FIELD

[0001] Embodiments of the present disclosure relates to a motor assembly, and in particular, a motor assembly with improved dust, dirt or moisture resistant design.

BACKGROUND

[0002] A powered mask is increasingly used in daily life to counteract dangers caused by air pollution. The powered mask generally comprises a motor part for moving blades of a fan and a driver for powering and driving the motor part. An electrical connection is created between the motor part and the driver. However, such an electrical connection is subject to failures during use of the powered mask. There is a need to improve reliability of the powered mask.

SUMMARY

[0003] In view of the above, one of the objectives of the embodiments of the present disclosure is to provide a motor assembly, a fan assembly, and a powered mask, which can at least solve one or more of aforesaid technical problems existing in the prior art.

[0004] According to one aspect of the disclosure, there is provided a motor assembly. The motor assembly comprises a motor part; a driver adapted to be electrically connected to the motor part and to drive the motor part; and a motor seat plate configured to support the motor part and to divide space in the motor assembly into a first cavity communicating with the atmosphere and a sealed second cavity, wherein the motor part is installed in the first cavity, and the driver is installed in the second cavity, and wherein the motor seat plate comprises a sealed connection arrangement for hermetically and electrically connecting a wire of the motor part to the driver.

[0005] According to the embodiment of the disclosure, a sealed connection arrangement is provided. Accordingly, dust, dirt or moisture is prevented from entering the driver side from the motor side. Accordingly, the life span of the motor assembly is improved.

[0006] In some embodiments, the sealed connection arrangement may comprise a pin having a hollow cavity and a sealant adhesive filled the hollow cavity. In this manner, in order to form the sealing between the motor part and the driver, no extra components are needed and this can be realized by simply modifying the structure of the motor seat plate, which is cost efficient, with reduced process and costs.

[0007] With the pin being provided on the motor seat plate, the electrical connection between the motor part and the driver can be easily created. Also, by means of the pin, the amount of the sealant adhesive used for filling the cavity is well controlled and thus can be limited to a predetermined amount. Also, with the sealant adhesive, the foreign matters (such as moisture) in the first cavity are prevented from entering the second cavity.

[0008] In some embodiments, the pin may include a tapered opening on a side of the first cavity. With the tapered opening, the sealant adhesive can be filled easily and conveniently. Also, the sealing performance can be further improved.

[0009] In some embodiments, the pin may be a conductive metal pin and may be integrally formed with the motor seat plate by insert injection moulding. With the conductive metal pin, the electrical connection between the motor part and the driver can be easily created. Also, the structure of the sealing arrangement is further simplified.

[0010] In some embodiments, the pin may include a wedge-shaped ring groove along a circumferential side wall of the pin. With the wedge-shaped ring groove, the pin can be prevented from falling when manufacturing the motor seat plate, for example, by insert moulding.

[0011] In some embodiments, the pin and the motor seat plate both may be made of plastic and are integrally formed with each other. With the plastic pin, the mould for forming the sealing arrangement is further simplified.

[0012] In some embodiments, the hollow cavity of the pin is formed as a blind hole.

[0013] In some embodiments, the hollow cavity of the pin may be formed as a through hole.

[0014] In some embodiments, an opening of the hollow cavity on the side of the second cavity may be sealed by a solder. With the solder, the foreign matters can be further prevented from entering the driver side.

[0015] In some embodiments, the driver may comprise a driver substrate, wherein the driver substrate is fixed to the motor seat plate on the side of the second cavity.

[0016] According to second aspect of the disclosure, there is provided a fan assembly. The fan assembly comprises: the motor assembly according to any one of the first aspect, wherein a rotor of the motor assembly forms a fan blades of the fan assembly; a first housing delimiting the first cavity at a first side of the motor seat plate; and a second housing delimiting the second cavity at a second side, opposite to the second side, of the motor seat plate.

