1. Field of the Invention
The present invention relates to a fan arranged to produce an axial air current.
2. Description of the Related Art
A housing of a fan disclosed in FIGS. 9 and 10 of WO 2003/075433 has a structure in which two segments thereof are in contact with each other on a lower side of fan blades. The radial thickness of the housing is uniform with respect to an axial direction and a circumferential direction. Both the inside diameter and the outside diameter of the housing gradually increase with decreasing height.
In a casing of a fan disclosed in JP 2003-532026, an inner shell portion is used as a guide surface. The guide surface has the shape of a truncated cone, increasing in diameter with decreasing height, except in an inlet portion thereof. An end edge of each of a plurality of blades extends along the guide surface with a clearance space defined between the end edge and the guide surface. The casing is made up of a radially inner portion and a radially outer portion.
In the case where, as disclosed in WO 2003/075433, the diameter of an inner circumferential surface of a housing is arranged to increase from an inlet side toward an outlet side, and an outer circumferential edge of each blade is arranged to spread radially outward as it extends from the inlet side toward the outlet side, the housing is sometimes constructed of upper and lower segments which are capable of being detached from each other in order to prevent interference between the housing and any blade during an assembling process. However, when the housing is constructed of the upper and lower segments which are capable of being detached from each other, it is difficult to provide a fastening structure for fitting the upper and lower segments to each other while also achieving a small size of the housing. Accordingly, in the fan disclosed in FIGS. 9 and 10 of WO 2003/075433, the fastening structure is not provided, and each of the upper and lower segments of the housing is fixed to a fan installation location through screws. Such a structure, however, does not allow the fan to be treated as a single device, which makes an operation of installing the fan troublesome.
According to a preferred embodiment of the present invention, a fan includes an impeller; a motor portion arranged to rotate the impeller about a central axis extending in a vertical direction; a tubular housing arranged to surround an outer circumference of the impeller; and a plurality of ribs, each of which is arranged to join the motor portion and the housing to each other. The impeller includes a plurality of blades arranged to extend radially outward. An upper opening of the housing is an air inlet while a lower opening of the housing is an air outlet. The housing includes a plurality of decreased thickness portions and a plurality of increased thickness portions arranged alternately in a circumferential direction. A diameter of an inner circumferential surface of the housing is arranged to increase with decreasing height between the air inlet and an axial middle portion of a radially outer edge of each blade. Below the axial middle portion of the radially outer edge of each blade, the diameter of the inner circumferential surface of the housing is arranged to increase with decreasing height, to be uniform, or to increase with decreasing height while being uniform over an area or areas. A distance between the central axis and the radially outer edge of each blade is arranged to increase from the air inlet toward the air outlet. The inner circumferential surface of the housing is arranged to have a minimum radius smaller than a distance between the central axis and an outermost portion of the radially outer edge of each blade. The housing includes an upper housing portion and a lower housing portion arranged to be in contact with a lower portion of the upper housing portion. At a boundary between the upper and lower housing portions, the inner circumferential surface of the housing is arranged to have a radius greater than the distance between the central axis and the outermost portion of the radially outer edge of each blade. The lower housing portion, the ribs, and a base portion of the motor portion are defined by a single continuous monolithic member produced by, for example, an injection molding process. The increased thickness portions include a plurality of component fastening structures defining a fastening structure arranged to fit the upper and lower housing portions to each other.
According to the above preferred embodiment of the present invention, the fastening structure arranged to fit the upper and lower housing portions to each other can be easily provided in the housing, whose inner circumferential surface includes a portion which is inclined with respect to an axial direction, while an increase in the size of the housing is reduced.
The above and other elements, features, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with reference to the attached drawings.
