This disclosure relates generally to axial fans, and more particularly to the structure and arrangement of components connecting fan blades to a hub of the fan.
Axial fans rotate a series of fan blades around an axis to generate airflow in a direction generally parallel to the rotational axis. Some axial fans have a series of radially extending spokes connecting the fan blades to a hub driven by an electric motor.
To reduce stratification or circulate air within a space (e.g., a room), axial fans can be mounted to or suspended from an elevated structure, such as a ceiling, a roof joist, a truss, or an overhead beam. In such a mounting arrangement, an axial fan can be referred to as an overhead fan or a ceiling fan.
Overhead fans intended for use in large spaces typically have relatively long fan blades to cover a broad area of the space or room. With long fan blades (i.e., a larger diameter), an overhead fan can provide adequate air circulation while rotating slower than other fans with shorter blades (i.e., smaller diameter), and consequently may be generally referred to as high volume low speed (or HVLS) fans. Rotating slower can reduce fan-generated noise and avoid creating significant or isolated drafts within a room.
In the illustrated example of
In some examples, fasteners (e.g., bolts and nuts) 26 and/or a friction fit securely couple fan blade 14 to spoke 12. As shown in the illustrated examples, the connection portion of each fan blade 14 and spoke 12 is configured such that when assembled and mounted, the spoke 12 remains connected to and bears the weight of the fan blade 14. Accordingly, in the event that fastener 26 fails, the blade 14 will not disconnect from the fan 10. In some examples of fan 10, fasteners (e.g., screws) 28 on opposite sides of rotational axis 20 securely couple spokes 12a-c to hub 16, fasteners (e.g., bolts and nuts) 30 securely couple housing 24 to pole 22, and fasteners (e.g., screws) 32 securely couple pole 22 to elevated structure 18. Fasteners 26, 28, 30, and 32 are schematically illustrated to represent any type of suitable fastener for securing the components together.
In the illustrated example, a bearing 34 couples hub 16 to housing 24 for rotational relative movement. A ring nut 36 and a stationary hollow shaft 38 couple an inner race 40 of bearing 34 to housing 24, while a clamp ring 42 couples an outer race 44 of bearing 34 to hub 16. In some examples, bearing 34 is a duplex tapered roller bearing providing hub 16 with axial and radial support and ensuring smooth rotation of hub 16 with respect to the stationary portion of fan 10 (e.g., housing 24) about axis 20.
In some examples, hub 16 is rotated by a permanent magnet brushless motor 45 to achieve desirable torque/speed characteristics without the need for a gearbox. Some gearboxes can be noisy, drip oil and require periodic servicing. Commutator brushes of brushed motors, can also be noisy and require occasional replacement.
As shown in the illustrated example, when assembled and mounted, fan blades 14 are supported in a cantilevered manner and apply a significant vertical load and rotational moment on spokes 12. To ensure spokes 12 support the load of blades 14, some examples of spokes 12 are positioned such that they extend in a radial direction 50 across the fan's rotational axis 20 and are secured on both sides of the axis. Each spoke 12 can have at least one inboard fastener 28a and at least one outboard fastener 28b on opposite sides of rotational axis 20 for securing each spoke 12 to hub 16. In some examples, spoke 12 extends across the entire or most of the diameter of the hub 16, and is secured on either side (for example with inboard and outboard fasteners 28a, 28b) at or immediately adjacent to the periphery (bottom surface) of the hub 16.
To avoid irregular airflow patterns that could generate vibration and noise, fan blades 14 are mounted so as to share a common path of rotation 52, whereby one fan blade 14 follows in substantially the same path as every other fan blade 14. The term, “path of rotation” refers to the swept area in space through which fan blades 14 travel. Examples in which fan blades 14 extend straight out from hub 16 in a radial horizontal direction 54, the path of rotation 52 is generally a horizontal disc or cylindrical shape. In other examples, in which fan blades 14 are angled downward or upward, path of rotation 52 is generally a conical or frustoconical shape.
In order for a fan 10 to have fan blades 14 travel along the same path of rotation 52 while each spoke 12 extends across rotational axis 20, some examples of spokes 12 include notches (e.g., a first notch, a second notch, etc.) that allow spokes 12 to be mounted in an overlapping or nested relationship with each other. Upper spoke 12a, as shown in
In some examples, spokes 12a-c each have an individual shape (e.g., first shape, second shape, etc.) distinguishable from the others. Accordingly, spokes 12a-c must be assembled in one arrangement with all three spokes 12a-c interlocking as shown. In some examples, spokes 12a-c are substantially equal in length 66, which can provide balance and symmetry.
