Patent Application
20180372107
This application claims the benefit of German Patent Application No. 102017210634.4 filed Jun. 23, 2017, the disclosure of which is herein incorporated by reference in its entirety.
The present disclosure relates to an electric fan with an integrated rotor module having quick assembly features.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
In one form, the present disclosure provides a fan assembly that includes a fan and an electric motor. The fan has a fan member with a hub and a plurality of fan blades. The hub is rotatable about a rotational axis and has a front wall and a circumferentially extending wall that cooperate to form a rotor cavity. The electric motor has a rotor and a stator. The rotor has a plurality of first coupling features and a plurality of first snap-fit features formed thereon. The hub has a plurality of second coupling features and a plurality of second snap-fit features formed thereon. The first coupling features and the second coupling features engage one another to couple the rotor to the hub in a manner that inhibits relative rotation but which permits relative axial movement along the rotational axis. The first snap-fit features and the second snap-fit features engage one another to inhibit the rotor from being withdrawn from the rotor cavity.
In a further form, the second snap-fit features include retaining arms having an arm member and an abutment. Each of the arm members has a fixed end, which is fixedly coupled to the hub, and a cantilevered end to which the abutment is mounted. Each of the first snap-fit features comprises an engagement surface against which the abutment is engaged. Optionally, each of the first snap-fit features has a lead surface that is shaped as a part of a frustum, and each of the lead surfaces is configured to deflect the arm members as the rotor is seated into the rotor cavity.
In a further form, the stator comprises a plurality of windings.
In a further form, the rotor includes a rotor member and a mounting structure that is fixedly coupled to the rotor member. The mounting structure defines the first coupling features and the first snap-fit features. Optionally, the rotor member is at least partly encapsulated in the mounting structure. Also optionally the rotor includes a multipole magnet.
In a further form, one of the first coupling features and the second coupling features comprise a plurality of dovetail sockets and the other one of the first coupling features and the second coupling features comprise tails that are configured to be received into the dovetail sockets.
In a further form, the fan comprises an axle that is fixedly coupled to the fan member, the axle having an axle shaft that is rotatably supported by a bearing that is mounted to the stator. Optionally, the axle comprises a head that is encapsulated into the front wall of the hub.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
With reference to
The rotor 26 can comprise a rotor member 30 and a mounting structure 32. The rotor member 30 can be a magnet having a multipole oriented configuration with a plurality of north poles 36 and a plurality of south poles 38 that are juxtaposed with the north poles 36. The mounting structure 32 can be formed of plastic and in the particular example provided, is insert (injection) molded over and onto the rotor member 30 so as to at least partly encapsulate the rotor member 30.
With reference to
In the example illustrated, the first coupling features 42 are identical in their configuration (i.e., shape and size), but it will be appreciated that one or more of the first coupling features 42 could be configured differently from other ones of the first coupling features 42. The use of two or more different configurations for the first coupling features 42 can be employed, for example, to “key” the rotor 26 to the fan so that the rotor 26 can be assembled to the fan 16 in a desired orientation (rotational position).
In the particular example provided, the first coupling features 42 comprise dovetail sockets having first and second pins 50 and 52, respectively, that are disposed circumferentially apart from one another to define a groove or socket 54. The first and second pins 50 and 52 can define interior sidewalls 56 and 58, respectively, that can be transverse to a line L that extends from the rotary axis 60 of the rotor 26 through a mid-point of a span between the first and second pins 50 and 52. The interior sidewalls 56 and 58 can be sloped in a manner that would converge to the line L with increasing distance from the rotary axis 60 of the rotor 26. In the example provided, the interior sidewalls 56 and 58 are disposed symmetrically about the line L, but it will be appreciated that the interior sidewalls 56 and 58 could be sized and/or shaped differently.
With reference to
In
The circumferentially extending wall 102 can be coupled to a radially outer edge of the front wall 100. The circumferentially extending wall 102 and the front wall 100 can cooperate to form a rotor cavity 150 into which the rotor 26 can be received.
With reference to
While the first and second coupling features 42 and 104 have been described as comprising dovetail sockets 54 and tails 162, respectively, it will be appreciated that the second coupling features could comprise dovetail sockets and the first coupling features could comprise tails that are configured to be received in and engage the dovetail sockets.
With reference to
The abutment 202 can contact the lead surface 68 on the projections 64 that are formed on the mounting structure 32 as the rotor 26 is moved toward its's fully seated position in the rotor cavity 150. This contact can urge the abutment 202 radially inward and can (resiliently) deflect the cantilevered end 212 of the arm member 200. Alignment of the abutments 202 to the through-holes 72 in the projections 64 permits the arm members 200 to urge the abutments 202 radially outward (into the through-holes 72) so that the abutment surfaces 216 engage the engagement surfaces 70. It will be appreciated that engagement of the abutment surfaces 216 to the engagement surfaces 70 inhibits the withdrawal of the rotor 26 from the rotor cavity 150 along the rotary axis 60 (
While the first snap-fit features 44 have been described as comprising projections 64 and the second snap-fit features 106 have been described as comprising retaining arms (having an arm member 200 and an abutment 202), it will be appreciated that the first snap-fit features 44 could comprise retaining arms and that the second snap-fit features 106 could comprise projections 64.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102017210634.4 | Jun 2017 | DE | national |
