, cup gasket 89, mating ring 91, seal ring 94, and the seal spring 30 and is supported by the ball bearing 95. The impeller shank 86 also extends partly through the central cylinder 52 so that the distal end of the shaft 15 is securely recei~xed therein. 'the seal spring 30 is located around the impeller shank 86, with.one end anchored on and restricted by the seal ring 94. 'fhe second end of the seal spring 30 contacts the inboard surface 85 of the, impeller. Thus the spring 30 biases the cup gasket 89, mating ring 91, and sealing ring 94 toward the nub 58 in a direction away from the motor 12. , The heater 26 is positioned between the impeller 28 and the base vaall 32 with its inboard surface 88 facing the base wall 32 and its outboard surface 90 facing the impeller 2B.
During rotation of the impeller 28 with the distal end of the drive shaft 15, fluid in the inlet pipe 66 is pumped through the inlet nipple 64, through the inlet e0, and impelled by the vanes 82 to move radially outwardly and eventually exits the impeller 28 through the respective outlets 84 to enter the high pressure space or pumping chamber 78 provided around the impeller 28 where the heater 26 is located. As liquid passes by the heatez 26, it is heated to a desired temperature.
As known in the axt, the trolute channel 38 increases the water pressure as the amount of accelerated mater is ancreased_ Referring again to Fig. 3, ~rhile only a small volume of liquid has a high velocity in the shallow portion of the volute channeuid exiting the outlet end 42 WO 96/19672 PCT/U5951~ 6679 forms a high velocity jet. The high velocity jet exits the outlet channel 22 and is directed by an outlet pipe to a desired destination, By providing the ball bearing 95 within the central support cylinder 52, an end suppozting portion of the motor housing which normally includes a supporting ball bearing can be eliminated. Once the end ppz~tion of the motor housing 26 is eliminated, the entire area required by,.the pump and motor housings 16 is reduced. ,_ 8y placing the supporting ball bearing 95 closer to the motor 1Z than would normally be the case, both the heater 26 and volute channel 38 can be positioned around the shaft 15 and sandwiched between the impeller ZB and the motor l2,as opposed to being positioned somewhex'e else. In this manner, area around the shaft 15 which would normally include the end portion of the motor housing can accommodate necessary components of the .
heater/pump unit lo.
By sandwiching the heater 26 between the impeller 2s and the motor 16, a plural~.ty of collateral advantages also result. For example, it is advantageous to have any and all elements of the heater/pump unit 1o that require electricity positioned adjacent the base wall 32 of the pump housing 20. When so positioxy.ed, electricity which is required to operate the motor and control circuitry and which is therefore readily available within the motor housing 16, can also be provided through the be,se wall 32 and need nvt be provided from an external side of one of the cylindrical outer walls 33, 74. Referring again to Figs. Z and 3, the heater aperture 51 is provided in the base wall. 32 in an area that is not within the volute channel 38. The mounting extension 92 extends through the heater aperture 51 and into the matox housing 16 where the contacts 93 can be electrically connected. A
flat gasket (not shown) can be located around the mounting extension 92 to form a water-tight seal between the extension'92 and the base wall 32.
In addition, as the liquid characteristics within the deepest portion o~ the volute channel 38 are the , characteristics o~ the liquid exiting the heater/pump unit lo, these are the characteristics which are most likely of interest. Deferring to Fig. 1, because the deepest portion of the volute channel 38 (i.e. the exit portion) is formed by Lhe base wall 32, sensors that might require electricity can be located on the motor side of the base wall 32 with an appropriate insert extending thez~ethrough at a point 41 within the volute channel.
zt should be noted, however, that for safety purposed, it is desirable to ground all sensors that extend through the base wall 32 and into the pumping chamber ~8. Grounding eliminates the possibility of electrocuting a whirlpool occupant if stray current shorts into the insert.
Referring now to Fig. 5, the present invention also includes a circuitry cooling configuration 100. While the motor shown in Fig. 1 limits the overall size of the heater, pump, and motor, if the area provided for mounting the heater/pump unit to is severely restricted, both the.motor 1Z and control circuitry (not shown in WO 9d/1967z ' PC~,'/US95/16679 1~4 Fig. 1) will tend to heat up at an accelerated rate and ~~an damage or destroy both motor components. or control circuitry.
The circuitry coo7.ing configuration 10o as shown in Fig. 5 minimizes the area required for the heater/pump unit_ Both a motor 12 and a fan unit 102 are located within the motor housing 7.6. The motor housing 16 includes a plurality of air inlets 1D4 positioned near a pump end 105 of the housing az~d a plurality of air ...
outlets 106 at an exhaust end 107 of the motor houei.ng.
