U.S. patent application number 09/532054 was filed with the patent office on 2002-02-07 for fan unit, fan assembly, and an apparatus comprising the fan assembly.
Invention is credited to Kosugi, Naofumi.
Application Number | 20020015648 09/532054 |
Document ID | / |
Family ID | 17619850 |
Filed Date | 2002-02-07 |
United States Patent
Application |
20020015648 |
Kind Code |
A1 |
Kosugi, Naofumi |
February 7, 2002 |
FAN UNIT, FAN ASSEMBLY, AND AN APPARATUS COMPRISING THE FAN
ASSEMBLY
Abstract
The fan unit has a fan 150, fan housing frame 110, and fan
housing cover 170. The fan 150 has a frame 151, a fan blade 152
freely rotatable to the frame, and a mounting hole 153 disposed to
the frame. The box frame 110 has an opening 115 on one (top) side
for disposing the fan 150 internally thereto, a ventilation opening
in the opposite (bottom) side, and engaging members 117 formed on
an inside wall for fitting into a mounting hole 153 of the
internally disposed fan and thereby determining the fan position.
The cover 170 has a ventilation opening, and an engaging protrusion
on an inside wall for fitting into a mounting hole 153 of the fan
internally disposed to the fan housing frame. The fan housing cover
170 thus engages the fan housing frame 110 so as to cover the
opening 115 into which the fan is installed, and in conjunction
with the fan housing frame 110 secures the fan in the fan housing
frame.
Inventors: |
Kosugi, Naofumi; (Kawasaki,
JP) |
Correspondence
Address: |
ARMSTRONG,WESTERMAN, HATTORI,
MCLELAND & NAUGHTON, LLP
1725 K STREET, NW, SUITE 1000
WASHINGTON
DC
20006
US
|
Family ID: |
17619850 |
Appl. No.: |
09/532054 |
Filed: |
March 21, 2000 |
Current U.S.
Class: |
417/423.14 ;
165/80.3; 416/247R |
Current CPC
Class: |
F04D 25/166 20130101;
F04D 29/602 20130101 |
Class at
Publication: |
417/423.14 ;
165/80.3; 416/247.00R |
International
Class: |
F04B 017/00; F04B
035/04 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 30, 1999 |
JP |
11-280067 |
Claims
What is claimed is:
1. A fan unit comprising: a fan having a frame, a fan blade freely
rotatable to said frame, and an installation member disposed to
said frame; a fan housing frame having an opening in a top surface
for disposing internally thereto said fan, a ventilation opening in
a bottom surface, and an engaging member formed on an inside wall
for engaging said installation member of the internally disposed
fan and determining said fan position; and a fan housing cover for
engaging said fan housing frame so as to cover the top surface
opening in said fan housing frame, and securing said fan disposed
internally to said fan housing frame in conjunction with said fan
housing frame, said fan housing cover having a ventilation opening,
and an engaging member on an inside wall for engaging said
installation member of the fan internally disposed to said fan
housing frame.
2. A fan unit according to claim 1, further comprising: a finger
guard formed to said bottom surface opening of the fan housing
frame; and a finger guard formed to said opening in the fan housing
cover.
3. A fan unit according to claim 1, further comprising: a printed
circuit board having on one end a card edge for connecting by
insertion to a connector, and having mounted thereon a control
circuit for controlling fan blade rotation; wherein the fan housing
frame further has an opening for passing said card edge of a
printed circuit board disposed internally to said fan housing frame
outside the fan housing to the front in a specific insertion
direction intersecting a direction of air flow of air moved by said
fan, and a retainer on an internal wall for holding a side of said
printed circuit board disposed internally to said fan housing
frame; said fan housing cover further has on an internal wall a
retainer for holding the printed circuit board side opposite to
said above-noted side of a printed circuit board disposed
internally to said fan housing frame; and said fan housing cover in
conjunction with said fan housing frame secures a printed circuit
board disposed internally to said fan housing frame.
