AXIAL FAN UNIT

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an axial fan unit according to a first preferred embodiment of the present invention.

FIG. 2 shows two axial fans defining the axial fan unit of FIG. 1 which are separated from each other.

FIG. 3 is a cross-sectional view of the axial fan unit of FIG. 1.

FIG. 4 is a plan view of a first axial fan of the axial fan unit of FIG. 1.

FIG. 5 is a plan view of a second axial fan of the axial fan unit of FIG. 1.

FIG. 6 is a cross-sectional view of a portion of the axial fan unit of FIG. 1.

FIG. 7 shows a relationship between frequencies of noises of the axial fan unit of FIG. 1 and a sound pressure level thereof.

FIG. 8 is a cross-sectional view of a portion of an axial fan unit according to a second preferred embodiment of the present invention.

FIG. 9 is a cross-sectional view of a portion of an axial fan unit according to a third preferred embodiment of the present invention.

FIG. 10 is a cross-sectional view of a portion of an axial fan unit according to a fourth preferred embodiment of the present invention.

FIG. 11 is a cross-sectional view of a portion of an axial fan unit according to a fifth preferred embodiment of the present invention.

FIG. 12 is a cross-sectional view of a portion of an axial fan unit according to a sixth preferred embodiment of the present invention.

FIG. 13 is a cross-sectional view of a portion of an axial fan unit according to a seventh preferred embodiment of the present invention.

FIG. 14 is a cross-sectional view of a portion of an axial fan unit according to an eighth preferred embodiment of the present invention.

FIG. 15 is across-sectional view of another exemplary axial fan unit according to preferred embodiments of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIGS. 1 through 15, preferred embodiments of the present invention will be described in detail. It should be noted that in the explanation of the present invention, when positional relationships among and orientations of the different components are described as being up/down or left/right, ultimately positional relationships and orientations that are in the drawings are indicated; positional relationships among and orientations of the components once having been assembled into an actual device are not indicated. Meanwhile, in the following description, an axial direction indicates a direction parallel to a rotation axis, and a radial direction indicates a direction perpendicular to the rotation axis.

First Preferred Embodiment

FIG. 1 is a perspective view of an axial fan unit 1 according to a first preferred embodiment of the present invention. The axial fan unit 1 includes a first axial fan 2 and a second axial fan 3 which are disposed coaxially with each other. FIG. 2 shows the first and second axial fans 2 and 3 which are separated from each other. The axial fan unit 1 is used for cooling the inside of an electronic device such as a server, for example. In the example of FIG. 1, the first axial fan 2 is disposed above the second axial fan 3 in an axial direction parallel to or substantially parallel to a center axis of the axial fan unit 1. The first and second axial fans 2 and 3 are connected to each other, for example, by screwing.

The axial fan unit 1 of this preferred embodiment serves as a so-called contra-rotating axial fan in which a first impeller 21 of the first axial fan 2 and a second impeller 31 of the second axial fan 3 rotate in opposite directions relative to each other. The rotation of the first and second impellers 21 and 31 allows air to be taken in from the upper side in FIG. 1 (i.e., from above the first axial fan 2 side) and be sent downward (i.e., toward the second axial fan 3), so that an air flowing generally in the axial direction is created. In the following description, the upper side in FIG. 1 from which air is taken in is referred to as an air-inlet side while the lower side in FIG. 1 from which air is discharged is referred to as an air-outlet side. Since rotating directions of the first and second impellers 21 and 31 are opposite to each other in the axial fan unit 1, a higher static pressure and a larger flow rate of air can be achieved as compared with an axial fan unit in which two impellers rotate in the same direction as each other.

FIG. 3 is a cross-sectional view of the axial fan unit 1, taken along a plane including the center axis J1 thereof. FIG. 4 is a plan view of the first axial fan 2 as seen from the air-inlet side. Referring to FIGS. 3 and 4, the first axial fan 2 includes the first impeller 21 having a plurality of first blades 211 disposed about the center axis J1 at regular circumferential intervals. The first blades 211 extend outward in a radial direction that is perpendicular to or substantially perpendicular to the center axis J1. In this preferred embodiment, seven first blades 211 are provided, for example. The first axial fan 2 also includes a first motor 22 which rotates the first impeller 21 about the center axis J1 in a first rotating direction to create an airflow flowing generally in the axial direction. In this preferred embodiment, the first motor 22 rotates the first impeller 21 in a clockwise direction in FIGS. 2 and 4, thereby creating an airflow flowing downward in FIG. 3 generally in the axial direction. The first impeller 21 is radially surrounded by a first housing piece 23. A plurality of first ribs 24 are disposed below the first impeller 21 in the axial direction in FIG. 3, i.e., axially between the first and second impellers 21 and 31. The first ribs 24 are disposed about the center axis J1 so as to extend outward in the radial direction and are connected to the first motor 22 and the first housing piece 23. Thus, the first ribs 24 secure the first motor 22 to the first housing piece 23. In this preferred embodiment, three first ribs 24 are provided, for example. In the first axial fan 2, the first impeller 21, the first motor 22, and the first ribs 24 are accommodated inside the first housing piece 23.

FIG. 3 merely shows general shapes of each first blade 211 and each first rib 24 when seen in the radial direction, for the sake of convenience. Moreover, diagonal lines for representing a cross-section of a component are omitted for various components of the first motor 22. These are the same for the second axial fan 3 of this preferred embodiment, and are also the same for the second axial fans in other preferred embodiments of the present invention shown in FIGS. 6, 8 to 11, and 13 to 15.

Referring to FIG. 3, the first motor 22 includes a stationary portion 221 as a stationary assembly and a rotor portion 222 as a rotating assembly. The rotor portion 222 is supported by a bearing mechanism detailed later, in a rotatable manner about the center axis J1 relative to the stationary portion 221. In the following description, it is assumed that the center axis J1 is coincident with a direction of gravity. However, the center of axis J1 is not always coincident with the direction of gravity.