The fam. 102 may be constructed in various ways as well-known in the art but should at least include a plurality of vanes,which can force air into the motor housing 16 through the inlets 104, past the motor 12, and back out of the housing 16 through outlets 106. The fan 102 is mounted on the drive shaft 15 for joint rotation about the axis of rotation 17 therewith.
In the present invention, the control circuitry 110 is mounted in a separate circuitry housing 112 located within the mounting arrangement 18.
While the circuitry housing 112 and motor housing 16 are separate, a chimney chute 116 extends from a circuitry housing outlet 11B up to at least one motor housing inlet 10~. At the opposite end of the circuitry housing 112, a circuitry housing inlet 114 is provided in a floor member 120, Support legs 122 are provided on the bottom of the floor member 120 which allow air to pass unobstructed underneath the floor member 120, Importantly, the contxol circuitry 110 is located between the inlet 114 and the outlet x.18. Preferably, S
WO 96119672 PC'XYUS95116679 the circuitry 110 is also attached to either the floor member 120 or a heat sink member 124.
While the motor 12 is operating, the fan 102 rotates along with the drive shaft 15_ As the fan 102 z~otates, the fan draws air through the circuitry housing inlet 17.4, across the circuitry 110, through the chimney chute 116, and into the inle'~ 104 which is attached to the chimney chute. importantly, the fan 102 also draws additional air through inlet holes 104 which are not _ connected to the chimney chute 116 thus mixing the air from the chimney chute 116 with additional cooling air prior to forcing that air over the motor 12. The cooling air absorbs much of the heat produced by the motor 12 and ciz~cuitry 110 and finally is forced out the outlets l06_ Hy cooling both zhe motor and control circuitry using a single fan, a heater can be included with both a pump and control circuitry in a relatively small space without risking damage from overheating, Minimizing the space required for these components allows a des~.gner to maximize the size of the whirlpool tub.
One way to i~.stall an insert in the base Wall 32 would be to use an ultrasonic insert. As known in the art, an ultrasonic insert is forced through a wail by a jig tool which applies pressure axiaJ.ly along the length.
of the insert while the ix~.sert is aligned with a small hole_ At the same time, the insert is ultrasonically vibrated, This process continues until the insert melts forced through the hole and emerges on the other side_ The vibrating melts the plastic axound the hole making it easy to enforce the insert therethrough. After the WO 96/19672 ~ pCT/U595l16679 vibrating is stopped, the plastic solidifies and, secures the position of the insert. While manufacture and installation of such inserts is relatively inexpen$ive, the industry has yet to devise a waterproof insert which could be used with the base wall 32 in a liquid pump unit.
Referri,z~.g to Fig. 6, to provide a watertight ultrasonic insert for use with the present invent~.on, a cy~,indrical gland 126 is formed an the interns,l face..34 of the base wall 32. The gland 126 is formed around an insert axis 128. An ultrasonic insert 130 is also provided.
Referring also to Fig. 7, the insert 1.30 includes a head portion 132 and an extension 134. Preferably, the extension portion includes two annular nubs 136 near its distal end and two spzz'al knurls 138 located between the nubs 7.36 and the head portion 132. The head portion 132 includes a first shelf 140 adjacent the knurls 138, a second shelf 142 adjacent the first shelf 140 but separated therefrom, and a face plate 144 adjacent the second shelf 1.42 and opposite the distal end of the extension 134. A connection aperture 146 is provided in the face plate I44 and extends through the head portion 132 and partially into the extension 234. Preferably, the cox~nect~.on aperture Z46 is centrally located Within the head portion 132.
Referring also to Fig. 6, importantly, prior to insr.alling the insert 130, an elastomeric o-ring 149 is positioned around the fiz~st shelf 140. The gland 126 should be sized so that the diameter between facing WO 96/x.9672 ~ PCT/US95/166~9 internal surface portions is slightly greater than the diameter of the head portion 132 through the external surface 150 so that when an O-ring 249 is placed therebetween, it is slightly compacted. To install the insert, the insert 130 is aligned with a small hole along an insert axis 128, the jig tool (not shoran) applies force to the insert 130 along the insert axis 128 in the direction of the pump chamber ?8, and the insert is ultrasonically vibrated until ~.t melts through the base wall 32 so that an end is received within the pump chamber ?8. As the insert. 130 is vibrated, the 0-ring 149 is forced up and around the external suz~face 150 and provides a watertight seal between the ir;tez~nal surface of'the gland 126 and the external surface 150. The second shelf 142 is received within the gland 26 and the face plate 144 remains outside the gland 126.
zt will be appreciated that in addition to the specified embodiment shown, the invention caz~ appear in other embodiments. For example, referring to Fig. 1, it may be possible to limit the size of the heater in other embodiments. For example, referring to Fig. ~., it rnay be possible to limit the size of the heater/pump unit to even more if either the volute channel 38 and/or the heater 26 are positioned around the ba~.l bearing 95.