Middle spoke 12b, as shown in
Lower spoke 12c, as shown in
In some examples, when assembled, upper faces 60, 72, and 76 of spokes 12a, 12b and 12c; respectively, are substantially coplanar and in contact with the lower face 62 of the hub 16. The overlapping or nested arrangement of spokes 12 creates a plurality of overlapping interfaces 78, as shown in
Also, as shown in the example of
Some examples of retainer 88 extend through the entire height of fan 10 and can include an anchor 90 fixed to elevated structure 18 or some other structure, a vertically elongate member 92 (e.g., a cable, a chain, a rope, a strap, a wire, a rod, a bar, tube, etc.) with one end secured to anchor 90, and a fixture (e.g., bracket) 94 attached to an opposite end of elongate member 92 via a suitable fastener 96. In some examples, fixture 94 is also attached to the housing 24 and/or pole 22 (e.g., at an interface of the two components). In some examples, a catch member 98 attached to bracket 94 via a suitable fastener 100. Catch member 98 may be positioned at and/or is in contact with the lowermost portion (e.g., lowest spoke 12c) of the assembled and mounted fan. In some examples, catch member 98 has an outermost periphery (e.g., diameter) 102 that is greater than an innermost periphery (e.g., diameter) 104 of the bore 82 of the lowermost spoke 12c. In some examples, innermost periphery 104 is closer to rotational axis 20 than outermost periphery 102. In the illustrated example (
Although the example fan 10 shown in
Fan blade mounting structures and arrangements are disclosed herein. Further examples and combinations thereof include the following:
Example 1 includes an overhead fan comprising a housing, a hub being rotatable relative to the housing about a rotational axis that is perpendicular to a radial direction, a first fan blade, a first spoke connecting the first fan blade to the hub, a second fan blade, and a second spoke connecting the second fan blade to the hub, the second spoke overlapping the first spoke to define an overlapping interface between the first spoke and the second spoke, the overlapping interface lying substantially perpendicular to the rotational axis, both the first spoke and the second spoke extending lengthwise in the radial direction across the rotational axis.
Example 2 includes the overhead fan of example 1, wherein the first spoke defines a first notch at the rotational axis, the second spoke defines a second notch at the rotational axis, and the overlapping interface is between the first notch and the second notch.
Example 3 includes the overhead fan of example 1, further comprising a first inboard screw fastening the first spoke to the hub, a first outboard screw fastening the first spoke to the hub, the first fan blade being closer to the first inboard screw than to the first outboard screw, the first inboard screw and the first outboard screw being at opposite sides of the rotational axis, a second inboard screw fastening the second spoke to the hub, and a second outboard screw fastening the second spoke to the hub, the second fan blade being closer to the second inboard screw than to the second outboard screw, the second inboard screw and the second outboard screw being at opposite sides of the rotational axis.
Example 4 includes the overhead fan of example 1, wherein the first spoke defines a first hole, the second spoke defines a second hole, and the rotational axis extends through both the first hole and the second hole.
Example 5 includes the overhead fan of example 4, further comprising a hollow shaft extending from the housing and being substantially fixed relative thereto, a bearing coupling the hub to the hollow shaft, and a retainer that is vertically elongate, the retainer extending through the hollow shaft, through the first hole in the first spoke, and through the second hole in the second spoke, the retainer being in substantially fixed rotational relationship with the hollow shaft, the retainer including a catch member below both the first hole and the second hole, the catch member have an outermost periphery, at least one of the first hole and the second hole having an innermost periphery, the rotational axis being closer to the innermost periphery than to the outermost periphery.
Example 6 includes the overhead fan of example 1, further comprising a third fan blade, and a third spoke connecting the third fan blade to the hub, the third spoke having a section sandwiched between the first spoke and the second spoke at the overlapping interface.
Example 7 includes the overhead fan of example 1, further comprising a third fan blade connected to the first spoke.