The stationary portion 221 includes a base portion 2211. In this preferred embodiment, the base portion 2211 preferably is in the form of a generally annular plate centered on the center axis J1 as seen in the axial direction. The base portion 2211 is secured to an inner surface 231 of the first housing piece 23 with the first ribs 24 to support various components of the stationary portion 221, as shown in FIGS. 3 and 4. In this preferred embodiment, the first housing piece 23 is hollow and generally cylindrical and is made of resin. The base portion 2211 and the first ribs 24 are also made of resin in this preferred embodiment. The first housing piece 23, the base portion 2211, and the first ribs 24 are formed by injection molding, for example.

Referring to FIG. 3, a hollow bearing holder 2212 is received in an opening at a center of the base portion 2211 and is secured to the base portion 2211. In this preferred embodiment, the bearing holder 2212 is generally cylindrical. The bearing holder 2212 extends upward from the base portion 2212, i.e., toward the rotor portion 222 in the axial direction. Inside the bearing holder 2212 are disposed ball bearings 2213 and 2214 which define a portion of the bearing mechanism. The ball bearings 2213 and 2214 are axially separated from each other.

The stationary portion 221 includes an armature 2215 attached outside the bearing holder 2212 in the radial direction. In this preferred embodiment, the armature 2215 is attached to the base portion 2211 around the bearing holder 2212. A circuit board 2216 is attached below the armature 2215 and is electrically connected to the armature 2215. The circuit board 2216 includes a circuit (not shown) which controls a driving current supplied to the armature 2215. In this preferred embodiment, the circuit board 2216 is in the form of a generally ring-shaped plate. The circuit board 2216 is electrically connected to an external power supply (not shown) provided outside the axial fan unit 1 via a bundle of lead wires.

The rotor portion 222 includes a hollow yoke 2221 centered on the center axis J1, a magnet 2222 provided in the yoke 2221, and a shaft 2223 extending from the yoke 2221 axially downward. The yoke 2221 is made of magnetic metal and has a lid. In this preferred embodiment, the yoke 2221 is a hollow cylinder which is substantially closed at one axial end and is opened at the other axial end. The magnet 2222 in the yoke 2221 is disposed on an inner side surface of the yoke 2221 to radially face the armature 2215. In this preferred embodiment, the magnet 2222 is also hollow and generally cylindrical.

The shaft 2223 is inserted into the bearing holder 2212 and is supported by the ball bearings 2213 and 2214 in a rotatable manner. In the axial fan 2, the shaft 22 and the ball bearings 2213 and 2214 define a bearing mechanism which supports the yoke 2221 in a rotatable manner about the center axis J1 relative to the base portion 2211.

The first impeller 21 includes a hub 212 covering an outer surface of the yoke 2221 of the first motor 22, and a plurality of first blades 211 extending from an outer side surface of the hub 212 radially outward. The hub 212 is hollow and generally cylindrical in this preferred embodiment. The hub 212 and the first blades 211 are made of resin and are formed by injection molding, for example.

In the first axial fan 2, a driving current supplied to the armature 2215 is controlled by the circuit (not shown) of the circuit board 2216 of the first motor 22, so that a torque is generated about the center axis J1 between the armature 2215 and the magnet 22. Thus, the first blades 211 of the first impeller 21 are turned about the center axis J1 in a clockwise direction in FIG. 4, for example. In this preferred embodiment, the first impeller 21 is rotated at, for example, about 1000 min⁻¹. As a result, air is taken in from the upper side in FIG. 3 (from the rotor portion 222 side) and is sent downward (i.e., toward the second axial fan 3).

FIG. 5 is a plan view of the second axial fan 3 as seen in the axial direction. Referring to FIGS. 3 and 5, the second axial fan 3 includes a second impeller 31 disposed adjacent to the first impeller 21 in the axial direction. The second impeller 31 is coaxial with the first impeller 21. The second impeller 31 has a plurality of second blades 311 which are disposed about the center axis J1 at regular circumferential intervals and extend radially outward. In this preferred embodiment, five second blades 311 are provided.

The second axial fan 3 also includes a second motor 32 for rotating the second impeller 31 about the center axis J1. In this preferred embodiment, the second motor 32 rotates the second impeller 31 in a second rotating direction opposite to the first rotating direction, i.e., a counterclockwise direction in FIG. 5. The rotation of the second impeller 31 creates an airflow flowing generally in the same direction as the airflow created by the rotation of the first impeller 21. In this preferred embodiment, the airflows flow downward generally in the axial direction.

The second impeller 31 is radially surrounded by a second housing piece 33. A plurality of second ribs 34 are disposed below the second impeller 31, i.e., on the opposite side of the second impeller 31 to the first impeller 21. The second ribs 34 are disposed about the center axis J1 and extend radially outward to be connected to the second motor 32 and the second housing piece 33. That is, the second ribs 34 secure the second motor 32 to the second hosing piece 33. In this preferred embodiment, three second ribs 34 are provided.

In the second axial fan 3, the second impeller 31, the second motor 32, and the second ribs 34 are accommodated inside the second housing piece 33. Moreover, in the entire axial fan unit, the first impeller 21, the first ribs 24, the second impeller 31, and the second ribs 34 are disposed in that order from the upper side in FIG. 3 (i.e., from the air-inlet side) in an air passage defined in the first housing piece 23 and the second housing piece 33 which are joined to each other. In the axial fan unit 1 of this preferred embodiment, the number of the first ribs 24 is preferably the same as that of the second ribs 34.

The structure of the second motor 32 is preferably the same as that of the first motor 22, as shown in FIG. 3, and includes a stationary portion 321 and a rotor portion 322 disposed above the stationary portion 321 (i.e., on the air-inlet side of the stationary portion 321). The rotor portion 322 is supported in a rotatable manner relative to the stationary portion 321.