Any type of heater that can fit in a small area and that ~.s electrically safe could be used With the present invention. The insert shown in Fig. 7 is only shown as an exemplary insert and any type of ultrasonic insert could be used with the present invention and with the gland 126 and O-ring 1.49 shown in Fig. 6. Furthermore, WO 96119672 ~ PCYYUS95/16679 while Fig. 5 shows one circuitry/motor housing configuration, any configuration wherein circuitry is placed in a separate housing and a fan draws cooling air aver the circuitry and then forces air over the motor is contemplated by the present invention.
In addition, the control circuitry may include various temperature and water presence sensors that operate to protect the motor and heater components_ For example, a separate dual function thermostat may be ._ thermally connected to the heater to provide various functions. First, if the pump is turned on and there is minimal or little water in the pump and the tub, the heater temperature rises rapidly and could result in a dzy fire. The thermostat can be used to directly shut off the heater to prevents dry fires, Second, the same thermostat can be used to provide an upper temperature limit which prevents water temperatures from exceeding 120°F which is the upper temperature alZowed_
Zn yet another embodiment, the pump includes an insert that is forced through the pump housing by ultzasonic vibrations, the insert having a sensing end extending into the pump chamber and a distal end located outside the pump chamber. An O-ring may be included at the junction between the insert and the pump housing for providing a seal. In addition, a sensor may be connected to the distal end of the insert and the ~.nsert may be thermally and electrically conductive. The sensor may be either a water temperature or water presence sensor.
Zn another embodiment, a gland is included outside the pump chamber on the pump chamber wall, the gland surrounding at least a portion of the insert and having an internal surface which opposes an external surface of the insert. The O-ring fits tightly between the internal and external surfaces.
Zn yet another embodiment the motor is enclosed in a motor housing having at least one aar intake and a circuit housing is positioned adjacent the motor housing CVO 96119672 ~ PCTIUS95/~6679 near the intake. ~'he control circuitry for the motor and pump are positioned within the circuitry housing. The circuitry housing includes a chimney chute at a first end that communicates with the intake and a.n intake hole at a second end opposite the first end. A fan is included within the motor housing that forc~a air through the intake hole, over the control circuitry, through the chimney chute and intake, and over the motor.
.., As will be apparent from the description belo~r,, the present invention allows a user to increase the volume of a whirlpool tub by minimizing the space required for certain hidden components of a whirlpool system. The user may provide a whirlpool tub having a comfortable size even in a relativel~r small alcove. In addition, even a small existing alcove need r~.ot be specially altered to receive a whirlpool system including components designed according to the present invention.
Furthermore, overheating problems involving the motor and control circuitry can be minimized even where all of the hidden components are located in a relatively small area.
The objects of the invention therefore include providing a heater/pump assembly of the above kind:
(a) which is inexpensive to produce;
(b) which. requires a minimal ampunt of space;
(c) wherein the system is designed to cool both motor and control circuitry;
(d) which provides a watertight ultrasonic insert for use with a ~.iquid pump; and (e) which is easy to service and maintain.
WO 96/19672 ' PCTIUS951i6679 The foregoing and other objects and advantages of the i,n~rention will appear from the following description.
In. the description, reference is made to the .
accompanying drawings which form a part hereof, arid in which there is shown by way of illustration preferred embodiments of the invention. Such embodiments do not represent the full scope of the invention. Reference is made therefore to the claims herein for interpreting the full. scope of the invention. .
Brief Description Of The Drawings Fig. 1 is an axial sectional view through a pump/heater unit embodying the present invention;
Fig. 2 is an exploded view of certain. of the components of the pump/heater unit of Fig. 1;
Fig. 3 is an end elevational view of the pump housing according to the invention;
Fig.-4 is a cross-sectional view taken along the line ~k-4 of Fig. 3;
Fig, 5 is a partial cross-sectional view of a motor including a separate circuit housing according to the present invention;
Fig. 6 is an enlarged view of the ultrasonic insert shown in Fig. 1; and Fig. 7 is an enlarged view of an ultrasonic insert.
Description Of The Preferred ~oda.metits Referring now to Fig. 1, a pumping arrangement embodying the present invention includes, as its main components, a motor 1Z and a pump/heater unit l~k which is mounted to the motor 22.
WO 96!19672 ~ ~C'f/US9~116679 The motor 12 is of any kr~.own construction and includes a motor housing l6 which is supported by means of a mounting arrangement 1B. In the following discussion, it will be assumed, unless otherwise indicated, that the motor housing 16 will be mounted on the mounting arrangement 18 in the illustrs.ted position, that is, vn a substantially horizontal surface of support. .The motor 12 includes a drive shaft 15 which extends from the mator housing 16 for rotatable motion about an axis of rotation 17.
