Patent Grant
9551346
1. Field of the Invention
The present invention relates to a serial axial fan, and more specifically to a serial axial fan including two impellers arranged in series.
2. Description of the Related Art
Blower fans are widely used to cool household electrical appliances, office equipment, industrial equipment, and so on, for air conditioning or ventilation, or as blowers for use in vehicles and so on. As such a blower fan, a serial axial fan including two axial fans connected in series along a central axis is known. For example, a counter-rotating axial blower is disclosed in JP-A 2004-278370. In this blower, a first impeller and a second impeller are arranged in series along a central axis inside a housing. The first and second impellers are arranged to rotate in mutually opposite directions.
JP-A 2002-21777 discloses a jet fan installed on a ceiling of a tunnel. The jet fan includes a first impeller, a second impeller, and reverse rotation means arranged to cause the first and second impellers to rotate in mutually opposite directions. Each of the first and second impellers is arranged to be reversible in rotation. JP-A 2009-250225 discloses an axial blower. The axial blower includes two impellers arranged in series, and is arranged to be capable of rotating in both a normal direction and a reverse direction. Each of rotor blades of each impeller has a curved cross-section.
The serial axial fan is typically arranged to send air in a fixed direction as is the case with the counter-rotating axial blower disclosed in JP-A 2004-278370. Therefore, each blade is arranged to have a shape appropriate for sending air in the single fixed direction. In the counter-rotating axial blower disclosed in JP-A 2004-278370, for example, each of front and rear blades has a curved shape with a concave portion thereof being open toward an outlet side.
Meanwhile, depending on a purpose of the blower fan, the blower fan is demanded to be capable of sending air in both directions equivalently, and an increase in static pressure is demanded for each of the case where the blower fan sends air in one direction and the case where the blower fan sends air in an opposite direction. In the case where blower fans having the same design are installed on a variety of devices, for example, it is desirable that the blower fans should be capable of sending air in both directions. However, a blower fan designed to send air in a single fixed direction suffers a significant decrease in a static pressure characteristic when sending air in an opposite direction.
The jet fan disclosed in JP-A 2002-21777 is capable of sending air in both directions. Each blade of the jet fan is in the shape of a flat plate, and therefore, high static pressure cannot be obtained. The axial blower disclosed in JP-A 2009-250225 is also capable of sending air in both directions. However, because the two impellers are arranged to rotate in the same direction when viewed along a central axis, an outgoing air current has a large whirl component and spreads radially. Therefore, high static pressure cannot be obtained.
Preferred embodiments of the present invention are configured to easily obtain high static pressure both in the case where a serial axial fan sends a fluid in one direction and in the case where the serial axial fan sends a fluid in an opposite direction.
A serial axial fan according to a preferred embodiment of the present invention includes a first motor portion including a first rotating portion; a first impeller fixed to the first rotating portion of the first motor portion; a second motor portion arranged along a central axis of the first motor portion, and including a second rotating portion; a second impeller fixed to the second rotating portion of the second motor portion; a tubular wind channel portion arranged to surround outer circumferences of the first and second impellers; and a plurality of support ribs arranged to join the wind channel portion to both the first and second motor portions. The first impeller includes a plurality of first blades arranged in a circumferential direction about the central axis, while the second impeller includes a plurality of second blades arranged in the circumferential direction. Each of the first and second impellers is configured to be rotatable in both directions, and a rotation direction of the second impeller is opposite to a rotation direction of the first impeller. A surface of each of the plurality of first blades, the surface facing the second impeller, is concave. A surface of each of the plurality of second blades, the surface facing the first impeller, is concave.
Preferred embodiments of the present invention make it easy to obtain high static pressure both in the case where the serial axial fan sends a fluid in one direction and in the case where the serial axial fan sends a fluid in an opposite direction.