The stationary portion 321 is secured to an inner surface 331 of the second housing piece 33 with the second ribs 34. In this preferred embodiment, the second housing piece 33 is hollow and generally cylindrical. The stationary portion 321 includes a base portion 3211 which supports other components of the stationary portion 321, a hollow bearing holder 3212 in which ball bearings 3213 and 3214 are disposed, and an armature 3215 attached radially outside the bearing holder 3212. The bearing holder 3212 is hollow and generally cylindrical in this preferred embodiment. Below the armature 3215 of the stationary portion 321 is provided a circuit board 3216 which is electrically connected to the armature 3215. In this preferred embodiment, the circuit board 3216 is generally ring-shaped. The circuit board 3216 includes a circuit (not shown) which controls a driving current supplied to the armature 3215.

In this preferred embodiment, the base portion 3211, the second ribs 34, and the second housing piece 33 are made of resin, and are formed by injection molding, for example. The circuit board 3216 is electrically connected to an external power supply (not shown) provided outside the axial fan unit 1 via a bundle of lead wires.

The rotor portion 322 includes a metal yoke 3221, a magnet 3222 secured to an inner side surface of the yoke 3221, and a shaft 3223 extending downward from the yoke 3221. The shaft 3223 is supported by the ball bearings 3213 and 3214 in the bearing holder 3212 in a rotatable manner about the center axis J1. In the second axial fan 3, the shaft 3223 and the ball bearings 3213 and 3214 serve as a bearing mechanism which supports the yoke 3221 in a rotatable manner about the center axis J1 relative to the base portion 3211.

The second impeller 31 includes a hub 312 covering an outer surface of the yoke 3221 of the second motor 32 and a plurality of second blades 311 extending from an outer side surface of the hub 312 radially outward. In this preferred embodiment, the hub 312 and the second blades 311 are made of resin and are formed by injection molding, for example.

In the second axial fan 3, when the second motor 32 is driven, the second blades 311 of the second impeller 31 are turned about the center axis J1 in a counterclockwise direction in FIG. 5, for example. In this preferred embodiment, the second blades 311 are turned about at, for example, about 8000 min⁻¹. Due to this rotation, air is taken in from the upper side in FIG. 3 (i.e., from the first axial fan 2 side) and is sent downward (i.e., toward the second ribs 34).

FIG. 6 is an enlarged cross-sectional view of a portion (a right half) of the axial fan unit 1 with respect to the center axis J1. Referring to FIG. 6, in the axial fan unit 1, a second-impeller side edge 2111 of the first blade 211, which is a trailing edge (air-outlet side edge) of the first blade 211 from which air is separated from the first blade 211, is inclined with respect to the radial direction that is perpendicular to or substantially perpendicular to the center axis J1 such that the edge 2111 (hereinafter, referred to as the first blade edge 2111) gets closer to the air-inlet side end of the axial fan unit 1 as it moves away from the center axis J1. Similarly, a first-impeller side edge 241 (hereinafter, referred to a first rib edge) of the first rib 24 is also inclined with to the radial direction such that it gets closer to the air-inlet side end of the axial fan unit 1 as it moves away from the center axis J1. That is, not only the first blade edge 2111 but also the first rib edge 241 get closer to the air-inlet side end of the axial fan unit 1 as they move away from the center axis J1. Furthermore, a first-impeller side edge 3111 of the second blade 311, which also serves as an air-inlet side edge or a leading edge of the second blade 311, and a second-impeller side edge (hereinafter, referred to as a second rib edge) 242 of the first rib 24 are also inclined with respect to the radial direction such that they get closer to the air-inlet side end of the axial fan unit 1 as they move away from the center axis J1.

Please note that, in the axial fan unit 1, the first blades 211, the first supporting ribs 24 and the second blades 311 other than those shown in FIG. 6 are also inclined in a similar manner to those shown in FIG. 6, such that they get closer to the air-inlet side end of the axial fan unit 1 as they move away from the center axis J1.

It is assumed that an envelope formed by turning the first blade edges 2111 of the first blades 211 about the center axis J1 is a first envelope and an envelope formed by turning the second blade edges 3111 of the second blades 311 about the center axis J1 is a second envelope. The first rib edges 241 of the first ribs 24 extend along the first envelope such that a distance between the first rib edges 241 and the first envelope is approximately constant. The second rib edges 242 of the first ribs 24 extend along the second envelope such that a distance between the second rib edges 242 and the second envelope is approximately constant.

The distance between the first rib edges 241 and the first envelope may be appropriately determined so as to substantially separate the first rib edges 241 and the first envelope from each other. For example, the aforementioned distance between the first rib edges 241 and the first envelope may be an axial distance therebetween or may be a shortest distance therebetween. This is the same for the distance between the second rib edges 242 and the second envelope. In the following description, the distance between the rib edges and the corresponding envelope is defined as an axial distance therebetweeen.

In the axial fan unit 1, at any position on each first rib 24 in the radial direction, the axial distance between the first rib edge 241 and the first envelope is equal to or substantially equal to the axial distance between the second rib edge 242 and the second envelope.

In addition, an edge 3112 of each second blade 311 of the second impeller 31, which is opposite to the first impeller 21 and serves as an air-outlet side edge of the second blade 311, is inclined with respect to the radial direction such that it gets closer to the air-inlet side end of the axial fan unit 1 as it moves away from the center axis J1. The edge 3112 of the second blade 311 is hereinafter referred to as a third blade edge 3112. Moreover, a second impeller side edge of each second rib 34, i.e., an air-inlet side edge 341 is also inclined to the radial direction such that it gets closer to the air-inlet side end of the axial fan unit 1 as it moves away from the center axis J1. The third rib edges 341 extend along a third envelope formed by turning the third blade edges 3112 about the center axis J1 with an axial distance therebetween kept approximately constant.

FIG. 7 shows a relationship between the frequencies and the sound pressure level of noises of the axial fan unit 1. Curve 101 represents the noises of the axial fan unit 1 of this preferred embodiment, while curve 102 represents noises of an axial fan unit of Comparative Example in which the first and second blades have the same shapes as those of the axial fan unit 1 but the first and second rib edges of the first ribs extend perpendicular to the center axis of the axial fan unit. As shown in FIG. 7, the noise is reduced in the axial fan unit 1 by about 10 dB around a frequency of 1.167 kHz (this frequency corresponds to a first-order rotation frequency component of the first impeller 21), as compared with the axial fan unit of Comparative Example.