[0017] According to third aspect of the disclosure, there is provided a powered mask. The face mask comprises the fan assembly according to the second aspect of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Now, the embodiments of the present disclosure will be described with reference to the accompanying drawings only in an exemplary manner, wherein:

[0019] Fig. 1 is a schematic overall view of a powered mask according to one embodiment of the disclosure;

[0020] Fig. 2 is a exploded view of a powered mask according to one embodiment of the disclosure, showing main parts of a fan assembly;

[0021] Fig. 3 is another exploded view of a fan assembly according to one embodiment of the disclosure;

[0022] Fig. 4 is a cross-sectional view of the assembled fan assembly in Fig. 3;

[0023] Fig.5 is a cross-sectional view of a motor assembly according to one embodiment of the disclosure;

[0024] Fig. 6a and 6b are schematic views of pins according to different embodiments of the disclosure; and

[0025] Fig.7 is a cross-sectional view of a motor assembly according to another embodiment of the disclosure.

[0026] In the drawings, similar/same reference signs throughout different views generally represent similar/same parts. Drawings are not necessarily to scale. Rather, emphasis is placed upon the illustration of the principles of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] Embodiments of the disclosure will be described in more detail with reference to the drawings. Although the drawings illustrate some embodiments of the disclosure, it should be appreciated that the disclosure can be implemented in various manners and should not be interpreted as being limited to the embodiments explained herein. On the contrary, the embodiments are provided to understand the disclosure in a more thorough and complete way. It should be appreciated that drawings and embodiments of the disclosure are only for exemplary purposes rather than restricting the protection scope of the disclosure.

[0028] In the descriptions of the embodiments of the disclosure, the term “comprise”, “include”, “have”, and their variants are to be read as open-ended terms that mean “includes, but is not limited to.” The term “based on” is to be read as “based at least in part on.” The terms “one embodiment” and “this embodiment” are to be read as “at least one embodiment.” The following text also can comprise other explicit and implicit definitions.

[0029] Embodiments of the present disclosure will be described in conjunction with figures. It should be appreciated that the inventive idea according to the present disclosure is illustrated by taking a powered mask as an example, but it should be appreciated that the inventive idea is not limited to a powered mask but can be used in any other devices that employing the motor assembly.

[0030] Fig.l shows a schematic overall view of a powered mask according to one embodiment of the disclosure. As shown in Fig. 1, the powered mask 100 comprises a fan assembly 10 and a mask body 20. The fan assembly 10 may be attached to the mask body 20 using various methods. During use, the fan assembly 10 can operate to draw air from a cavity formed between a wearer’s face and the mask body 20 to the environment or to draw air from the environment to the cavity. A filter, for example, can be arranged on the air flow path. In this way, the wearer can breathe clean air to keep healthy even when the wearer is in heavily polluted environment. In some embodiments, the fan assembly 10 may be controlled by a controller (now shown) which includes instructions to operate the fan assembly 10 according to predetermined patterns. Since these components are known in the art, their detailed description is omitted.

[0031] Fig. 2 shows an exploded view of the powered mask 100 according to one embodiment of the disclosure and Fig. 3 shows an exploded view of the fan assembly according to one embodiment of the disclosure. As shown in Figs. 2 and 3, the fan assembly 10 comprises a first housing 30, a second housing 40, and a motor assembly arranged between the first housing 30 and the second housing 40.

[0032] Fig. 4 is a cross-sectional view of the assembled fan assembly in Fig. 3. As shown in Fig. 4, also in conjunction with Figs. 2 and 3, the motor assembly comprises a motor part 12; a driver 16 adapted to be electrically connected to the motor part 12 and to drive the motor part 12; and a motor seat plate 14 configured to support the motor part 12.

[0033] The motor part 12 may include coils and a rotor. In the illustrated embodiment, the rotor includes fan blades. For example, the fan blades may be integrally formed with the rotor. Alternatively, the fan blades may be attached to the rotor. The coils are electrically connected to the driver 16 and can be energized so as to move the fan blades. The driver 16 may include a driver substrate. The driver substrate may be attached to the motor seat plate 14. Various electrical components, such as a controller, can be arranged on the driver substrate. The motor seat plate 14 is configured to mechanically support a shaft of the motor. When the coils are energized, the shaft rotates. The motor seat plate 14 mechanically supports the motor.