4. A fan unit according to claim 1, wherein: the fan housing frame
further comprises a cantilevered beam-shaped operating lever
extending backwards relative to a specific insertion direction
intersecting a direction of air flow of air moved by said fan, said
operating lever having an engaging member for preventing removal of
a fan unit from a fan case when the fan unit is installed to the
fan case for housing the fan unit, said engaging member formed in a
middle part between operating lever ends.
5. A fan assembly comprising: a fan case for housing a fan unit,
said fan unit comprising a fan having a frame and a fan blade
freely rotatable to said frame; a printed circuit board having on
one end a card edge for connecting by insertion to a connector, and
having mounted thereon a control circuit for controlling fan blade
rotation; and a fan housing for internally housing said fan,
internally housing said printed circuit board with said card edge
projecting externally to the front in a specific insertion
direction intersecting a direction of air flow of air moved by said
fan, and having a ventilation opening on both walls in said
direction of air flow; and a connector freely removably fixed to
the fan case, the connector being connected with the card edge of
the printed circuit board projecting forward in the insertion
direction by an operation installing the fan unit to the fan
case.
6. A fan assembly according to claim 5, wherein: said connector has
a body with an opening for inserting said card edge of the printed
circuit board, first and second arms projecting to both sides from
said body, and an engaging protrusion formed on said first arm; and
said fan case has an arm engaging hole for holding said second arm
of the connector inserted thereto by sliding said connector in the
direction in which said second arm extends, and a slot in which
said engaging protrusion of the first arm is inserted, the slot
having an engaging protrusion protruding inwardly for engaging said
engaging protrusion of the first arm when said second arm is
slidingly inserted to said arm engaging hole.
7. A fan assembly according to claim 5, wherein: said fan unit
further comprises a cantilevered beam-shaped operating lever
extending in a direction opposite to a specific insertion
direction, and a specific engaging member formed on the operating
lever in a middle part between operating lever ends; and said fan
case further comprises a removal prevention member for preventing
fan unit removal by interfering with said engaging member of a fan
unit housed internally to the fan case, and allowing fan unit
removal by operating said operating lever to release interference
with said engaging member.
8. A fan assembly according to claim 5, wherein the fan case houses
a plurality of fan units mutually stacked in a direction of air
flow.
9. A fan assembly according to claim 5, said fan unit further
comprising a guide channel in an exterior part of a side wall, said
side wall extending in said direction of air flow and said
insertion direction, and having two edges extending in said
insertion direction, and said guide channel having a first channel
part extending from one said side wall edge into a middle toward
said other side wall edge, and a second channel part extending to
the back in said insertion direction from said end of the first
channel part; and said fan case further comprising on an inside
wall a guide protrusion for fitting into said guide channel;
wherein the fan unit is installed to the fan case by sliding the
fan unit along the first channel part and then sliding the fan unit
along the second channel part with the guide protrusion fit into
the guide channel.
10. A fan assembly according to claim 5, said fan unit further
comprising a guide channel in an exterior part of a side wall, said
side wall extending in said direction of air flow and said
insertion direction, and having two edges extending in said
insertion direction, and said guide channel having a first channel
part extending from one said side wall edge into a middle toward
said other side wall edge, and a second channel part extending to
the back in said insertion direction from said end of the first
channel part; and said fan case houses a plurality of fan units
with at least two arranged in the insertion direction, is freely
removably inserted in said insertion direction to a specific
apparatus, and comprises a first section in the back in said
insertion direction for holding a fan unit, and a second section in
the front in said insertion direction for holding a fan unit, said
second section having on an inside wall a guide protrusion for
fitting into said guide channel; wherein a fan unit is installed to
said first section by sliding in said insertion direction, and a
fan unit is installed to said second section by sliding said fan
unit along said first channel part and then sliding said fan unit
along said second channel part with said guide protrusion fit into
said guide channel.