As described above, the first rib edges 231 of the first ribs 24 and the first blade edges 2111 as the air-outlet side edges of the first blades 211 are inclined with respect to the radial direction toward the same direction, i.e., toward the air-inlet side end of the axial fan unit 1. Thus, interference of air sent from the first blades 211 with the first ribs 24 can be suppressed and therefore the noises of the axial fan unit 1 can be reduced. Moreover, the axial distance between the first envelope obtained by turning the first blade edges 2111 about the center axis J1 and the first rib edges 241 is kept approximately constant. Thus, the interference of the air from the first blades 211 with the first ribs 24 can be further suppressed, resulting in further reduction in the noises of the axial fan unit 1.

Also, the second rib edges 242 of the first ribs 24 and the second blade edges 3111 as the air-inlet side edges of the second blades 311 are inclined with respect to the radial direction toward the same direction, i.e., toward the air-inlet side end of the axial fan unit 1. Thus, interference of air flowing into the second blades 311 and the first ribs 24 can be suppressed and therefore the noises of the axial fan unit 1 can be further reduced. Since the axial distance between the second envelope obtained by turning the second blade edges 3111 about the center axis J1 and the second rib edges 242 are kept approximately constant, the interference of the air flowing into the second blades 311 with the first ribs 24 can be further effectively suppressed, resulting in further reduction in the noises of the axial fan unit 1.

In addition, the axial distance between the first rib edges 241 of the first ribs 24 and the first envelope and the axial distance of the second rib edges 242 and the second envelope are equal to or substantially equal to each other. Therefore, interference of air flowing around the first ribs 24 with the first ribs 24 can be suppressed, resulting in further reduction in the noises of the axial fan unit 1.

In the axial fan unit 1, the second ribs 34 are disposed on the air-outlet side of the second impeller 31, i.e., on the opposite side of the second impeller 31 to the first impeller 21, and what interferes with air sent from the first blades 211 between the first and second impellers 21 and 31 is the first ribs 24 only. Thus, the noises of the axial fan unit 1 can be further reduced.

In a region adjacent to the air-outlet side end of the axial fan unit 1, the third rib edges 231 of the second ribs 34 and the third blade edges 3112 as the air-outlet side edges of the second blades 3111 are inclined with respect to the radial direction toward the same direction, i.e., toward the air-inlet side end of the axial fan unit 1. Thus, interference of air sent out from the second blades 311 with the second ribs 34 can be suppressed. This contributes to further reduction in the noises of the axial fan unit 1. Moreover, the axial distance between the third envelope obtained by turning the third blade edges 3112 about the center axis J1 and the third rib edges 231 are kept approximately constant. Thus, the interference of the air from the second blades 311 with the second ribs 34 can be further suppressed, resulting in further reduction in the noises of the axial fan unit 1.

In the axial fan unit 1, two housing pieces which are formed separately from each other, i.e., the first and second housing pieces 23 and 33 are joined to each other to form a hollow housing which radially surrounds the first and second impellers 21 and 31. With this configuration, the housing of the axial fan unit 1 can be easily formed. It is also possible to easily attach the first and second impellers 21 and 31 and the first and second motors 22 and 32 to the housing. Consequently, the axial fan unit 1 can be easily manufactured.

Second Preferred Embodiment

An axial fan unit according to a second preferred embodiment of the present invention is now described. FIG. 8 is a cross-sectional view of a portion of the axial fan unit 1a of the second preferred embodiment. As shown in FIG. 8, first blades 211a and second blades 311a are provided in the axial fan unit 1a, in place of the first and second blades 211 and 3111 of the axial fan unit 1 shown in FIG. 3. Moreover, the first and second ribs 24 and 34 of the axial fan unit 1 of the first preferred embodiment are replaced with first and second ribs 24a and 34a which are different from the first and second ribs 24 and 34 in shapes of rib edges. Except for the above, the axial fan unit 1a of this preferred embodiment is preferably substantially the same as the axial fan unit 1 of the first preferred embodiment. Therefore, like parts are given like reference numerals in the following description.

Referring to FIG. 8, the first blade edge 2111 which is a second impeller side or an air-outlet side edge of each first blade 211a of the first impeller 21 includes an inclined portion 2113 and another inclined portion 2114 both of which are inclined with respect to the radial direction. The inclined portion 2113 is disposed radially inside the inclined portion 2114, i.e., on the center axis side of the inclined portion 214, and is inclined such that it gets closer to the air-inlet side end of the axial fan unit 1a (the upper side in FIG. 8) as it moves away from the center axis J1. The inclined portion 2114 is disposed radially outside the inclined portion 2113 and is inclined such that it gets closer to the air-outlet side end of the axial fan unit 1a as it moves away from the center axis J1.

Similarly, the second blade edge 3111 which is the first impeller side edge or the air-inlet side edge of each second blade 311a of the second impeller 31 includes an inclined portion 3113 and another inclined portion 3114, both of which are inclined with respect to the radial direction. The inclined portion 3113 is disposed radially inside the inclined portion 3114 and is inclined such that as it gets closer to the air-inlet side end of the axial fan unit 1a as it moves away from the center axis J1. The inclined portion 3114 is disposed radially outside the inclined portion 3114 and is inclined such that it gets closer to the air-outlet side end of the axial fan unit 1a as it moves away from the center axis J1.

Between the first and second impellers 21 and 31, the first rib edges 241 of the first ribs 24a, which are the first impeller side edges or the air-inlet side edges, extend along the first envelope obtained by turning the first blade edges 2111 of the first blades 211a about the center axis J1 with a gap kept between the first envelope and the first rib edges 241. Similarly, the second rib edges 242 of the first ribs 24, which are the second impeller side edges or the air-outlet side edges, extend along the second envelope obtained by turning the second blade edges 3111 of the second blades 311a about the center axis J1 with a gap kept between the second envelope and the second rib edges 242.