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 or substantially parallel to a central axis J1 of a serial axial fan 1 in
The serial axial fan 1 is configured to be capable of sending air both upward and downward. That is, the serial axial fan 1 is arranged to be capable both of taking in air from the upper side in
The first axial fan 11 preferably includes a first impeller 111, a first motor portion 112, a first housing 113, and a plurality of first rib components 114. The first motor portion 112 is arranged to rotate the first impeller 111 about the central axis J1 to generate air current. The first housing 113 is preferably tubular and arranged to surround an outer circumference of the first impeller 111. The first rib components 114 are preferably arranged on a lower side of the first impeller 111. The first rib components 114 are arranged to support the first motor portion 112.
The first impeller 111 includes a plurality of first blades 121 and a cup 122. The cup 122 preferably has a shape of a covered cylinder or substantially a covered cylinder, and is arranged to cover an outside of the first motor portion 112. The first blades 121 are arranged to extend radially outward from an outside surface of the cup 122, and are arranged in a circumferential direction. The first blades 121 may be arranged either at regular intervals or at irregular intervals. The first motor portion 112 includes a first rotating portion 131, which is a rotating body, and a first stationary portion 132, which is a stationary body. The first rotating portion 131 is arranged on an upper side of the first stationary portion 132.
In
The first rotating portion 131 preferably includes a metallic yoke 141, which preferably has a shape of a covered cylinder or substantially a covered cylinder, a cylindrical or substantially cylindrical rotor magnet 142, and a shaft 143. The rotor magnet 142 is fixed to an inside of the yoke 141. The shaft 143 is arranged to project downward from a center of a top portion of the yoke 141. The first impeller 111 is fixed to the first rotating portion 131 such that the cup 122 covers the yoke 141.
The first stationary portion 132 preferably includes a disk-shaped or substantially disk-shaped base portion 151, a bearing holding portion 152, a stator 153, and a circuit board 154. The bearing holding portion 152 is cylindrical or substantially cylindrical, and is arranged to project upward from a center of the base portion 151. The stator 153 is fitted to an outer circumference of the bearing holding portion 152. The circuit board 154 is arranged on a lower side of the stator 153, and is electrically connected to the stator 153.
The first housing 113, the base portion 151, and the first rib components 114 are preferably defined as one monolithic piece by a resin injection molding process, for example. This results in a reduction in production costs of parts. The first housing 113 and the base portion 151 are joined to each other through the first rib components 114.
The stator 153 is arranged radially opposite the rotor magnet 142. A torque centered on the central axis J1 is produced between the stator 153 and the rotor magnet 142. Ball bearings 155 and 156, each of which is a bearing mechanism, are arranged inside an upper portion and a lower portion, respectively, of the bearing holding portion 152. The shaft 143 is inserted in the bearing holding portion 152, and is rotatably supported by the ball bearings 155 and 156.
The second axial fan 21 is preferably arranged to have the same structure as that of the first axial fan 11 turned upside down except in the shape of a portion thereof. The second axial fan 21 preferably includes a second impeller 211, a second motor portion 212, a second housing 213, and a plurality of second rib components 214. The second motor portion 212 is arranged to rotate the second impeller 211 to generate air current traveling in the same direction as that of the air current generated by the first impeller 111. A rotation direction of the first impeller 111 and a rotation direction of the second impeller 211 are opposite to each other when viewed in one direction along the central axis J1. Each of the first and second impellers 111 and 211 is rotatable in both directions.
The first and second motor portions 112 and 212 are arranged along the central axis J1. The central axis J1 coincides with both a central axis of the first motor portion 112 and a central axis of the second motor portion 212. In other words, the second motor portion 212 is arranged along the central axis of the first motor portion 112.
The second housing 213 is tubular and arranged to surround an outer circumference of the second impeller 211. The second rib components 214 are arranged on an upper side of the second impeller 211. The second rib components 214 are arranged to support the second motor portion 212. The second housing 213 is joined to the first housing 113 along the central axis J1. Joining of the first and second housings 113 and 213 may be accomplished by a variety of methods. For example, the first housing 113 may be provided with a plurality of projecting portions, each of which is arranged to extend toward the second housing 213, and the first and second housings 113 and 213 may be joined to each other through snap fitting using elastic deformation of the projecting portions. Alternatively, the first and second housings 113 and 213 may be joined to each other through fasteners, such as, for example, screws, clips, etc. A tubular wind channel portion 110 is defined as a result of the joining of the first and second housings 113 and 213. The wind channel portion 110 is arranged to surround outer circumferences of the first and second impellers 111 and 211.