11. An apparatus comprising a fan assembly, the fan assembly
having: a fan case for housing a fan unit, said fan unit comprising
a fan having a frame and a fan blade freely rotatable to said
frame; a printed circuit board having on one end a card edge for
connecting by insertion to a connector, and having mounted thereon
a control circuit for controlling fan blade rotation; and a fan
housing for internally housing said fan, internally housing said
printed circuit board with said card edge projecting externally to
the front in a specific insertion direction intersecting a
direction of air flow of air moved by said fan, and having a
ventilation opening on both walls in said direction of air flow;
and a connector freely removably fixed to the fan case, the
connector being connected with the card edge of the printed circuit
board projecting forward in the insertion direction by an operation
installing the fan unit to the fan case.
12. An apparatus according to claim 11, wherein: the connector of
the fan assembly has a body with an opening for inserting said card
edge of the printed circuit board, first and second arms projecting
to both sides from said body, and an engaging protrusion formed on
said first arm; and the fan case of the fan assembly has an arm
engaging hole for holding said second arm of the connector inserted
thereto by sliding said connector in the direction in which said
second arm extends, and a slot in which said engaging protrusion of
the first arm is inserted, the slot having an engaging protrusion
protruding inwardly for engaging said engaging protrusion of the
first arm when said second arm is slidingly inserted to said arm
engaging hole.
13. An apparatus according to claim 11, wherein: the fan unit of
the fan assembly further comprises a cantilevered beam-shaped
operating lever extending in a direction opposite to a specific
insertion direction, and a specific engaging member formed on the
operating lever in a middle part between operating lever ends; and
the fan case of the fan assembly further comprises a removal
prevention member for preventing fan unit removal by interfering
with said engaging member of a fan unit housed internally to the
fan case, and allowing fan unit removal by operating said operating
lever to release interference with said engaging member.
14. An apparatus according to claim 11, wherein: the fan case of
the fan assembly houses a plurality of fan units mutually stacked
in a direction of air flow through the fan units.
15. An apparatus according to claim 11, in which: the fan unit
further comprises a guide channel in an exterior part of a side
wall, said side wall extending in said direction of air flow and
said insertion direction, and having two edges extending in said
insertion direction, and said guide channel having a first channel
part extending from one said side wall edge into a middle toward
said other side wall edge, and a second channel part extending to
the back in said insertion direction from said end of the first
channel part; and the fan case further comprises on an inside wall
a guide protrusion for fitting into said guide channel; wherein the
fan unit is installed to the fan case by sliding the fan unit along
the first channel part and then sliding the fan unit along the
second channel part with the guide protrusion fit into the guide
channel.
16. An apparatus according to claim 11, in which: the fan unit
further comprises a guide channel in an exterior part of a side
wall, said side wall extending in said direction of air flow and
said insertion direction, and having two edges extending in said
insertion direction, and said guide channel having a first channel
part extending from one said side wall edge into a middle toward
said other side wall edge, and a second channel part extending to
the back in said insertion direction from said end of the first
channel part; and the fan case houses a plurality of fan units with
at least two arranged in the insertion direction, is freely
removably insertable in the same insertion direction to the
apparatus, and has a first section in the back in said insertion
direction for holding a fan unit, and a second section in the front
in said insertion direction for holding a fan unit, said second
section having on an inside wall a guide protrusion for fitting
into said guide channel; wherein a fan unit is installed to said
first section by sliding in the insertion direction, and a fan unit
is installed to said second section by sliding the fan unit along
the first channel part and then sliding the fan unit along the
second channel part with the guide protrusion fit into the guide
channel.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a fan unit assembled as a
single unit, a fan assembly having a fan case for housing the fan
unit, and a product comprising this fan assembly.