Referring also to Fig. 2 the pump/heater unit 14 consists pra...marily of a pump housizig 20, a housing lid Z4, a heater 26, an impeller 28, and a seal spring 30.
Preferably, the pump housing 20, lid 24, heater 26, impeller 28, and spring 30 are arranged around the axis of rotation 1~.
Referring also to Figs. 3 and 4, the pump housing 20 includes a base wa~.l 32 having a substantially circu~.ar shape when viewed from an end elevational position and a cylindrical outer wall 33 which extends from the circumferential edge of the base wall 32 perpendicular to the axis of rotation 17 and in ~ direction away from the motor 12. ?he base wall 32 has an internal face 34 which faces the motor and an external face 35 facing in the opposite direction, A. hole 36, which is centered on the axis of rotation Z7, is provided in the base wall 32.
Preferably, a volute channel 38 is formed in the external facE~ 35.
Referring specifically to Fig. 3, in the preferred ,embodiment, the volute channel 38 begins at an angle F
WO 96/19672 PCTlUS95/16679 (approximately 45°) from vertical and wraps around the hole 36 (through approximately 225°) to a point at which it follows a tangent to a lateral edge of the internal face 34. The intez~nal rz and external r~ radii of the channel 3B are constant throughout the wrapping portion of the channel 38. The depth of the Channel 38 increases throughout its wrapping portion, being relatively narrow at an inlet end 4o and relativeJ.y deeper at an outlet end 42. - .
Referring also to Fig. 4, it can be seen that the Channel 3B is one depth at a cross section 44 near the inlet end 4o and a deeper depth at a different cross sectional area g6 near the outlet end 42. A heater aperture 51 is provided in the portion of the base wall 32 that does not form the volute 3B (i.e_ between the outlet 42 and the inlet 4o ends of the volute channel 38) .
Central and outer support cylinders 52, 53 extend from the base wall 32 tows.rd the motoz 12 and are centered on the centzal axis 17. The central cylinder 52 cir~umscxibes the hula 36, extending from the internal surface 34 of the base wall 32. Around a portion of the pump housing 2o where the volute channel 38 is relatively deep, the outer cylinder 53 extends from an external edge of the base wall 32. Where the volute channel 38 is relatively shallow, an additional support member 56 extends radially from the central cylinder 52 to support the outer cylinder 53. A recess 49 is provided on the external surface of the outer cylinder 53 along the cylinder's distal edge.
t WO 96119671 PCTlUS95116679 Referring still to Fig_ 4, both an annular nub 5s and an annular recess 6o are provided on the internal surface of the central cylinder 52. The nub 5e is loca.Zed approximately centrally within the cylinder, extends radially inwardly, and provides support for various sealing components as will be described in more detail below. Referring also to Fig. 1, the recess 6d is located on the edge of the i~nterzla~, surface of the cylinder 5Z f acing the motor 12 and provides support.. for a ball bearing 95 which is of a construction well-known in the art.
Referring again to Figs. 1, 2, and 3, the pump housing 2o also includes an outlet channel 22 which extends radially from the pump housing 20. As best seen in Fig. 3, the outlet channel 22 is aligned with the outlet end 42 of the volute channel 38 so that liquid flowing in the volute channel 38 naturally proceed out the outlet channel 22. The pump kZOUSing 2o also includes four bolt holes 62 which are used to fasten the housing adjaoent a motor.
Referring now to Figs. 1 and 2, the housing lid 24 has an axially extending iz~.let nipple 64 which can be attached to an inlet pipe 66 in any known manner. The lid 24 includes a lid wall 68 having an internal surface 7o which farms an annular receiving shelf 72 centered on the ax~.s of rots.tion 17. The lid 24, like the pump housing 20, also has a cyliz~.drieal outer wall 74 which extends parallel to the axis of rotation 17. Outer wall 78 extends in the direction of the motor 12. The radii of bath the lid and housing cylindrical walls 33, 74 is a WO 96/19G~2 PCTIU695/I6679 identical so that when fastex~ed together, a tight seal carp be fcormed therebetween .
Referring to Figs. 1 and 4, a seal receiving channel 50 is provided on the distal edge of the housing outer wall 33 for receiving an elastomeric O-ring 76. When the lid 24 is installed on the pump housing 20, the elastomeric O-zing 76 is pressed between the distal ends of the outer walls 33, ~4 and forms a watertight seal therebetween_ ._ The outer walls 33, 74 together form a pumping chamber 7B which houses the heater 26, impeller 2B, and seal spring.30. The impeller 28 is of a known construction having inboard 65 az~d outboard 83 surfaces and includes an axial inlet eo extending away from the motor 13, a plurality of impeller vanes 82 and a plurality of substantially radially opening outlets 84_ The inlet 80 should be sized so that it fits between, and does not contact, the receiving shelf 72, so that it can freely rotate therein. The impeller 2B also includes a cylindrical shank 86 extending from a side opposite the ~.mpeller inlet 80. The shank 86 has a hollow notched bore 87 for receiving the end of the shaft 15, The distal end of the shaft 15 is threaded and the internal.
surface of the bore 87 is oppositelx threaded so that the shaft can be securely screwed to the end~of the shank B6.