The second impeller 211 includes a plurality of second blades 221 and a cup 222. The cup 222 is cylindrical or substantially cylindrical and includes a bottom, and is arranged to cover an outside of the second motor portion 212. The second blades 221 are arranged to extend radially outward from an outside surface of the cup 222, and are arranged in the circumferential direction. The second blades 221 may be arranged either at regular intervals or at irregular intervals. The second motor portion 212 is preferably arranged to have the same or substantially the same structure as that of the first motor portion 112. The second motor portion 212 preferably includes a second rotating portion 231, which is a rotating body, and a second stationary portion 232, which is a stationary body. The second rotating portion 231 is arranged on a lower side of the second stationary portion 232.
The second rotating portion 231 preferably includes a metallic yoke 241, which is cylindrical or substantially cylindrical and includes a bottom, a substantially cylindrical rotor magnet 242, and a shaft 243. The rotor magnet 242 is fixed to an inside of the yoke 241. The shaft 243 is arranged to project upward from a center of the yoke 241. The second impeller 211 is fixed to the second rotating portion 231 such that the cup 222 covers the yoke 241.
The second stationary portion 232 preferably includes a disk-shaped or substantially disk-shaped base portion 251, a bearing holding portion 252, a stator 253, and a circuit board 254. The bearing holding portion 252 is preferably cylindrical or substantially cylindrical, and is arranged to project downward from a center of the base portion 251. The stator 253 is fitted to an outer circumference of the bearing holding portion 252. The circuit board 254 is arranged on an upper side of the stator 253, and is electrically connected to the stator 253.
The second housing 213, the base portion 251, and the second rib components 214 are preferably defined as one monolithic piece by a resin injection molding process, for example. This results in a reduction in the production costs of the parts. The second housing 213 and the base portion 251 are joined to each other through the second rib components 214.
The stator 253 is arranged radially opposite the rotor magnet 242. A torque centered on the central axis J1 is produced between the stator 253 and the rotor magnet 242. Ball bearings 255 and 256, each of which is a bearing mechanism, are arranged inside a lower portion and an upper portion, respectively, of the bearing holding portion 252. The shaft 243 is inserted in the bearing holding portion 252, and is rotatably supported by the ball bearings 255 and 256.
The first rib components 114 are arranged in a radial manner. Each first rib component 114 is arranged to extend straight in a radial direction. The second rib components 214 are also arranged in a radial manner. Each second rib component 214 is arranged to extend straight or substantially straight in a radial direction. The number of first rib components 114 and the number of second rib components 214 are preferably equal or substantially equal to each other. As illustrated in
Each one of the first rib components 114 and a corresponding one of the second rib components 214 are arranged to be in axial contact with or in close axial proximity to each other to together define a single support rib 120. That is, a plurality of support ribs 120 are preferably arranged in a radial manner between the first and second impellers 111 and 211, and each support rib 120 is arranged to extend straight in a radial direction. An extension line of a center line of each support rib 120 passes through the central axis J1. The support ribs 120 are arranged to join the wind channel portion 110 to both the first and second motor portions 112 and 212. The first and second motor portions 112 and 212 are thus supported with respect to the wind channel portion 110.
Referring to
Referring to
Four conducting wires 158, for example, are preferably drawn out of the first motor portion 112. Similarly, four conducting wires 258, for example, are preferably drawn out of the second motor portion 212. Two of the four conducting wires are preferably power lines. Another one of the four conducting wires is preferably used to output a signal corresponding to a rotation speed of the motor portion to an outside. The remaining one of the four conducting wires is preferably used to input a signal which controls the rotation speed from the outside into the motor portion. A PWM (Pulse Width Modulation) signal is preferably used as the signal which controls the rotation speed. A rotation direction of the rotating portion is different depending on whether a pulse width of the signal is below a predetermined value or exceeds the predetermined value. A drive circuit arranged to change the rotation direction and the rotation speed in accordance with the pulse width is preferably arranged on each of the circuit boards 154 and 254.