It is assumed herein that an upper side and a lower side in a direction parallel to a central axis J1 of a fan 1 in
The impeller 11 includes a plurality of blades 111 and a tubular portion 112. The diameter of an outer circumferential surface of the tubular portion 112 may be arranged to gradually and slightly increase with decreasing height. The blades 111 are arranged to extend radially outward from the outer circumferential surface of the tubular portion 112. The blades 111 are preferably arranged at a regular pitch in a circumferential direction. Note that, in
The motor portion 12 includes a rotating portion 121, which is a rotating body, and a stationary portion 122, which is a stationary body. The rotating portion 121 is arranged on an upper side of the stationary portion 122. The tubular portion 112 is arranged to cover an outer circumference of the rotating portion 121. The rotating portion 121 preferably includes a rotor holder 211, a rotor magnet 212, and a shaft 213. The rotor holder 211 is preferably made of, for example, a metal material. The rotor holder 211 is substantially in the shape of a covered cylinder and centered on the central axis J1. The rotor magnet 212 is substantially cylindrical, and is fixed to an inner circumferential surface of the rotor holder 211. The shaft 213 is arranged to extend downward from a center of a cover portion of the rotor holder 211. The tubular portion 112 of the impeller 11 may be arranged to cover an upper surface of the rotor holder 211.
The stationary portion 122 preferably includes a base portion 221, a bearing holder 222, a stator 223, a circuit board 224, and two bearings 225. The base portion 221 is a lower portion of the stationary portion 122. The bearing holder 222 is substantially cylindrical. The bearing holder 222 is arranged to project upward from a center of the base portion 221. The stator 223 is attached to an outer circumferential surface of the bearing holder 222. The circuit board 224 is arranged between the base portion 221 and the stator 223. The base portion 221 is fixed to the lower portion of the housing 13 through the ribs 14.
The two bearings 225 are arranged inside the bearing holder 222. The bearings 225 are arranged to support the shaft 213 such that the shaft 213 is rotatable about the central axis J1. Each bearing 225 may preferably be, for example, a ball bearing, a plain bearing, etc. The stator 223 is arranged radially inside the rotor magnet 212. A torque centered on the central axis J1 is generated between the stator 223 and the rotor magnet 212.
The housing 13 is substantially cylindrical. Rotation of the impeller 11 produces a downward air current inside the housing 13. That is, an upper opening of the housing 13 is preferably an air inlet 231, while a lower opening of the housing 13 is preferably an air outlet 232. The housing 13 preferably includes an upper housing portion 131 and a lower housing portion 132. It is assumed in the present preferred embodiment that an axial position at which the diameter of an inner circumferential surface 133 of the housing 13 is smallest is the axial position of the air inlet 231, and that the axial position of a lower end of the inner circumferential surface 133 is the axial position of the air outlet 232.
An upper portion of the lower housing portion 132 is arranged to be in contact with a lower portion of the upper housing portion 131. The upper housing portion 131 is preferably molded, for example, by a resin injection molding process. The lower housing portion 132, the ribs 14, and the base portion 221 are preferably molded, for example, by a resin injection molding process as a single continuous member.
The diameter of the inner circumferential surface 133 of the housing 13 is arranged to increase from the air inlet 231 toward the air outlet 232. As shown in the right-hand side of
Note that the distance between the central axis J1 and the edge 113 may not necessarily be arranged to gradually increase from the air inlet 231 toward the air outlet 232 in strict terms. For example, the edge 113 may include a slight portion parallel or substantially parallel to the central axis J1. Also note that the edge 113 may have a variety of other shapes at an upper end and a lower end thereof.
An outer circumferential surface 134 of the housing 13 is preferably arranged to extend parallel or substantially parallel to the central axis J1 except in an upper end portion and a lower end portion thereof. The radial thickness of the housing 13 is therefore arranged to decrease from the air inlet 231 toward the air outlet 232. A wind channel can thereby be expanded while securing a sufficient rigidity of the housing 13 according to the present preferred embodiment. Note that the outer circumferential surface 134 need not necessarily be parallel to the central axis J1.