In the axial fan unit 1a, at any position on each first rib 24a in the radial direction, the axial distance between the first rib edges 241 and the first envelope and the axial distance between the second rib edges 242 and the second envelope are approximately constant and approximately equal to each other.

Each of the third blade edges 3112 of the second blades 311a of the second impeller 31, which are the edges on the air-outlet side or the opposite side of the second blades 311a to the first impeller 21, includes an inclined portion 3115 and another inclined portion 3116. The inclined portion 3115 gets closer to the air-inlet side end of the axial fan unit 1a as it moves away from the center axis J1, while the other inclined portion 3116 gets closer to the air-outlet side end of the axial fan unit 1a as it moves away from the center axis J1. The third rib edges 341 of the second ribs 34a, which are the second impeller side or the air-inlet side edges, extend along the third envelope obtained by turning the third blade edges 3112 of the second blades 311a about the center axis J1 with a gap kept between the third envelope and the third rib edges 341. At any position on each second rib 34a in the radial direction, the axial distance between the third rib edge 341 and the third envelope is approximately the same.

Since the first rib edges 241 of the first ribs 24a extend along the first blade edges 2111 of the first blades 211a, interference of air sent from the first blades 211a with the first ribs 24a can be suppressed, thus reducing noises of the axial fan unit 1a. Moreover, the axial distance between the first rib edges 241 and the first envelope is approximately constant. Thus, the interference of the air from the first blades 211a with the first ribs 24a can be further suppressed, resulting in further reduction in the noises of the axial fan unit 1a.

In the axial fan unit 1a of FIG. 8, the second rib edges 242 of the first ribs 24a extend along the second blade edges 3111 of the second blades 311a. Thus, interference of air flowing into the second blades 311a with the first ribs 24a can be suppressed. This results in further reduction in the noise of the axial fan unit 1a. Moreover, since the axial distance between the second rib edges 242 and the second envelope is approximately constant, the interference of the air flowing into the second blades 311a with the first ribs 24a can be further suppressed. This contributes to further reduction in the noises of the axial fan unit 1a.

In addition, the axial distance between the first rib edges 241 of the first ribs 24a and the first envelope is approximately equal to the axial distance between the second rib edges 242 and the second envelope. Thus, interference of air flowing around the first ribs 24a with the first ribs 24a can be further suppressed, resulting in further reduction of the noises of the axial fan unit 1a.

In an air-outlet side region of the axial fan unit 1a, the third rib edges 341 of the second ribs 34a extend along the third blade edges 3112 of the second blades 311a. Thus, interference of air sent out by the second blades 311a with the second ribs 34a can be suppressed, resulting in further reduction in the noises of the axial fan unit 1a. Moreover, since the axial distance between the third rib edges 341 and the third envelope is approximately constant, the interference of the air from the second blades 311a with the second ribs 34a can be further suppressed. Therefore, the noises of the axial fan unit 1a can be further reduced.

In the axial fan unit 1a of this preferred embodiment, the second ribs 34a are disposed on the air-outlet side of the second impeller 31, as in the first preferred embodiment. Therefore, the noises of the axial fan unit 1a can be further reduced. In addition, a hollow housing radially surrounding the first and second impellers 21 and 31 are formed by two separately formed housing pieces, i.e., the first and second housing pieces 23 and 33. Therefore, it is possible to easily manufacture the axial fan unit 1a. Furthermore, since the rotating directions of the first and second impellers 21 and 31 are opposite to each other, the static pressure and the flow rate of air of the axial fan unit 1a can be made larger.

Third Preferred Embodiment

An axial fan unit according to a third preferred embodiment of the present invention is now described. FIG. 9 is a cross-sectional view of a portion of the axial fan unit 1b of the third preferred embodiment. As shown in FIG. 9, the axial fan unit 1c includes second blades 311b which are different in shape from the second blades 311 of the axial fan unit 1 of the first preferred embodiment shown in FIG. 1. Also, first ribs 24b provided in the axial fan unit 1b are different in rib edge shape from the first ribs 24 in the first preferred embodiment shown in FIG. 1. Except for the above, the axial fan unit 1b preferably is substantially the same as the axial fan unit 1 of the first preferred embodiment shown in FIG. 3. Therefore, like parts are given like reference numerals in the following description and FIG. 9.

Referring to FIG. 9, the second blade edge 3111 of each second blade 311b of the second impeller 31, which is the edge on the first impeller side or the air-inlet side of the second blade 311b, includes inclined portions 3113 and 3114 which are inclined with respect to the radial direction. The inclined portion 3113 which is disposed radially inside the inclined portion 3114 is inclined such that it gets closer to the air-inlet side end of the axial fan unit 1b as it moves away from the center axis J1. The inclined portion 3114 disposed radially outside the inclined portion 3113 is inclined such that it gets closer to the air-outlet side end of the axial fan unit 1b as it moves away from the center axis J1. Between the first and second impellers 21 and 31, the second rib edges 242 of the first ribs 24b, which are the second impeller side edges or the air-outlet side edges, extend along the second envelope obtained by turning the second blade edges 3111 of the second blades 311b about the center axis J1 with a gap kept between the second envelope and the second rib edges 242.

At any position on each first rib 24b in the radial direction, the axial distance between the second rib edges 242 and the second envelope is approximately constant and is approximately equal to the axial distance between the first rib edges 241 and the first envelope.

In the axial fan unit 1b of this preferred embodiment, interference of air sent by the first blades 211 with the first ribs 24b is suppressed as in the first and second preferred embodiments. Thus, noises of the axial fan unit 1b can be reduced. Moreover, interference of air flowing into the second blades 311b with the first ribs 24b can be suppressed. Thus, the noises of the axial fan unit 1b can be further reduced.