[0003] 2. Description of the Related Art
[0004] Fans are installed in a wide range of industrial and
consumer products for moving air heated by heat sources inside the
product to the outside of the product. More and more industrial
products-operate continuously all the day, and the ability to
maintain and replace parts without turning the power off and with
the product continuing to operate is desirable. Fans are no
exception, and fans which can be replaced while the power supply to
the product in which the fan is used remains on are needed.
Continuous operation also shortens fan service life, thus
increasing the opportunities for fan replacement. It is therefore
also necessary to improve the safety and ease with which fans can
be replaced.
[0005] FIGS. 37 to 39 show a typical fan unit, FIGS. 37 and 38
being perspective views thereof from different directions, and FIG.
39 being an exploded perspective view of the fan unit.
[0006] As shown in these figures, the fan unit 900 comprises a fan
910, fan box 920, printed circuit board 930, LED 940, and a
plurality of screws 950.
[0007] The fan 910 has a frame 911 and a fan blade 912 freely
rotatable to the frame 911. A mounting hole 913 is disposed at each
of the four corners of the frame 911.
[0008] The fan box 920 is typically formed by shaping sheet metal.
A finger guard 921 preventing a finger from entering the fan is
formed at the ventilation opening in the bottom or side as seen in
FIG. 38. A cantilevered beam-shaped operating lever 922 is further
disposed to the fan box 920. When the fan unit 900 is housed in a
fan case (not shown in the figures), this operating lever 922
prevents unintentional removal of the fan unit 900 from the fan
case. It can also be operated so that the fan unit 900 can be
removed from the fan case.
[0009] A control circuit (not shown in the figures) for controlling
rotation of the fan blade 912, and switching the LED 940 on/off, is
provided on the printed circuit board 930. Also provided thereon
are a connector 931 for connection with the LED 940, and a
connector 932 for connection with the fan 910 motor (not shown in
the figures). These connectors 931, 932 are connected with the LED
940 and fan 910 (that is, the fan motor) by wiring not shown in the
figures. As also shown in FIG. 37, a guard edge 933 protruding to
the front of the fan unit when the fan unit 900 is assembled is
also formed on this printed circuit board 930. This guard edge 933
is inserted to a connector (not shown in the figures) coupled to
the printed circuit board 930, and transfers power and signals
therefrom to the printed circuit board 930.
[0010] A plurality of screws 950 of a plurality of types are used
to assemble this fan unit 900.
[0011] As shown in FIGS. 37 to 39, a conventional fan unit thus
comprised has a plurality of fan boxes 920 made from sheet metal,
and is assembled using a large number of screws. Assembly is thus
inefficient and costly.
[0012] The productivity of the process for housing this fan unit
900 into a fan case (not shown in the figures), and connecting a
connector to the guard edge 933 of the printed circuit board 930
[920, sic] is also poor. There are also maintenance-related
problems.
SUMMARY OF THE INVENTION
[0013] With respect to the aforementioned problems, it is therefore
an object of the present invention to provide a fan unit that is
easy to handle and reduces cost. A further object is to provide a
fan assembly whereby fan unit maintenance and replacement are
simple. Another object is to provide an apparatus (product)
comprising a fan assembly of the present invention.
[0014] To achieve this object a fan unit according to the present
invention comprises a fan, a fan housing frame, and a fan housing
cover. The fan has a frame, a fan blade freely rotatable to the
frame, and an installation member disposed to the frame. The fan
housing frame has an opening on one side for disposing the fan
internally thereto, a ventilation opening in the opposite side, and
an engaging member formed on an inside wall for engaging the
installation member of the internally disposed fan and thereby
determining the fan position. The fan housing cover has a
ventilation opening, and an engaging member on an inside wall for
engaging the installation: member of the fan internally disposed to
the fan housing frame. The fan housing cover thus engages the fan
housing frame so as to cover the opening into which the fan is
installed, and in conjunction with the fan housing frame secures
the fan in the fan housing frame.