Each of an upper end of the upper housing portion 131 and a lower end of the lower housing portion 132 is preferably substantially rectangular or square, for example. In other words, four upper flange portions 136 each of which is arranged to project radially outward are arranged at an upper end of the housing 13, while four lower flange portions 137 each of which is arranged to project radially outward are arranged at a lower end of the housing 13. Circumferential positions of the lower flange portions 137 are preferably arranged to coincide with circumferential positions of the upper flange portions 136. Referring to
Referring to
The housing 13 further includes a fastening structure 24. The fastening structure 24 is preferably includes four component fastening structures 240. In
The lower housing portion 132 includes a plurality of other projecting portions 243 as portions of the fastening structure 24. Hereinafter, the projecting portions 243 will be referred to as “auxiliary projecting portions”. Each of the auxiliary projecting portions 243 is arranged to extend toward the upper housing portion 131. Each of the auxiliary projecting portions 243 is arranged in the vicinity of a separate one of the projecting portions 241, that is, in a separate one of the increased thickness portions 237. The upper housing portion 131 includes a plurality of other recessed portions 244 as portions of the fastening structure 24. Hereinafter, the recessed portions 244 will be referred to as “auxiliary recessed portions”. Each of the auxiliary projecting portions 243 is inserted into a separate one of the auxiliary recessed portions 244.
Circumferential positions of the component fastening structures 240 are preferably arranged to coincide with the circumferential positions of the upper and lower flange portions 136 and 137. In other words, the component fastening structures 240 are arranged in the increased thickness portions 237. The fastening structure 24 can thereby be easily provided while reducing an increase in the radial dimension of the housing 13.
On a bottom left corner of
Relative positions of the projecting portion 241 and the auxiliary projecting portion 243 in one of the component fastening structures 240 are arranged to be different from those in the other component fastening structures 240. This arrangement allows the lower housing portion 132 to be fitted to the upper housing portion 131 only when the lower housing portion 132 is placed in a single predetermined circumferential position relative to the upper housing portion 131. Therefore, the above arrangement according to the present preferred embodiment contributes to preventing a failure in fitting the upper and lower housing portions 131 and 132 to each other.
Referring to
More specifically, each projecting portion 241 includes a first contact surface 245, which is a surface on an upper side of the hole 251. Each recessed portion 242 includes a second contact surface 246, which is an upper surface of the minute projection 252. A direction normal to the first contact surface 245 is preferably oriented away from the upper housing portion 131. A direction normal to the second contact surface 246 is preferably oriented away from the lower housing portion 132. The first contact surface 245 of each projecting portion 241 is preferably in contact with the second contact surface 246 of the corresponding recessed portion 242 when each projecting portion 241 and the corresponding recessed portion 242 are engaged with each other. The upper and lower housing portions 131 and 132 are thereby fitted to each other in the axial direction. Needless to say, the upper and lower housing portions 131 and 132 are preferably fitted to each other in the circumferential direction as well, as a result of the minute projection 252 of each recessed portion 242 being fitted into the hole 251 of the corresponding projecting portion 241.
As described above, a so-called snap-fit structure is preferably adopted in the housing 13. That is, each projecting portion 241 is temporarily bent radially outward when the upper and lower housing portions 131 and 132 are fitted to each other. Therefore, when a force or forces acting in such a direction or directions that the upper and lower housing portions 131 and 132 will be detached from each other is applied to one or both of the upper and lower housing portions 131 and 132, a certain force which bends each projecting portion 241 radially outward is applied to the projecting portion 241. However, the auxiliary projecting portion 243, which is arranged in the vicinity of the projecting portion 241, has been inserted into a corresponding one of the auxiliary recessed portions 244, each of which is in the shape of a hole. Therefore, the auxiliary projecting portion 243 is not able to bend radially outward together with the projecting portion 241. The auxiliary projecting portion 243 thus contributes to preventing the projecting portion 241 from bending.
As a result, even when the snap-fit structure is adopted, an improvement in the strength with which the upper and lower housing portions 131 and 132 are fitted to each other, that is, shock resistance and a load capacity against a radially acting force, is preferably achieved. In addition, there is no need to increase the thickness of the housing in order to improve the fitting strength. This preferably prevents an effect of a change in outside dimensions of the housing on attachment of the housing to a target device. Examples of such an effect include a limitation on applications of the fan, and a need to change the design of the target device. Moreover, the auxiliary projecting portions 243 and the auxiliary recessed portions 244 contribute to preventing an amplification of a vibration of the fastening structure and a damage of the fastening structure.