[0034] In some embodiments, as shown in Fig. 4, the motor seat plate 14 divides space in the fan assembly into a first cavity 50 communicating with the atmosphere and a second cavity 60. The motor part 12 is installed in the first cavity 50, and the driver 16 is installed in the second cavity 60. The motor seat plate 14 thus separates the motor part 12 from the driver 16. In this way, the electrical devices can be physically separate from the motor part 12. This is particularly useful when the motor assembly is used in a powered mask. During operation of the powered mask, the motor part 12 is exposed to high temperature and high humidity, for example, caused by exhaled air by the wearer. Moisture in the motor part 12 can easily damage the driver 16. By use of the motor seat plate 14, the moisture in the first cavity 50 can be prevent from invading the second cavity 60.

[0035] As shown in Fig.4, during operation of the fan assembly, as indicated by arrow P, the air can be drawn in to the first cavity 50 through the opening provided on the first housing 30, then goes out the first cavity50 through circumferential openings (as indicated by the arrow). Through the above operation, the air can be discharged to the environment from the cavity formed by the mask body. On the other hand, the air can also be drawn from the atmosphere into the cavity formed by the mask body. Accordingly, when the fan assembly operates, the first cavity 50 communicates with the atmosphere to exchange air between the user’ s mask and the environment.

[0036] The motor part 12, for example, the coils in the first cavity 50, is electrically connected to the driver 16 in the second cavity 60. In one embodiment, the lead wire of the motor part 12 goes through a hole provided in the motor seat plate 14 so as to electrically connect the motor part 12 to the driver 16. However, the moisture in the first cavity 50 may invade the motor part 12 through the hole. When this happens, the electrical components of the driver can be easily damaged. In particular, when the motor assembly is used as a powered mask. During use of the powered mask, the exhaled gas from the wearer may greatly impact the reliability of the product. The first cavity 50 is of high humidity and high temperature. Moisture in the first cavity 50 will invade into the driver side and cause failure of electrical components on the diver side.

[0037] According to one embodiment, the motor seat plate 14 comprises a sealed connection arrangement for hermetically and electrically connecting a wire of the motor part 12 to the driver 16. In one example embodiment (not shown), the sealed connection arrangement comprises a wedge member which is arranged at the hole and a sealing ring which is sandwiched between the wedge member and the hole. The lead wire of the motor part 12 goes through the hole to connect to the components of the driver 16. Due to the sealing ring sandwiched between the wedge member and the hole, foreigner matters, such as moisture, dust, dirt, can be prevented from entering into the second cavity 60. Accordingly, the electrical components on the driver side can be well protected against the foreign matters, such as the moisture.

[0038] The sealed connection arrangement may comprise various implementations.

[0039] Fig.5 is a cross-sectional view of a motor assembly according to one embodiment of the disclosure. As shown in Fig. 5, the sealed connection arrangement comprises a pin 142 having a hollow cavity 145. The lead wire 122 of the motor par 12 can be received in the hollow cavity 145. The hollow cavity 145 provides a path for a passage of the lead wire 122. A sealant adhesive 144 is further provided. In one example embodiment, after the lead wire 122 passes through the hollow cavity 145, a sealant adhesive 144 further fills the hollow cavity 145. The sealant adhesive 144 is water proof and thus is moisture resistant.

[0040] By the pin 142, the sealed connection arrangement can be formed with fewer components. For example, when the motor seat plate 14 is made of plastic, the pin 142 can be integrally formed with the motor seat plate 14. Accordingly, there is no need of provision of additional components, such as a sealing ring and wedge member. In this manner, no extra complex components are used but just slightly modifying the structure of the motor seat plate 14, which is cost efficient, with reduced process and costs.

[0041] By the sealant adhesive 144, the foreign matters (such as moisture) in the first cavity 50 are prevented from entering the second cavity 60. By means of the pin 142, the volume of the sealant adhesive 144 used for filling the cavity can be limited to a predetermined amount. In this way, the flow of the sealant adhesive 144 can be well controlled so that the sealant adhesive 144 cannot flow freely. This can reduce overuse of the sealant adhesive 144. Also, it can improve quality of the product.