[0015] With a fan unit of the present invention, a fan placed into
the fan housing is positioned therein by inserting engaging
protrusions (tabs and claws) of the fan housing frame and cover
into corresponding holes. No screws are therefore needed to secure
the fan in the fan housing. The fan housing cover is similarly
engaged with the fan housing frame by means of matching tabs,
claws, and holes, and no screws are therefore needed to secure the
cover to the box frame.
[0016] A fan unit according to the present invention can thus be
easily assembled without using any screws or tools such as
screwdrivers, and thus helps reduce manufacturing cost.
[0017] The present fan unit further preferably has a finger guard
formed to the opening of the fan housing frame from which the fan
is not inserted (the bottom opening below); and a finger guard
formed to the opening in the fan housing cover.
[0018] As shown in FIG. 37 to FIG. 39, a fan unit according to the
related art only has a finger guard on one side. This makes
maintaining or replacing a fan while turning at high speed in the
product in which it is used potentially dangerous. Safety can be
improved, however, by providing a finger guard on both sides of the
fan unit as per the present invention.
[0019] Yet further preferably, the fan housing frame and fan
housing cover of a fan unit of the present invention are resin
moldings.
[0020] In addition to helping reduce cost, using resin moldings
assures that the box frame and cover are electrically isolated from
the power source so that safety can be further improved when
maintaining or replacing an operating fan.
[0021] The finger guard of a fan unit according to the related art
as shown in FIGS. 37 to 39 is made from sheet metal. The finger
guard thus provides great resistance to air flow, and is the source
of quite loud noise.
[0022] However, by molding the finger guard from resin, the finger
guard can be shaped to produce little air resistance, and is thus
effective as a way to reduce noise.
[0023] Yet further preferably, the fan unit comprises a printed
circuit board having on one end a card edge for insertion to a
connector, and having a control circuit mounted thereon for
controlling fan blade rotation. The fan housing frame in this case
also has an opening for passing the card edge of a printed circuit
board disposed internally to the fan housing frame outside the fan
housing to the front in a specific insertion direction orthogonal
to the direction of air flow of air moved by the fan. The fan
housing frame also has a retainer on an internal wall for holding a
side of the printed circuit board disposed internally to the fan
housing frame. The fan housing cover in this case further has on an
internal wall a retainer for holding the printed circuit board side
opposite the side held by the fan housing frame. In conjunction
with the fan housing frame, the fan housing cover thus secures a
printed circuit board disposed internally to said fan housing
frame.
[0024] Similarly to a fan unit according to the related art as
shown in FIG. 37 to FIG. 39, a printed circuit board is preferably
assembled into a fan unit of the present invention. In a fan unit
of the present invention, however, the printed circuit board is
held securely by the retainers provided on the fan housing frame in
which the printed circuit board is installed and the fan housing
cover. As a result, the fan unit of the present invention can still
be easily assembled without using any screws or tools even when a
printed circuit board is installed in the fan unit.
[0025] Yet further preferably, the fan housing frame also comprises
a cantilevered beam-shaped operating lever extending in the
direction opposite to the direction in which the fan unit is
inserted to a fan case. This insertion direction intersects the
direction of air flow of air moved by the fan. The operating lever
has an engaging member for preventing removal of the fan unit from
the fan case when the fan unit is installed to the fan case for
housing the fan unit. This engaging member is formed in the middle
of the operating lever between the front and back ends in the
insertion direction.
[0026] It should be noted that the provision of this operating
lever is the same as in the related art, but providing this
operating lever also improves handling the fan unit of the present
invention.
[0027] Yet further preferably, the fan housing frame of a fan unit
according to this invention has a side wall extending in the
direction of air flow and the insertion direction with two edges
extending in the insertion direction, and a guide channel formed in
the exterior side of this side wall. The guide channel has a first
channel part extending from one side wall edge into the middle
toward the other side wall edge, and a second channel part
extending from the end of the first channel part to the back in the
insertion direction.