The above-described beneficial effects can be obtained without each auxiliary recessed portion 244 being in the shape of a hole, as long as a radially outer surface of each auxiliary projecting portion 243 is arranged to make contact with a corresponding one of the auxiliary recessed portions 244. For example, each auxiliary recessed portion 244 may be defined in an inner circumference of the upper housing portion 131, and be arranged in the shape of a groove and arranged to extend upward from the lower end of the upper housing portion 131.
When the upper and lower housing portions 131 and 132 are brought closer to each other, each auxiliary projecting portion 243 is preferably inserted into a groove 247 defined in the outer circumferential surface of the upper housing portion 131 as illustrated in
As described above, the radial thickness of the housing 13 gradually decreases with decreasing height. If a recessed portion is defined in a side wall portion of the housing 13, the thickness of the side wall portion of the housing 13 preferably decreases locally. Therefore, the recessed portions 242 and the auxiliary recessed portions 244 are preferably defined in the upper housing portion 131, where it is easy to secure a sufficient thickness of the housing 13. Additionally, the projecting portions 241 and the auxiliary projecting portions 243 do not require a large thickness of the housing 13. Therefore, the projecting portions 241 and the auxiliary projecting portions 243 are preferably defined in the lower housing portion 132. It is thus made easier to provide the fastening structure 24, which requires a large thickness, in the housing 13. The radial thickness of each decreased thickness portion 236 is arranged to be substantially uniform in a lower portion of the housing 13.
In addition, the projecting portions 241 and the auxiliary projecting portions 243 are arranged at different circumferential positions. Therefore, the projecting portions 241 and the auxiliary projecting portions 243 do not interfere with each other in the radial direction. This makes it possible to achieve a reduction in the thickness of the housing 13 at the boundary 135.
As shown in the right-hand side of
In the housing 13, a radially outer surface of each of the projecting portions 241 defines a portion of the outer circumferential surface 134 of the housing 13. In other words, the distance from the radially outer surface of each projecting portion 241 to the central axis J1 is preferably equal or substantially equal to the distance from the central axis J1 to the outer circumferential surface 134 of the housing 13. Meanwhile, the radially outer surface of each of the auxiliary projecting portions 243 is arranged radially inward of the outer circumferential surface 134 of the housing 13. Thus, when the screws are inserted into the holes 138 of the upper and lower flange portions 136 and 137, it is possible to prevent the screws from interfering with the component fastening structures 240, which thus facilitates an operation of installing the fan 1. Moreover, since it is possible to increase the outside diameter of the housing 13 insofar as the housing 13 does not make contact with the screws, it is possible to achieve an increase in the inside diameter of the housing 13.
Note that prevention of interference between the component fastening structures 240 and the screws can be achieved when the radially outer surface of each of the projecting portions 241 either defines a portion of the outer circumferential surface of the housing 13 or is positioned radially inward of the outer circumferential surface of the housing 13, and, in addition, the radially outer surface of each of the auxiliary projecting portions 243 either defines a portion of the outer circumferential surface of the housing 13 or is positioned radially inward of the outer circumferential surface of the housing 13.
In
In the case of
When the distance between the upper end of the joint range 261 and the upper end of the lower housing portion 132 is smaller than the distance between the lower end of the joint range 261 and the lower end of the lower housing portion 132, each stationary vane 14 is joined to an axially upper portion of the lower housing portion 132. As a result, a reduction in an unwanted extent of an inner circumferential surface of the lower housing portion 132 on an upper side of each stationary vane 14 is achieved.
In the case of
A section of the inner circumferential surface 133 of a housing 13a taken along a plane including the central axis J1 is preferably a straight line which becomes progressively more distant from the central axis J1 with decreasing height between the air inlet 231 and the air outlet 232. Hereinafter, a section of the inner circumferential surface 133 taken along the plane including the central axis J1 will be referred to simply as a “section of the inner circumferential surface 133”. A portion of a section of the inner circumferential surface 133 of a housing 13b, the portion extending between the air inlet 231 and the air outlet 232, preferably has an angle of inclination with respect to the central axis J1 becoming progressively smaller with decreasing height. This arrangement contributes to expanding the wind channel. A portion of a section of the inner circumferential surface 133 of a housing 13c, the portion extending between the air inlet 231 and the air outlet 232, preferably has an angle of inclination with respect to the central axis J1 becoming progressively larger with decreasing height.