[0042] The sealant adhesive 144 may be of any proper moisture resistant adhesive. In one example embodiment, the sealant adhesive 144 is a UV adhesive. The UV adhesive cures fast when UV light is applied thereon. In this way, the manufacturing time can be reduced.

[0043] In some embodiments (also referring to Figs. 6a and 6b), the pin 142 includes a tapered opening 147 on a side of the first cavity 50. The tapered opening 147 may facilitate the flow of the sealant adhesive 144 and can collect the sealant adhesive 144 easily. Regarding the shape of the opening 137, the shown embodiment is merely illustrative and any other proper shapes can be used.

[0044] In some embodiments, the pin 142 is a conductive metal pin. In this case, the lead wire 122 can be directly connected to the pin 142. The lead wire 122 thus does not necessarily pass through the hollow cavity 145. The pin 142 can be integrally formed with the motor seat plate 14, for example, by insert moulding.

[0045] In some embodiments (also referring to Figs. 6a and 6b), the pin 142 includes a wedge-shaped ring groove 143 along a circumferential side wall of the pin 142. By means the wedge-shaped ring groove 143, the pin 142 is prevented from falling during insert moulding and can maintain proper position with respect to the mould. In this way, the sealed connection arrangement can be moulded properly and simply. It is to be understood that the groove 143 may be any other proper shapes as long as the pin 142 can be positioned properly with respect to the mould during moulding process (for example, insert moulding).

[0046] In some embodiments, the pin 142 is made of plastic and is of the same material as the motor seat plate 14. In this case, there is no need of provisions of the groove 143. Since the pin 142 and the motor seat plate 14 are of the same material, the design of mould for producing the motor seat plate 14 is simplified.

[0047] In some embodiments, an opening of the hollow cavity 145 on the side of the second cavity 60 is sealed by a solder 148. By means of the solder, the sealing performance can be further improved. Even when the foreign matters invade the hollow cavity 145, the solder can further prevent the foreign matters from entering the second cavity.

[0048] Figs. 6a and 6b shows two embodiments of the pins 142. As shown in Fig. 6a, the hollow cavity 145 of the pin 142 is formed as a blind hole. In this case, the pin 142 may be made of conductive metal. The lead wires 144 can be electrically connected to the pin 142 which is in turn connected to the driver. In some embodiments, the pin 142 may be made of plastic. As an example, the pin 142 may extend beyond a bottom surface of the motor seat plate 14 and a hole may be provided on the side walls of the pin 142 for passage of the lead wire 122.

[0049] As shown in Fig. 6b, the hollow cavity 145 of the pin 142 is formed as a through hole. In this case, the pin 142 may be made of conductive metal. The lead wires 144 can be electrically connected to the pin 142 which is in turn connected to the driver. In some embodiments, the pin 142 may be made of plastic. The lead wires 122 can directly passes through the through hole to connect to driver.

[0050] Fig. 7 shows an embodiment of a motor assembly which is similar to the embodiment shown in Fig. 5. The differences between the two embodiments are that the pin 142 is provided with a blind hole. In one example embodiment, the pin 142 is a conductive metal pin. As shown in Fig. 7, the lead wire 122 from the coil of the motor is connected to the pin 142 which is in turn connected to the driver.

[0051] As shown in Fig. 7, the sealing arrangement also comprises the sealant adhesive 144 which fills the hollow cavity 145. The sealant adhesive 144 is water proof and thus prevents the moisture from entering the driver side.

[0052] In one example embodiment, the pin 142 is a plastic pin. As an example, the pin 142 may extend beyond a bottom surface of the motor seat plate 14 and a hole (not shown) may be provided on the side walls of the pin 142 for passage of the lead wire 122.

[0053] With the above arrangement, the pin 142 is integrally formed with the motor seat plate 14. Thus, there is no need of extra components for sealing. The sealing arrangement of electrical connection is significantly simplified, with reduced cost.

[0054] In the shown embodiments, the connection between the motor part 12 and the driver 16 is through a lead wire 122. It is to be understood that this is merely illustrative, the lead wire 122 may take any other forms.

[0055] Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.