Fourth Preferred Embodiment

An axial fan unit according to a fourth preferred embodiment of the present invention is now described. FIG. 10 is a cross-sectional view of a portion of the axial fan unit 1c of the fourth preferred embodiment. As shown in FIG. 10, the axial fan unit 1c includes first blades 211c and second blades 311c which are different in the shape of blade edges from the first blades 211 and the second blades 311 of the axial fan unit 1 of the first preferred embodiment shown in FIG. 3. Also, first and second ribs 24c and 34c which are different in the shape of rib edges from the first and second ribs 24 and 34 in the first preferred embodiment are provided in the axial fan unit 1c. Except for the above, the axial fan unit 1c preferably is substantially the same as the axial fan unit 1 of the first preferred embodiment shown in FIG. 1. Therefore, like parts are given like reference numerals.

Referring to FIG. 10, in the axial fan unit 1c, the first blade edge 2111 of each first blade 211c, i.e., the second impeller side or the air-outlet side edge of each first blade 211c and the second blade edge 3111 of each second blade 311c, i.e., the first impeller side or the air-inlet side edge of each second blade 311c are inclined with respect to the radial direction such that they get closer to the air-outlet side end of the axial fan unit 1c as they move away from the center axis J1.

Between the first and second impellers 21 and 31, the first rib edge 241 of each first rib 24c, i.e., the first impeller side or the air-inlet side edge of each first rib 24c is inclined with respect to the radial direction such that it gets closer to the air-outlet side end of the axial fan unit 1c as it moves away from the center axis J1. Similarly, the second rib edge 241 of each first rib 24c, i.e., the second impeller side or the air-outlet side edge thereof is inclined with respect to the radial direction such that it gets close to the air-outlet side end of the axial fan unit 1c as it moves away from the center axis J1. The axial distance between the first rib edges 241 and the first envelope obtained by turning the first blade edges 2111 about the center axis J1 and the axial distance between the second rib edges 242 and the second envelope obtained by turning the second blade edges 3111 about the center axis J1 are approximately constant and are approximately equal to each other.

On the air-outlet side of the second impeller 31, the third blade edge 3112 of each second blade 311c, which is the air-outlet side or the opposite side to the first impeller 21, is inclined with respect to the radial direction. The third blade edge 3112 is inclined such that it gets closer to the air-outlet side end of the axial fan unit 1c as it moves away from the center axis J1. The third rib edge 341 of each second rib 34c, i.e., the second impeller side edge or the air-inlet side edge thereof, is inclined with respect to the radial direction such that it gets closer to the air-outlet side end of the axial fan unit 1c as it moves away from the center axis J1. The third rib edges 341 extend along the third envelope with an approximately constant gap kept therebetween.

With this configuration, interference of air sent from the first blades 211c with the first ribs 24c can be suppressed, as in the first through third preferred embodiments. Thus, it is possible to reduce noises of the axial fan unit 1c. Moreover, interference of air flowing into the second blades 311c with the first ribs 24c can be also suppressed. Thus, the noises of the axial fan unit 1c can be further reduced. Furthermore, interference of air sent by the second blades 311c with the second ribs 34c can be suppressed, thus further reducing the noises of the axial fan unit 1c.

Fifth Preferred Embodiment

An axial fan unit according to a fifth preferred embodiment of the present invention is now described. FIG. 11 is a cross-sectional view of the axial fan unit 1d of the fifth preferred embodiment. As shown in FIG. 11, the axial fan unit 1d includes the second axial fan 3 which is turned upside down and is disposed on the air-outlet side of the first axial fan 2.

Referring to FIG. 11, the base portion 3211 of the second motor 32 of the second axial fan 3 is disposed on the first impeller side (the air-inlet side) of the second impeller 31. A plurality of second ribs 34d are disposed on the second impeller side (the air-outlet side) of a plurality of first ribs 24d of the first axial fan 2. In this preferred embodiment, the number of the second ribs 34d and the number of the first ribs 24d are the same as each other. For example, three first ribs 24d and three second ribs 34d are disposed. When seen in the axial direction, one of the first rib 24d and the corresponding second rib 34d are laid over the other over its entire length. The first rib 24d and its corresponding second rib 34d define a rib 44. That is, the first and second motors 22 and 32 are supported axially between the first and second impellers 21 and 31 with a plurality of ribs 44 each defined by the first rib 24d and the second rib 34d.

The first impeller side edge 241 and the second impeller side edge 242 of each rib 44, which are referred to as the first rib edge 241 and the second rib edge 242 are inclined with respect to the radial direction such that they get closer to the air-inlet side end of the axial fan unit 1d as they move away from the center axis J1. Please note that the first rib edge 241 and the second rib edge 242 of the rib 44 are the air-inlet side edge of the first rib 24 and the air-outlet side edge of the second rib 34d, respectively. Similarly, the first blade edge 2111 of each first blade 211d, which is the second impeller side edge thereof, and the second blade edge 3111 of each second blade 311d, which is the first impeller side edge thereof are inclined with respect to the radial direction such that they get closer to the air-inlet side end of the axial fan unit 1d as they move away from the center axis J1. An axial distance between the first rib edges 241 and the first envelope and an axial distance between the second rib edges 242 and the second envelope are approximately constant and are approximately equal to each other.

In the axial fan unit 1d of this preferred embodiment, interference of air sent by the first blades 211d and air flowing into the second blades 311d with the ribs 44 can be suppressed. Thus, noises of the axial fan unit 1d can be reduced as in the first preferred embodiment.

Moreover, in the axial fan unit 1d, an axial distance between the first and second impellers 21 and 31 can be set to be larger as compared with that in the aforementioned preferred embodiments, especially because the first and second ribs 24d and 34d are disposed between the first and second impellers 21 and 31. Thus, interference of air from the first blades 211d with the second blades 311d can be suppressed, resulting in reduction in the noises of the axial fan unit 1d. In addition, one of the first ribs 24d and the second ribs 34d are laid over the other when seen in the axial direction. Therefore, interference of air from the first blades 211d with the ribs 44 (especially the second ribs 34d) can be suppressed. Therefore, the noises of the axial fan unit 1d can be further reduced.