Example 8 includes an overhead fan comprising a housing, a hollow shaft extending from the housing, a hub, a bearing coupling the hub to the hollow shaft such that the hub is rotatable relative to the housing about a rotational axis, a first fan blade, a first spoke connecting the first fan blade to the hub, the first spoke defining a first hole, a second fan blade, and a second spoke connecting the second fan blade to the hub, the second spoke defining a second hole, and a retainer that is vertically elongate, the retainer extending through the hollow shaft, through the first hole in the first spoke, and through the second hole in the second spoke, the retainer being in substantially fixed rotational relationship with the housing, the retainer including a catch member below both the first hole and the second hole, the catch member have an outermost periphery, at least one of the first hole and the second hole having an innermost periphery, the rotational axis being closer to the innermost periphery than to the outermost periphery.
Example 9 includes the overhead fan of example 8, wherein the rotational axis is perpendicular to a radial direction, the second spoke overlaps the first spoke to define an overlapping interface between the first spoke and the second spoke, the overlapping interface lies substantially perpendicular to the rotational axis, and both the first spoke and the second spoke extend in the radial direction across the rotational axis.
Example 10 includes the overhead fan of example 9, wherein the first spoke defines a first notch at the rotational axis, the second spoke defines a second notch at the rotational axis, and the overlapping interface is between the first notch and the second notch.
Example 11 includes the overhead fan of example 9, further comprising a third fan blade, and a third spoke connecting the third fan blade to the hub, the third spoke having a section sandwiched between the first spoke and the second spoke at the overlapping interface.
Example 12 includes the overhead fan of example 8, further comprising a third fan blade connected to the first spoke.
Example 13 includes the overhead fan of example 8, further comprising a first inboard screw fastening the first spoke to the hub, a first outboard screw fastening the first spoke to the hub, the first fan blade being closer to the first inboard screw than to the first outboard screw, the first inboard screw and the first outboard screw being at opposite sides of the rotational axis, a second inboard screw fastening the second spoke to the hub, and a second outboard screw fastening the second spoke to the hub, the second fan blade being closer to the second inboard screw than to the second outboard screw, the second inboard screw and the second outboard screw being at opposite sides of the rotational axis.
Example 14 includes the overhead fan of example 8, wherein the rotational axis extends through the hollow shaft, through the first hole of the first spoke and through the second hole of the second spoke.
Example 15 includes an overhead fan comprising a housing, a hub being rotatable relative to the housing about a rotational axis, a first fan blade being rotatable to define a path of rotation, a first spoke connecting the first fan blade to the hub, the first spoke having a first shape, a second fan blade being rotatable along the path of rotation, and a second spoke connecting the second fan blade to the hub, the second spoke having a second shape that is distinguishable from the first shape.
Example 16 includes the overhead fan of example 15, wherein the first spoke and the second spoke are substantially equal in length.
Example 17 includes the overhead fan of example 15, wherein the second spoke overlaps the first spoke to define an overlapping interface between the first spoke and the second spoke, the overlapping interface lying substantially perpendicular to the rotational axis, both the first spoke and the second spoke extending lengthwise in a radial direction across the rotational axis, wherein the radial direction is perpendicular to the rotational axis.
Example 18 includes the overhead fan of example 15, wherein the first spoke defines a first notch, the second spoke defines a second notch, and the first notch and the second notch overlap each other.
Example 19 includes the overhead fan of example 15, further comprising a first inboard screw fastening the first spoke to the hub, a first outboard screw fastening the first spoke to the hub, the first fan blade being closer to the first inboard screw than to the first outboard screw, the first inboard screw and the first outboard screw being at opposite sides of the rotational axis, a second inboard screw fastening the second spoke to the hub, and a second outboard screw fastening the second spoke to the hub, the second fan blade being closer to the second inboard screw than to the second outboard screw, the second inboard screw and the second outboard screw being at opposite sides of the rotational axis.
Example 20 includes the overhead fan of example 15, wherein the first spoke defines a first hole, the second spoke defines a second hole, the rotational axis extends through both the first hole and the second hole, and the overhead fan further comprising a hollow shaft extending from the housing, a bearing coupling the hub to the hollow shaft, and a retainer that is vertically elongate, the retainer extending through the hollow shaft, through the first hole in the first spoke, and through the second hole in the second spoke, the retainer including a catch member below both the first hole and the second hole, the catch member have an outermost periphery, at least one of the first hole and the second hole having an innermost periphery, and the rotational axis being closer to the innermost periphery than to the outermost periphery.
Although certain example methods, apparatus, and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the claims of this patent.