The surface 161 only needs to be concave as a whole, and the entire surface 161 does not need to be concave in an exact sense. The same is true of the surface 261. A surface 162 of each first blade 121 opposite to the surface 161 is preferably convex. A surface 262 of each second blade 221 opposite to the surface 261 is also preferably convex. Each of the surfaces 162 and 262 only needs to be convex as a whole, and each of the entire surfaces 162 and 262 does not need to be convex in an exact sense.
The sections of the blades whose shapes have been explained above are sections of the blades taken at radially outer positions. The radial positions of the sections do not need to be limited to any particular positions in principle. The above-described shapes may not necessarily be applied to the shapes of sections of the blades taken at bases of the blades or the like. For example, the base of each blade may be in the shape of a flat plate, or may be curved in a direction opposite to that in which another portion of the blade is curved.
In the case where the air is sent downward as indicated by arrow 91, the first blade 121 moves from the left to the right and the second blade 221 moves from the right to the left as indicated by arrows 911 and 912, respectively. In the case where the air is sent upward as indicated by arrow 92, the first blade 121 moves from the right to the left and the second blade 221 moves from the left to the right as indicated by arrows 922 and 921, respectively. The number of first blades 121 and the number of second blades 221 are preferably equal to each other. This makes it easier to make air-blowing performance in the case where the serial axial fan 1 sends the air downward and air-blowing performance in the case where the serial axial fan 1 sends the air upward close to each other. Moreover, the axial dimension of each of the first blades 121, that is, a distance between an upper end and a lower end of each first blade 121, is preferably arranged to be equal to the axial dimension of each of the second blades 221. This also makes it easier to make the air-blowing performance in the case where the serial axial fan 1 sends the air downward and the air-blowing performance in the case where the serial axial fan 1 sends the air upward close to each other. Preferably, the first and second impellers 111 and 211 are arranged to be symmetric with respect to a plane which is perpendicular or substantially perpendicular to the central axis J1 and which divides a space between the first and second motor portions 112 and 212 into two equal or substantially equal portions.
As illustrated schematically in
Regarding the preferred embodiment illustrated in
Whether each blade is warped forward or backward with respect to the rotation direction is determined appropriately in accordance with a desired air-blowing performance. Note, however, that the direction in which each first blade 121 is warped with respect to the rotation direction of the first impeller 111 is arranged to be opposite to the direction in which each second blade 221 is warped with respect to the rotation direction of the second impeller 211, i.e., the rotation direction opposite to the rotation direction of the first impeller 111. In other words, each first blade 121 and each second blade 221 are preferably arranged to be warped in the same direction when viewed from above.
In still other words, the leading edge of each of the first blades 121 with respect to the rotation direction of the first impeller 111 and a trailing edge of each of the second blades 221 with respect to the rotation direction of the second impeller 211 are located on the same side of the blades in a plan view, and the leading edge of the first blade 121 and the trailing edge of the second blade 221 are warped in different directions with respect to the rotation directions of the first and second impellers 111 and 211, respectively. This makes it easy to make the air-blowing performance in the case where the serial axial fan 1 sends the air downward and the air-blowing performance in the case where the serial axial fan 1 sends the air upward close to each other.
The leading edge and the trailing edge of each of the first and second blades 121 and 221 may be arranged to be warped in both circumferential directions with increasing distance from the central axis J1. In this case, the leading edge is arranged to be warped forward with respect to the rotation direction, while the trailing edge is arranged to be warped backward with respect to the rotation direction. That is, each of the first and second blades 121 and 221 may be fan-shaped in a plan view. Conversely, in a plan view, the leading edge and the trailing edge of each of the first and second blades 121 and 221 may be arranged to be warped backward and forward, respectively, with respect to the rotation direction with increasing distance from the central axis J1. In this case, each blade tapers toward a tip.