Sixth Preferred Embodiment

An axial fan unit according to a sixth preferred embodiment of the present invention is now described. FIG. 12 is a plan view of the axial fan unit 1e of the sixth preferred embodiment when seen from its air-inlet side. As shown in FIG. 12, no first rib 24d is laid over the second rib 34. That is, the first ribs 24d are located between the second ribs 34 when seen in the axial direction. Except for this point, the axial fan unit 1e preferably has substantially the same structure as the axial fan unit 1d of the fifth preferred embodiment shown in FIG. 11. Therefore, components of the axial fan unit 1e that are the same as those of the axial fan unit 1d are labeled with the same reference numerals as those in FIG. 11. In the following description, the first ribs 24d and the second ribs 34d are collectively referred to as ribs 44a. In the axial fan unit 1e, the ribs 33a are disposed about the center axis J1 at regular angular intervals. In this preferred embodiment, six ribs 44a (three first ribs 24d and three second ribs 34d), for example, are preferably disposed about the center axis J1 at an angular interval of about 60 degrees.

As shown in FIG. 11, the first rib edge 241 of the rib 44a (the air-inlet side edge of the first rib 24d) and the second rib edge 242 of the rib 44a (the air-outlet side edge of the second rib 34d) are inclined with respect to the radial direction such that they get closer to the air-inlet side end of the axial fan unit 1e as they move away from the center axis J1. Similarly, the first blade edge 2111 of the first blade 211d and the second blade edge 3111 of the second blade 311d are inclined with respect to the radial direction such that they get closer to the air-inlet side end of the axial fan unit 1e as they move away from the center axis J1, as shown in FIG. 11. Moreover, an axial distance between the first rib edges 241 and the first envelope and an axial distance between the second rib edges 2442 and the second envelope are approximately constant and are approximately equal to each other.

In the axial fan unit 1e, interference of air sent from the first blades 211d and air flowing into the second blades 311d (see FIG. 11) with the ribs 44a can be suppressed. Thus, noises of the axial fan unit 1e can be reduced as in the fifth preferred embodiment. Moreover, when the axial fan unit 1e of this preferred embodiment is seen in the axial direction, the first and second ribs 24d and 34d are disposed between the first and second impellers 21 and 31 (see FIG. 11). This arrangement contributes to further reduction in the noises of the axial fan unit 1e.

Seventh Preferred Embodiment

An axial fan unit according to a seventh preferred embodiment of the present invention is now described. FIG. 13 is a cross-sectional view of a portion of the axial fan unit 1f of the seventh preferred embodiment. As shown in FIG. 13, the axial fan unit if includes first blades 211e and second blades 311e which are different in the shape of blade edges from the first blades 211d and the second blades 311d of the axial fan unit 1d of the fifth preferred embodiment shown in FIG. 11. Also, the first and second ribs 24d and 34d of the axial fan unit 1d of the fifth preferred embodiment are replaced with first and second ribs 24e and 34e which are different in the shape of rib edges from the first and second ribs 24d and 34d, respectively. Except for the above, the axial fan unit 1f preferably has substantially the same structure as the axial fan unit 1d of the fifth preferred embodiment shown in FIG. 11. Therefore, like components are given like reference numerals in the following description. Please note that the first and second ribs 24e and 34e may be collectively referred to as “ribs 44b”.

Referring to FIG. 13, the first blade edges 2111 of the first blades 211e of the first impeller 21 and the second blade edges 3111 of the second blades 311e of the second impeller 31 are inclined with respect to the radial direction such that they get closer to the air-outlet side end of the axial fan unit 1f as they move away from the center axis J1. Similarly, the first rib edges 241 of the ribs 44b, which are the air-inlet side edges of the first ribs 24e, and the second rib edges 242, which are the air-outlet side edges of the second ribs 34e, are inclined with respect to the radial direction such that they get closer to the air-outlet side end of the axial fan unit 1f as they move away from the center axis J1. An axial distance between the first rib edges 241 and the first envelope and an axial distance between the second rib edges 242 and the second envelope are approximately constant and are approximately equal to each other.

In the axial fan unit 1f, interference of air sent by the second blades 211e and air flowing into the second blades 311e with the ribs 44b are suppressed. Thus, noises of the axial fan unit 1f of this preferred embodiment can be reduced as in the fifth preferred embodiment.

Eighth Preferred Embodiment

An axial fan unit according to an eighth preferred embodiment of the present invention is now described. FIG. 14 is a cross-sectional view of a portion of the axial fan unit 1g of the eighth preferred embodiment. As shown in FIG. 14, the axial fan unit 1g includes first and second blades 211f and 311f which are different in the shape of blade edges from the first and second blades 211d and 311d of the axial fan unit 1d of the fifth preferred embodiment shown in FIG. 11, and also includes first and second ribs 24f and 34f which are different in the rib edges from the first and second ribs 24d and 34d of the axial fan unit 1d. Except for the above, the axial fan unit 1g of this preferred embodiment preferably has substantially the same structure as the axial fan unit 1d of the fifth preferred embodiment shown in FIG. 11. Therefore, like parts are given like reference numerals in the following description.

In the axial fan unit 1g, the number of the second ribs 34f is the same as the number of the first ribs 24f and the second ribs 34f are disposed on the second impeller side (the air-outlet side) of the first ribs 24f, as in the fifth preferred embodiment. Each first rib 24f is laid over a corresponding one of the second ribs 34f over its entire length, when seen in the axial direction. In the following description, the first and second ribs 24f and 34f are collectively referred to as ribs 44c.