An annular rubber cup gasket 89 ~.s sized so as to snugly fit within the hole 36 on the nub 5B: A~ceramic mating ring 91 fits v~rithin the cup gasket 89. An annular carbon seal ring 94 communicates with the mating ring 92.
wo ssn94~z pCf/U$951~6679 Referring to Figs. 1 and 2, the heater 26 is substantially donut-shaped having an inboard face B8 and an outboard face 9D. As best seen in Fig_ 2, a single mounting extension 92 extends fz~om the inboard face 8B
parallel to the axis of rotation 17_ Two electrical contacts 93 extend from the distal end of the mounting extension 92 'and are also parallel to the axis of rotation 17.
... The heater 26 includes an electrical resistance_~ire inside a stainless steel tube. Electrical i~.sulation surrounds the wire_ Aluminum is cast around the stainless steel tube. The aluminum cast is grounded. As the resistance wire and tube heat up, heat transfers to the aluminum and into water therearound. Importantly, the aluminum acts as an electrical current collector for the entire tub: This eliminates the need for separate current collectors in the tub or pump apparatus. In addition, the aluminum eliminates corrosion of the heating element.
~teferring to Fig. 1, the seal spring 3o is a standard helical spring having a diameter that is greater than. the diameter of the shank s6 so that Lhe shank 86 fits loosely therethrough. The diameter of the spring should be limited so that~it fits within the central support cylinder 52 and is supported by the annular nub S8.
When the pump housing 2o is insta~.led on the end of the motor housing 16, the recess 49 on the distal edge of the outer support cylinder 53 receives an adjacent edge of the motor housing 1G. The drive shaft 15 extends WO 96!19672 PCT/US95/16679 through the central cylinder 52, cup gasket 89, mating ring 91, seal ring 94, and the seal spring 30 and is supported by the ball bearing 95. The impeller shank 86 also extends partly through the central cylinder 52 so that the distal end of the shaft 15 is securely recei~xed therein. 'the seal spring 30 is located around the impeller shank 86, with.one end anchored on and restricted by the seal ring 94. 'fhe second end of the seal spring 30 contacts the inboard surface 85 of the, impeller. Thus the spring 30 biases the cup gasket 89, mating ring 91, and sealing ring 94 toward the nub 58 in a direction away from the motor 12. , The heater 26 is positioned between the impeller 28 and the base vaall 32 with its inboard surface 88 facing the base wall 32 and its outboard surface 90 facing the impeller 2B.
During rotation of the impeller 28 with the distal end of the drive shaft 15, fluid in the inlet pipe 66 is pumped through the inlet nipple 64, through the inlet e0, and impelled by the vanes 82 to move radially outwardly and eventually exits the impeller 28 through the respective outlets 84 to enter the high pressure space or pumping chamber 78 provided around the impeller 28 where the heater 26 is located. As liquid passes by the heatez 26, it is heated to a desired temperature.
As known in the axt, the trolute channel 38 increases the water pressure as the amount of accelerated mater is ancreased_ Referring again to Fig. 3, ~rhile only a small volume of liquid has a high velocity in the shallow portion of the volute channeuid exiting the outlet end 42 WO 96/19672 PCT/U5951~ 6679 forms a high velocity jet. The high velocity jet exits the outlet channel 22 and is directed by an outlet pipe to a desired destination, By providing the ball bearing 95 within the central support cylinder 52, an end suppozting portion of the motor housing which normally includes a supporting ball bearing can be eliminated. Once the end ppz~tion of the motor housing 26 is eliminated, the entire area required by,.the pump and motor housings 16 is reduced. ,_ 8y placing the supporting ball bearing 95 closer to the motor 1Z than would normally be the case, both the heater 26 and volute channel 38 can be positioned around the shaft 15 and sandwiched between the impeller ZB and the motor l2,as opposed to being positioned somewhex'e else. In this manner, area around the shaft 15 which would normally include the end portion of the motor housing can accommodate necessary components of the .
heater/pump unit lo.
By sandwiching the heater 26 between the impeller 2s and the motor 16, a plural~.ty of collateral advantages also result. For example, it is advantageous to have any and all elements of the heater/pump unit 1o that require electricity positioned adjacent the base wall 32 of the pump housing 20. When so positioxy.ed, electricity which is required to operate the motor and control circuitry and which is therefore readily available within the motor housing 16, can also be provided through the be,se wall 32 and need nvt be provided from an external side of one of the cylindrical outer walls 33, 74. Referring again to Figs. Z and 3, the heater aperture 51 is provided in the base wall. 32 in an area that is not within the volute channel 38. The mounting extension 92 extends through the heater aperture 51 and into the matox housing 16 where the contacts 93 can be electrically connected. A
flat gasket (not shown) can be located around the mounting extension 92 to form a water-tight seal between the extension'92 and the base wall 32.