[0028] By thus forming a guide channel in the fan unit, the fan
unit can be easily installed to and removed from a fan case even
when space is confined as further described below. This improves
fan unit handling, as well as the ease of fan unit maintenance and
replacement.
[0029] A fan assembly achieving the above object comprises a fan
case for housing a fan unit, and a connector to which connection is
made by installing the fan unit to the fan case. More specifically,
the fan unit housed in the fan case comprises a fan having a frame
and a fan blade freely rotatable to the frame; a printed circuit
board having on one end a card edge for connecting by insertion to
a connector, and having mounted thereon a control circuit for
controlling fan blade rotation; and a fan housing for internally
housing the fan, the printed circuit board with the card edge
thereof projecting externally to the front in a specific insertion
direction intersecting a direction of air flow of air moved by said
fan, and having a ventilation opening on both walls in the
direction of air flow. The connector is removably fixed to the fan
case, and is connected with the card edge of the printed circuit
board projecting forward in the insertion direction by the action
of installing the fan unit to the fan case.
[0030] A fan assembly according to the present invention thus
comprises a fan case in which a fan unit is installed, and a
connector to which the card edge of a printed circuit board in the
fan unit is inserted. The connector is removably fixed to the fan
case, and the card edge of the printed circuit board is inserted to
the connector by the operation for installing the fan unit to the
fan case. Connection to the connector can thus be accomplished by
simply installing the fan unit to the fan case, and a fan assembly
in which the assembled fan unit can be installed, maintained, and
replaced with great simplicity is thus achieved.
[0031] Further preferably, the connector of this fan assembly has a
body with an opening for inserting the card edge of the printed
circuit board, first and second arms projecting to both sides from
the body, and an engaging protrusion formed on the first arm. In
addition, the fan case has an arm engaging hole for holding the
second arm of the connector, which is inserted thereto by sliding
the connector in the direction in which the second arm extends, and
a slot in which the engaging protrusion of the first arm is
inserted. This slot has an inwardly protruding engaging protrusion
for engaging the engaging protrusion of the first arm when the
second arm is inserted into the arm engaging hole.
[0032] Thus comprised, the connector can be easily and reliably
installed and removed from the fan case without using any screws or
other fasteners, or any tools.
[0033] Yet further preferably, the fan unit of this fan assembly
comprises a cantilevered beam-shaped operating lever extending in a
direction opposite to a specific insertion direction, and a
specific engaging member formed on the operating lever between the
ends of the operating lever. The fan case further comprises a
removal prevention member for preventing fan unit removal by
interfering with the engaging member of a fan unit housed
internally to the fan case, and allowing fan unit removal when the
operating lever is operated to release interference with the
engaging member.
[0034] Unintentional removal of the fan unit from the fan case can
thus be prevented while also allowing for easy installation and
removal of the fan unit to and from the fan case as necessary.
[0035] Yet further preferably, the fan case of the fan assembly
holds a plurality of fan units stacked together in the direction of
air flow.
[0036] When thus comprised, air flow can be maintained even part of
the plurality of fan units fails.
[0037] Yet further preferably, the fan unit of the fan assembly
comprises a guide channel in an exterior part of a side wall, and
the fan case comprises on an inside wall thereof a guide protrusion
that fits into the guide channel. This side wall of the fan unit
extends in the direction of air flow and the insertion direction,
and has two edges extending in the insertion direction. The guide
channel has a first channel part extending from one side wall edge
into the middle toward the other side wall edge, and a second
channel part extending in the direction opposite the insertion
direction from the end of the first channel part. The fan unit is
installed to the fan case by sliding the fan unit along the first
channel part and then sliding it along the second channel part with
the guide protrusion fit into the guide channel.
[0038] A fan unit thus comprised can be easily installed to and
removed from the fan case even in confined spaces.