In
Moreover, in order to make the air-blowing performance in the case where the serial axial fan 1 sends the air downward and the air-blowing performance in the case where the serial axial fan 1 sends the air upward close to each other, it is preferable that the overall shape of the support ribs 120 as viewed from the direction of the first impeller 111 along the central axis J1 should be identical to the overall shape of the support ribs 120 as viewed from the direction of the second impeller 211 along the central axis J1. Here, the term “overall shape” comprehends the arrangement of the support ribs 120 and the three-dimensional shape of each support rib 120.
The rotation control portion 3 preferably includes air-blowing direction setting portion 31 and a rotation speed setting portion 32. The air-blowing direction setting portion 31 is arranged to set air-blowing direction of the serial axial fan 1 in accordance with an input from an outside. Note that, in the case where the air-blowing direction is previously set to only one direction in the device on which the serial axial fan 1 is installed, the air-blowing direction setting portion 31 may be omitted.
The rotation speed setting portion 32 is arranged to set rotation speeds of the first and second axial fans 11 and 12 individually. Only one value, e.g., a proportion to a maximum rotation speed, is inputted from the device into the rotation speed setting portion 32. Based on this value, the rotation speed of the axial fan on the inlet side and the rotation speed of the axial fan on an outlet side are set by the rotation speed setting portion 32.
Here, in the serial axial fan 1, the rotation speed of one of the first and second impellers 111 and 211 which is located on the inlet side, i.e., on the upstream side, is preferably set higher than the rotation speed of the other impeller 111 or 211 located on the outlet side, i.e., on the downstream side, by the rotation speed setting portion 32. Suppose, for example, that a maximum rotation speed of the axial fan on the inlet side and a maximum rotation speed of the axial fan on the outlet side are previously set to 10,000 min−1 (revolutions/minute) and 7,000 min−1, respectively, and that a signal that indicates 50% rotation is inputted from the device into the rotation control portion 3. In this case, the rotation speed setting portion 32 inputs a rotation control signal that indicates rotation at 5,000 min−1 to the axial fan on the inlet side and a rotation control signal that indicates rotation at 3,500 min−1 to the axial fan on the outlet side.
In the serial axial fan 1, the surface of each of the blades of the impeller on the inlet side, the surface facing the impeller on the outlet side, is concave, and therefore, the axial fan on the inlet side exhibits higher air blowing efficiency than the axial fan on the outlet side. Therefore, an improvement in the air blowing efficiency of the serial axial fan 1 as a whole is easily achieved by arranging the rotation speed of the axial fan on the inlet side to be higher than the rotation speed of the axial fan on the outlet side. Moreover, the different rotation speeds of the two axial fans result in a difference in fundamental frequency of noises caused by the respective fans, such that desirable frequency characteristics of the noises are obtained.
Note that the rotation control portion 3 may be a portion of the serial axial fan 1. Furthermore, the rotation control portion 3 may be arranged on each of the circuit boards 154 and 254 of the serial axial fan 1 individually. In this case, the signal is inputted from the device into each of the first and second axial fans 11 and 21, and the rotation control portion arranged in each axial fan generates the rotation control signal in accordance with this signal, for example.
Note, however, that a small region 165 defining a portion of the surface 162 is concave. The region 165 is preferably a region in the surface 162 which is located forward with respect to a rotation direction of the first impeller 111 when the first impeller 111 sends air out of an wind channel portion 110, that is, when a first axial fan 11 is a fan on an outlet side. Similarly, a small region 265 defining a portion of the surface 262 is concave. The region 265 is preferably a region in the surface 262 which is located forward with respect to a rotation direction of the second impeller 211 when the second impeller 211 sends air out of the wind channel portion 110, that is, when a second axial fan 21 is the fan on the outlet side. This contributes to reducing or preventing a decrease in air blowing efficiency of a serial axial fan 1 as a whole owing to the fan on the outlet side. A region 166 on the first blade 121 on an opposite side with respect to the region 165 is convex. A region 266 on the second blade 221 on an opposite side with respect to the region 265 is convex.