A portion of a section of the inner circumferential surface 133 of a housing 13d, the portion extending from the air inlet 231 to an upper portion of the lower housing portion 132, is preferably a straight line which becomes progressively more distant from the central axis J1 with decreasing height. A portion of the section of the inner circumferential surface 133 of the housing 13d, the portion extending in a lower portion of the lower housing portion 132, is preferably a straight line parallel or substantially parallel to the central axis J1. A portion of a section of the inner circumferential surface 133 of a housing 13e, the portion extending from the air inlet 231 to a lower portion of the upper housing portion 131, is preferably a straight line which becomes progressively more distant from the central axis J1 with decreasing height. A portion of the section of the inner circumferential surface 133 of the housing 13e, the portion extending downward from the lower portion of the upper housing portion 131, is preferably a straight line parallel or substantially parallel to the central axis J1.
A housing 13f is preferably identical to the housing 13a except that a portion of a section of the inner circumferential surface 133 of the housing 13f, the portion being near the air inlet 231, is preferably a smooth curved line. A housing 13g is preferably identical to the housing 13a except that a portion of a section of the inner circumferential surface 133 of the housing 13g, the portion being near the air outlet 232, is a smooth curved line. Note that at least one of the air inlet 231 and the air outlet 232 may be arranged to also have a smooth shape in the other examples of the housing 13.
A portion of a section of the inner circumferential surface 133 of a housing 13h, the portion extending from the air inlet 231 to the boundary 135, is preferably a straight line which becomes progressively more distant from the central axis J1 with decreasing height. A portion of the section of the inner circumferential surface 133 of the housing 13h, the portion extending downward from the boundary 135, is preferably a straight line parallel or substantially parallel to the central axis J1. A housing 13i is preferably identical to the housing 13d except that a lower portion of the housing 13i is elongated downward.
In the case where the section of the inner circumferential surface 133 includes, between the air inlet 231 and the air outlet 232, a straight line which becomes progressively more distant from the central axis J1 with decreasing height, as is the case with each of the housings 13a and 13d to 13i, it is easy to design the housing 13. A portion of the section of the inner circumferential surface 133, which is parallel or substantially parallel to the central axis J1, need not necessarily be arranged at a lower end. In general terms, the diameter of the inner circumferential surface 133 of the housing 13 is arranged to increase with decreasing height between the air inlet 231 and an axial middle portion of the radially outer edge of each of the blades 111. In addition, below the axial middle portion of the radially outer edge of each blade 111, the diameter of the inner circumferential surface 133 is preferably arranged to increase with decreasing height, to be uniform, or to increase with decreasing height while being uniform over an area or areas. That is, the inner circumferential surface 133 preferably does not include a portion whose diameter decreases with decreasing height.
Therefore, the radial thickness of the housing 13 is not necessarily required to be arranged to gradually decrease with decreasing height. Note, however, that the radial thickness of the housing 13 is preferably arranged to decrease from the air inlet 231 toward the air outlet 232, or to decrease from the air inlet 231 toward the air outlet 232 while being uniform over an area or areas. A portion of the housing 13 which has a uniform thickness is preferably arranged in the lower portion of the housing 13.
Note that the housing 13 may be arranged such that the upper housing portion 131 includes the projecting portions 241 while the lower housing portion 132 includes the recessed portions 242. In this case, each projecting portion 241 is arranged to extend from the upper housing portion 131 toward the lower housing portion 132. Also note that the upper housing portion 131 may include the auxiliary projecting portions 243 with the lower housing portion 132 including the auxiliary recessed portions 244. In this case, each auxiliary projecting portion 243 is arranged to extend from the upper housing portion 131 toward the lower housing portion 132. Therefore, the projecting portions 241 and the auxiliary projecting portions 243 may be included in the lower housing portion 132 and the upper housing portion 131, respectively, for example.