In addition, as the liquid characteristics within the deepest portion o~ the volute channel 38 are the , characteristics o~ the liquid exiting the heater/pump unit lo, these are the characteristics which are most likely of interest. Deferring to Fig. 1, because the deepest portion of the volute channel 38 (i.e. the exit portion) is formed by Lhe base wall 32, sensors that might require electricity can be located on the motor side of the base wall 32 with an appropriate insert extending thez~ethrough at a point 41 within the volute channel.
zt should be noted, however, that for safety purposed, it is desirable to ground all sensors that extend through the base wall 32 and into the pumping chamber ~8. Grounding eliminates the possibility of electrocuting a whirlpool occupant if stray current shorts into the insert.
Referring now to Fig. 5, the present invention also includes a circuitry cooling configuration 100. While the motor shown in Fig. 1 limits the overall size of the heater, pump, and motor, if the area provided for mounting the heater/pump unit to is severely restricted, both the.motor 1Z and control circuitry (not shown in WO 9d/1967z ' PC~,'/US95/16679 1~4 Fig. 1) will tend to heat up at an accelerated rate and ~~an damage or destroy both motor components. or control circuitry.
The circuitry coo7.ing configuration 10o as shown in Fig. 5 minimizes the area required for the heater/pump unit_ Both a motor 12 and a fan unit 102 are located within the motor housing 7.6. The motor housing 16 includes a plurality of air inlets 1D4 positioned near a pump end 105 of the housing az~d a plurality of air ...
outlets 106 at an exhaust end 107 of the motor houei.ng.
The fam. 102 may be constructed in various ways as well-known in the art but should at least include a plurality of vanes,which can force air into the motor housing 16 through the inlets 104, past the motor 12, and back out of the housing 16 through outlets 106. The fan 102 is mounted on the drive shaft 15 for joint rotation about the axis of rotation 17 therewith.
In the present invention, the control circuitry 110 is mounted in a separate circuitry housing 112 located within the mounting arrangement 18.
While the circuitry housing 112 and motor housing 16 are separate, a chimney chute 116 extends from a circuitry housing outlet 11B up to at least one motor housing inlet 10~. At the opposite end of the circuitry housing 112, a circuitry housing inlet 114 is provided in a floor member 120, Support legs 122 are provided on the bottom of the floor member 120 which allow air to pass unobstructed underneath the floor member 120, Importantly, the contxol circuitry 110 is located between the inlet 114 and the outlet x.18. Preferably, S
WO 96119672 PC'XYUS95116679 the circuitry 110 is also attached to either the floor member 120 or a heat sink member 124.
While the motor 12 is operating, the fan 102 rotates along with the drive shaft 15_ As the fan 102 z~otates, the fan draws air through the circuitry housing inlet 17.4, across the circuitry 110, through the chimney chute 116, and into the inle'~ 104 which is attached to the chimney chute. importantly, the fan 102 also draws additional air through inlet holes 104 which are not _ connected to the chimney chute 116 thus mixing the air from the chimney chute 116 with additional cooling air prior to forcing that air over the motor 12. The cooling air absorbs much of the heat produced by the motor 12 and ciz~cuitry 110 and finally is forced out the outlets l06_ Hy cooling both zhe motor and control circuitry using a single fan, a heater can be included with both a pump and control circuitry in a relatively small space without risking damage from overheating, Minimizing the space required for these components allows a des~.gner to maximize the size of the whirlpool tub.
One way to i~.stall an insert in the base Wall 32 would be to use an ultrasonic insert. As known in the art, an ultrasonic insert is forced through a wail by a jig tool which applies pressure axiaJ.ly along the length.
of the insert while the ix~.sert is aligned with a small hole_ At the same time, the insert is ultrasonically vibrated, This process continues until the insert melts forced through the hole and emerges on the other side_ The vibrating melts the plastic axound the hole making it easy to enforce the insert therethrough. After the WO 96/19672 ~ pCT/U595l16679 vibrating is stopped, the plastic solidifies and, secures the position of the insert. While manufacture and installation of such inserts is relatively inexpen$ive, the industry has yet to devise a waterproof insert which could be used with the base wall 32 in a liquid pump unit.
Referri,z~.g to Fig. 6, to provide a watertight ultrasonic insert for use with the present invent~.on, a cy~,indrical gland 126 is formed an the interns,l face..34 of the base wall 32. The gland 126 is formed around an insert axis 128. An ultrasonic insert 130 is also provided.