Referring to FIG. 14, in the axial fan unit 1g, the first blade edge 2111 of each first blade 211f of the first impeller 21, which is the air-outlet side edge thereof, includes an inclined portion 2113 and an inclined portion 2114 which are inclined with respect to the radial direction, as in the axial fan unit 1a shown in FIG. 8. Similarly, the second blade edge 3111 of each second blade 311f of the second impeller 31, which is the air-inlet side edge thereof, includes an inclined portion 3113 and an inclined portion 3114 which are inclined with respect to the radial direction.

The air-inlet side edges of the first ribs 24f, i.e., the first rib edges 241 of the ribs 44c extend along the first envelope obtained by turning the first blade edges 2111 about the center axis J1 with a gap kept between the first envelope and the first rib edges 241. Similarly, the air-outlet side edges of the second ribs 34f, i.e., the second rib edges 242 of the ribs 44c extend along the second envelope obtained by turning the second blade edges 3111 about the center axis J1 with a gap kept between the second envelope and the second rib edges 242. Moreover, at any position on each rib 44c in the radial direction, an axial distance between the first rib edges 241 and the first envelope and an axial distance between the second rib edges 242 and the second envelope are approximately constant and approximately equal to each other.

In the axial fan unit 1g of this preferred embodiment, the first rib edges 241 of the ribs 44c extend along the first blade edges 2111 of the first blades 211f, while the second rib edges 242 of the ribs 44c extend along the second blade edges 3111 of the second blades 311f. With this configuration, interference of air flowing into the second blades 311f with the ribs 44c are suppressed, reducing noises of the axial fan unit 1g, as in the second preferred embodiment.

Ninth Preferred Embodiment

An axial fan unit according to a ninth preferred embodiment of the present invention is now described. The axial fan unit of the ninth preferred embodiment preferably has substantially the same structure as the axial fan unit 1g of the eighth preferred embodiment shown in FIG. 14, except that the first ribs are disposed between the second ribs when seen in the axial direction, as in the axial fan unit 1e shown in FIG. 12. With this configuration, noises of the axial fan unit of this preferred embodiment can be suppressed as in the eighth preferred embodiment.

The first through ninth preferred embodiments of the present invention are described above. However, the present invention is not limited thereto but can be modified in various ways.

For example, in the axial fan unit 1 of the first preferred embodiment, the air-outlet side edges 3112 of the second blades 311, i.e., the third blade edges 3112 and the air-inlet side edges of the second ribs 34, i.e., the third rib edges 341 may be inclined with respect to the radial direction such that they get closer to the air-outlet side end of the axial fan unit 1 as they move away from the center axis J1. In other words, the first blade edges 2111, the first rib edges 241, the second rib edges 242, and the second blade edges 3111 get closer to one axial end of the axial fan unit while the third blade edges 3112 and the third rib edges 341 get closer to the other axial end of the axial fan unit, as they move away from the center axis J1.

FIG. 15 shows another exemplary axial fan unit 1h. In the axial fan unit 1h, the first blade edges 2111 of the first blades 211g get closer to the air-inlet side end of the axial fan unit 1h and the second blade edges 3111 of the second blades 311g get closer to the air-outlet side end of the axial fan unit 1h, as they move away from the center axis J1. The first rib edges 24a and the second rib edges 242 of the first ribs 24g are inclined with respect to the radial direction such that they get closer to the air-outlet side end of the axial fan unit 1h as they move away from the center axis J1. At any position on each first rib 24g in the radial direction, an axial distance between the first rib edges 241 and the first envelope and an axial distance between the second rib edges 242 and the second envelope are substantially equal to each other. As described above, even if the inclination direction of the first rib edges 241 of the first ribs 24g with respect to the radial direction is opposite to the inclination direction of the first blade edges 2111 of the first blades 211g, interference of air from the first blades 211g with the first ribs 24g can be suppressed. Thus, noises of the axial fan unit 1h can be reduced. Please note that the first blade edges 2111 are not necessarily inclined with respect to the radial direction but may extend perpendicularly or substantially perpendicularly to the center axis J1.

In the axial fan unit 1d of the fifth preferred embodiment, it is not necessary that each first rib 24d is laid over a corresponding second rib 34d. It is enough that at least a portion of the first rib 24d is laid over a corresponding second rib 34d in the radial direction. This is the same in the seventh and eighth preferred embodiments.

In the axial fan units of the aforementioned preferred embodiments, a member in which a cross section perpendicular to the radial direction is blade-like, i.e., a so-called stator vane, may be provided as the first rib. In this case, the first rib has a stator function of suppressing spreading of air sent from the first impeller 21 away from the center axis J1. This is the same for the second ribs.

In the axial fan unit 1e of the sixth preferred embodiment, the first and second ribs 24d and 34d are not necessarily disposed about the center axis J1 at regular angular intervals. Instead, the first and second ribs 24d and 34d may be disposed at non-regular intervals which are appropriately determined to reduce the noises of the axial fan unit 1e. This is the same for the ninth preferred embodiment.

In the axial fan units of the aforementioned preferred embodiments, the number of the first ribs is equal to the number of the second ribs. However, the number of the first ribs is different from the number of the second ribs. For example, three first ribs are disposed on the air-outlet side of the first impeller 21, while four second ribs are disposed on the air-outlet side of the second impeller 31. Moreover, the first and second housing pieces 23 and 33 may be replaced with a single hollow housing which is disposed radially outside the first and second impellers 21 and 31 and radially surrounds them, if necessary.

In the axial fan units of the aforementioned preferred embodiments, the first impeller 21 of the first axial fan 2 and the second impeller 31 of the second axial fan 3 may rotate in the same direction as each other. Moreover, air may be taken from the second axial fan side and be discharged from the first axial fan side by changing the blade shapes of the blades, the arrangement of the blades, and the rotating directions of the impellers, and the like. Furthermore, the axial fan units of the aforementioned preferred embodiments may be modified to include at least one axial fan in addition to the first and second axial fans 2 and 3 such that all the axial fans are disposed coaxially with each other.

As described above, according to the preferred embodiments of the present invention, noises of an axial fan unit can be significantly reduced and minimized.

While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.

AXIAL FAN UNIT

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CPC

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