The present invention is not limited to the serial axial fan 1 according to the above-described preferred embodiments and modifications thereof. A variety of additional modifications are also possible within the scope of the present invention.
Concavity and convexity of each of the upper and lower surfaces of each blade as a whole in a cross-section can be defined in a variety of manners. A variety of methods of definition can be adopted as long as the methods are usable to indicate an approximate state of bending of the surface as a whole. For example, a straight line that joins both circumferential end points of the blade in the cross-section may be defined as a chord, and a surface equidistant from the upper and lower surfaces of the blade may be defined as a middle surface of the blade. Then, each of the upper and lower surfaces of the blade may be defined as being convex or concave to a side of the chord on which more than half an entire region of the middle surface exists. Also note that, as mentioned above, the blade may be concave at one radial position and convex at another radial position in the cross-section.
Note that the air-blowing performance in the case where the serial axial fan 1 sends the air downward and the air-blowing performance in the case where the serial axial fan 1 sends the air upward may be different from each other as long as specifications of the serial axial fan 1 are met. Therefore, the number of first blades 121 and the number of second blades 221 may be different from each other.
In the above-described preferred embodiments and modifications thereof, the rotation speed of the impeller on the inlet side is configured to be higher than the rotation speed of the impeller on the outlet side. Note, however, that rotation control according to preferred embodiments of the present invention is not limited to the rotation control as described above. For example, the rotation speeds of both the impellers may be configured to be equal or substantially equal to each other. Furthermore, the rotation speed of the impeller on the inlet side may be arranged to be lower than the rotation speed of the impeller on the outlet side.
Note that each support rib 120 may not necessarily be straight. Because the first and second impellers 111 and 211 are preferably arranged to be symmetric or substantially symmetric with respect to a plane perpendicular or substantially perpendicular to the central axis J1, each support rib 120 can be curved without significantly affecting a difference between the air-blowing performance in the case where the serial axial fan 1 sends the air downward and the air-blowing performance in the case where the serial axial fan 1 sends the air upward. Also note that the support ribs 120 may not necessarily be arranged at regular intervals in the circumferential direction. Also note that each support rib 120 may be defined as one unitary body without the first and second rib components 114 and 214.
Also note that the first and second rib components 114 and 214 may not necessarily be located between the first and second motor portions 112 and 212. For example, it may be so arranged that the first rotating portion 131, the first stationary portion 132, the second rotating portion 231, and the second stationary portion 232 are arranged in the order named along the central axis J1, and the first impeller 111, the first rib components 114, the second impeller 211, and the second rib components 214 are arranged in the order named. In this case, each of the first and second rib components 114 and 214 functions as the support rib. Needless to say, the first rib components 114, the first impeller 111, the second impeller 211, and the second rib components 214 may be arranged in the order named.
Also note that each support rib 120 may be arranged to extend in a direction inclined with respect to a plane perpendicular to the central axis J1.
Also note that the wind channel portion 110 may be arranged to have a circular or substantially circular external shape. Also note that the wind channel portion 110 may be defined as one unitary body, for example.
It may be so arranged that the yoke is cylindrical and the shaft is joined to a center of the cup. Alternatively, it may be so arranged that the cup is molded in a cylindrical shape, and is fixed to an outer circumferential surface of the yoke which is in or substantially in the shape of a covered cylinder.
Also note that a fluid which is caused to flow by the serial axial fan 1 is not limited to the air. The fluid may be a different type of gas or a liquid.
Features of the above-described preferred embodiments and the modifications thereof may be combined appropriately as long as no conflict arises.
Various preferred embodiments of the present invention are applicable to a variety of axial fans arranged to cause a fluid to flow. A serial axial fan according to a preferred embodiment of the present invention is preferably used, for example, as a fan to cool an electronic device or the like.
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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|---|---|---|---|
| 2013-121198 | Jun 2013 | JP | national |
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| Number | Date | Country | |
|---|---|---|---|
| 20140363272 A1 | Dec 2014 | US |