Referring also to Fig. 7, the insert 1.30 includes a head portion 132 and an extension 134. Preferably, the extension portion includes two annular nubs 136 near its distal end and two spzz'al knurls 138 located between the nubs 7.36 and the head portion 132. The head portion 132 includes a first shelf 140 adjacent the knurls 138, a second shelf 142 adjacent the first shelf 140 but separated therefrom, and a face plate 144 adjacent the second shelf 1.42 and opposite the distal end of the extension 134. A connection aperture 146 is provided in the face plate I44 and extends through the head portion 132 and partially into the extension 234. Preferably, the cox~nect~.on aperture Z46 is centrally located Within the head portion 132.
Referring also to Fig. 6, importantly, prior to insr.alling the insert 130, an elastomeric o-ring 149 is positioned around the fiz~st shelf 140. The gland 126 should be sized so that the diameter between facing WO 96/x.9672 ~ PCT/US95/166~9 internal surface portions is slightly greater than the diameter of the head portion 132 through the external surface 150 so that when an O-ring 249 is placed therebetween, it is slightly compacted. To install the insert, the insert 130 is aligned with a small hole along an insert axis 128, the jig tool (not shoran) applies force to the insert 130 along the insert axis 128 in the direction of the pump chamber ?8, and the insert is ultrasonically vibrated until ~.t melts through the base wall 32 so that an end is received within the pump chamber ?8. As the insert. 130 is vibrated, the 0-ring 149 is forced up and around the external suz~face 150 and provides a watertight seal between the ir;tez~nal surface of'the gland 126 and the external surface 150. The second shelf 142 is received within the gland 26 and the face plate 144 remains outside the gland 126.
zt will be appreciated that in addition to the specified embodiment shown, the invention caz~ appear in other embodiments. For example, referring to Fig. 1, it may be possible to limit the size of the heater in other embodiments. For example, referring to Fig. ~., it rnay be possible to limit the size of the heater/pump unit to even more if either the volute channel 38 and/or the heater 26 are positioned around the ba~.l bearing 95.
Any type of heater that can fit in a small area and that ~.s electrically safe could be used With the present invention. The insert shown in Fig. 7 is only shown as an exemplary insert and any type of ultrasonic insert could be used with the present invention and with the gland 126 and O-ring 1.49 shown in Fig. 6. Furthermore, WO 96119672 ~ PCYYUS95/16679 while Fig. 5 shows one circuitry/motor housing configuration, any configuration wherein circuitry is placed in a separate housing and a fan draws cooling air aver the circuitry and then forces air over the motor is contemplated by the present invention.
In addition, the control circuitry may include various temperature and water presence sensors that operate to protect the motor and heater components_ For example, a separate dual function thermostat may be ._ thermally connected to the heater to provide various functions. First, if the pump is turned on and there is minimal or little water in the pump and the tub, the heater temperature rises rapidly and could result in a dzy fire. The thermostat can be used to directly shut off the heater to prevents dry fires, Second, the same thermostat can be used to provide an upper temperature limit which prevents water temperatures from exceeding 120°F which is the upper temperature alZowed_
Claims (17)
1. A pump for pumping and heating a liquid, the pump being drivable by a motor, the pump comprising:
a pump housing having an internal pump chamber, a liquid inlet into the chamber, a chamber base wall, and a radial outlet, the base wall having an opening therethrough;
a drive shaft rotatably mounted in the opening, the shaft being suitable to be attached to a motor located outside the chamber;
an impeller mounted on the drive shaft to rotate therewith in the chamber, the impeller mounted such that the outlet is between the impeller and the base wall; and a heater sandwiched in the chamber between the base wall and impeller;
whereby upon operation of the pump and connection of the pump to a liquid supply, rotation of the shaft can draw liquid in from the inlet, past the heater and through the outlet.
a pump housing having an internal pump chamber, a liquid inlet into the chamber, a chamber base wall, and a radial outlet, the base wall having an opening therethrough;
a drive shaft rotatably mounted in the opening, the shaft being suitable to be attached to a motor located outside the chamber;
an impeller mounted on the drive shaft to rotate therewith in the chamber, the impeller mounted such that the outlet is between the impeller and the base wall; and a heater sandwiched in the chamber between the base wall and impeller;
whereby upon operation of the pump and connection of the pump to a liquid supply, rotation of the shaft can draw liquid in from the inlet, past the heater and through the outlet.
2. The pump of claim 1, wherein the inlet opens into the chamber at a position opposite the base wall opening.
3. The pump of claim 1, wherein the drive shaft is an armature of a motor.
4. The pump of claim 1, wherein the heater includes an electrically resistive heating element, an electrical insulator around the heating element, and an electrically and thermally conductive cover covering the insulator, the cover being grounded, so that the cover operates as a current collector.