To express the upper and lower housing portions 131 and 132 in general terms as “housing segments”, one of the housing segments (hereinafter referred to as a “first housing segment”) preferably includes the plurality of projecting portions 241 each of which is arranged to extend toward the other housing segment (hereinafter referred to as a “second housing segment”), while the second housing segment preferably includes the plurality of recessed portions 242 each of which is arranged to have a separate one of the projecting portions 241 fitted thereinto. In addition, the first housing segment includes the plurality of auxiliary projecting portions 243, each of which is arranged to extend toward the second housing segment in the vicinity of a separate one of the projecting portions 241. Also, the second housing segment includes the plurality of auxiliary recessed portions 244, each of which is arranged to have a separate one of the auxiliary projecting portions 243 fitted thereinto. Alternatively, the second housing segment may include the plurality of auxiliary projecting portions 243, each of which is arranged to extend toward the first housing segment in the vicinity of a separate one of the recessed portions 242, with the first housing segment including the plurality of auxiliary recessed portions 244, each of which is arranged to have a separate one of the auxiliary projecting portions 243 fitted thereinto, as shown in
Note that the projecting portions 241 and the recessed portions 242 may be arranged in an inner circumference of the housing 13. In this case, when the upper and lower housing portions 131 and 132, which are detached from each other, are brought closer to each other in the axial direction, each of the projecting portions 241 is preferably brought into contact with an opposing one of the upper and lower housing portions 131 and 132, is thereby once elastically deformed radially inward, and then returns radially outward, so that the projecting portion 241 is brought into axial engagement with a corresponding one of the recessed portions 242.
The projecting portions 321 and 322 are placed one upon the other in the axial direction, and these projecting portions 321 and 322 are inserted into the hole 311 of the clip 31, whereby the upper and lower housing portions 131 and 132 are fitted to each other. The component fastening structure 240 is preferably provided in each of increased thickness portions 237 in a manner similar to that illustrated in
In the component fastening structure 240, a projecting portion 33 arranged to project toward the upper housing portion 131 is arranged in an upper end of the lower housing portion 132, while a recessed portion 34 is arranged in a lower portion of the upper housing portion 131. The recessed portion 34 is arranged to extend upward from a lower end of the upper housing portion 131, and includes a portion 341 which further extends to the right in
The projecting portion 33 is preferably inserted into the recessed portion 34, and the projecting portion 33 is then slid to the right in
According to the structure of the component fastening structure 240 illustrated in
While preferred embodiments of the present invention have been described above, it is to be understood that the present invention is not limited to the above-described preferred embodiments.
Other structures may be adopted as the fastening structure 24. For example, each projecting portion 241 may include, at the tip thereof, a protruding portion arranged to protrude radially inward, with each recessed portion 242 including a minute recessed portion arranged to be recessed radially inward. Moreover, the auxiliary projecting portions and the auxiliary recessed portions may be additionally provided in each of the structure illustrated in
A variety of other structures may be adopted as the structure designed to permit the lower housing portion 132 to be fitted to the upper housing portion 131 only when the lower housing portion 132 is placed in a single predetermined circumferential position relative to the upper housing portion 131. For example, a pair of one of the auxiliary projecting portions 243 and a corresponding one of the auxiliary recessed portions 244 may be arranged to differ in shape from the other auxiliary projecting portions 243 and the other auxiliary recessed portions 244.
Each of the upper and lower ends of the housing 13 need not necessarily be rectangular or square, but may instead be circular or in other shapes. The labyrinth structure defined between the upper and lower housing portions 131 and 132 may be modified in a variety of manners. For example, a plurality of radial shoulders may be arranged at the boundary 135. Each rib 14 may be arranged in the shape of a simple bar.
Features of the above-described preferred embodiments and the modifications thereof may be combined appropriately as long as no conflict arises.
The present invention is applicable to fans used for a variety of applications.
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 from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.
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