5. The pump as recited in claim 4, wherein the cover includes a stainless steel tube surrounding the insulator and an aluminum coating cast around the stainless steel tube and the aluminum coating is grounded.
6. The pump as recited in claim 1, wherein a portion of the pump chamber is a volute having a volute inlet end and a volute outlet end and wherein the volute is deeper at the outlet end than at the inlet end.
7. The pump as recited in claim 1, wherein a ball bearing is included within the opening for receiving and supporting the drive shaft.
8. The pump as recited in claim 1, further including at least one insert that has been forced through the pump housing by ultrasonic vibrations, the insert having an extension extending into the pump chamber and a head end located outside the pump chamber.
9. The pump as recited in claim 8, wherein there is an O-ring at a junction between the insert and the pump housing for providing a seal.
10. The pump as recited in claim 8, wherein a sensor is connected to the head end of the insert.
11. The pump as recited in claim 10, wherein the sensor is a dual function thermostat that can detect water presence and water temperature.
12. The pump as recited in claim 11, wherein the sensor can turn off the heater when no water is present in the pump or when the water temperature exceeds a temperature limit.
13. The pump of claim 10, wherein the insert is thermally and electrically conductive.
14. The pump as recited in claim 10, wherein the sensor is either a water temperature, water pressure, or a water presence sensor.
15. A pump for pumping and heating a liquid, the pump being drivable by a motor, the pump comprising:
a pump housing having an internal pump chamber, a fluid inlet into the chamber, a chamber base wall, and a radial outlet, the base wall having an opening therethrough;
a drive shaft rotatably mounted in the opening, the shaft being suitable to be attached to a motor located outside the chamber, the drive shaft being an armature of a motor;
an impeller mounted on the drive shaft to rotate therewith in the chamber;
a heater sandwiched in the chamber between the base wall and impeller;
whereby upon operation of the pump and connection of the pump to a liquid supply, rotation of the shaft can draw liquid in from the inlet, past the heater and through the outlet;
the motor is enclosed in a motor housing having at least one air intake, and there is a circuit housing positioned adjacent the motor housing near the intake;
control circuitry for the motor and pump is positioned within the circuit housing;
the circuit housing including a chimney chute at a first end that communicates with the intake and an intake hole at a second end opposite the first end; and the motor includes a fan within the motor housing that forces air through the intake hole, over the control circuitry, through the chimney chute and intake, and over the motor.
a pump housing having an internal pump chamber, a fluid inlet into the chamber, a chamber base wall, and a radial outlet, the base wall having an opening therethrough;
a drive shaft rotatably mounted in the opening, the shaft being suitable to be attached to a motor located outside the chamber, the drive shaft being an armature of a motor;
an impeller mounted on the drive shaft to rotate therewith in the chamber;
a heater sandwiched in the chamber between the base wall and impeller;
whereby upon operation of the pump and connection of the pump to a liquid supply, rotation of the shaft can draw liquid in from the inlet, past the heater and through the outlet;
the motor is enclosed in a motor housing having at least one air intake, and there is a circuit housing positioned adjacent the motor housing near the intake;
control circuitry for the motor and pump is positioned within the circuit housing;
the circuit housing including a chimney chute at a first end that communicates with the intake and an intake hole at a second end opposite the first end; and the motor includes a fan within the motor housing that forces air through the intake hole, over the control circuitry, through the chimney chute and intake, and over the motor.
16. The pump as recited in claim 15, wherein there are a plurality of air intakes to the motor housing, and the chimney chute communicates with less than all of the air intakes.
17. The pump as recited in claim 1, wherein the heater is donut-shaped and surrounds the drive shaft.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002495540A CA2495540A1 (en) | 1994-12-22 | 1995-12-19 | Combined heater and pump |
| CA002497872A CA2497872C (en) | 1994-12-22 | 1995-12-19 | Combined heater and pump |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/362,671 | 1994-12-22 | ||
| US08/362,671 US5701388A (en) | 1994-12-22 | 1994-12-22 | Combined heater and pump |
| PCT/US1995/016679 WO1996019672A1 (en) | 1994-12-22 | 1995-12-19 | Combined heater and pump |
Related Child Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002495540A Division CA2495540A1 (en) | 1994-12-22 | 1995-12-19 | Combined heater and pump |
| CA002497872A Division CA2497872C (en) | 1994-12-22 | 1995-12-19 | Combined heater and pump |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2208463A1 CA2208463A1 (en) | 1996-06-27 |
| CA2208463C true CA2208463C (en) | 2005-11-22 |
Family
ID=35474773
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002208463A Expired - Fee Related CA2208463C (en) | 1994-12-22 | 1995-12-19 | Combined heater and pump |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2208463C (en) |
-
1995
- 1995-12-19 CA CA002208463A patent/CA2208463C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2208463A1 (en) | 1996-06-27 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |
Effective date: 20141219 |