[0039] Further alternatively, the fan unit in a fan assembly
according to the present invention comprises a guide channel in an
exterior part of a side wall, which extends in the direction of air
flow and the insertion direction, and has two edges extending in
the insertion direction. The guide channel has a first channel part
extending from one side wall edge into the middle toward the other
side wall edge, and a second channel part extending in the
direction opposite the insertion direction from the end of the
first channel part. The fan case in this fan assembly houses a
plurality of fan units with at least two arranged in the insertion
direction, is freely removably inserted in the insertion direction
to a specific apparatus, and comprises a first section in the back
in the insertion direction for holding a fan unit, and a second
section in the front in the insertion direction for holding a fan
unit. This second section has on an inside wall thereof a guide
protrusion that fits into the guide channel. A fan unit is
installed to this first section by sliding it in the insertion
direction. A fan unit is installed to the second section by sliding
the fan unit along the first channel part and then sliding the fan
unit along the second channel part with the guide protrusion fit
into the guide channel.
[0040] When it is necessary to move air over a wide area using a
plurality of fan units arrayed side by side, a plurality of fan
units can be arranged side by side in the direction in which they
are inserted to the fan case, and the fan case is then inserted in
the same insertion direction to the device in which the fan array
is used. By using the design of the present invention for fitting a
guide protrusion (pin) into a guide channel and then sliding the
fan unit into place in the part of the fan case to the front in the
insertion direction, the fan unit installed to this front section
can be easily installed and removed as needed.
[0041] An apparatus (product) according to the present invention
incorporates any one of the fan assemblies of the invention as
described above.
[0042] By thus incorporating one of these fan assemblies, the
apparatus (product) of the invention provides for simple fan
maintenance and replacement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] These and other objects and features of the present
invention will be readily understood from the following detailed
description taken in conjunction with preferred embodiments thereof
with reference to the accompanying drawings, in which like parts
are designated by like reference numerals and in which:
[0044] FIG. 1 is an exploded perspective view of a fan unit
according to a preferred embodiment of the present invention;
[0045] FIG. 2 is an assembly diagram of the fan unit shown in FIG.
1;
[0046] FIG. 3 is a perspective view of a fan housing assembled from
the fan housing frame and fan housing cover shown in FIG. 1;
[0047] FIG. 4 is a perspective view, from a different angle of a
fan housing assembled from the fan housing frame and fan housing
cover shown in FIG. 1;
[0048] FIG. 5 shows five side views of the fan housing shown in
FIG. 3 ((A) is a front view, (B) is a plan (top) view, (C) is a
left side view, (D) is a right side view, and (E) is a bottom
view);
[0049] FIG. 6 is a perspective view of the fan housing frame shown
in FIG. 1;
[0050] FIG. 7 shows four side views of the fan housing frame shown
in FIG. 1;
[0051] FIG. 8 is an enlarged view of the area inside circle R1 in
FIG. 7(C);
[0052] FIG. 9 is an enlarged view of the part shown in FIG. 8 when
viewed in section through line A-A in FIG. 7(B);
[0053] FIG. 10 is a perspective view of the fan housing cover shown
in FIG. 1;
[0054] FIGS. 11 shows four side views of the cover shown in FIG. 10
((A) to (D) are front, top, left, and right sides views);
[0055] FIG. 12 is an enlarged view of the area inside circle R2 in
FIG. 11(D);
[0056] FIG. 13 is an enlarged view of the part shown in circle R3
in FIG. 11(A);
[0057] FIG. 14 and FIG. 15 are perspective views from different
angles of a fan assembly according to a preferred embodiment of the
present invention;
[0058] FIG. 16 is an exploded perspective view of the fan assembly
shown in FIG. 14 and FIG. 15;
[0059] FIG. 17 is a plan view of the fan case of the fan assembly
shown in FIG. 14;
[0060] FIG. 18 is a section view through line B-B in FIG. 17;
[0061] FIG. 19 is an enlarged view of the area in oval R4 in FIG.
18;
[0062] FIG. 20 is a perspective view from the back of the fan case
in FIG. 14;
[0063] FIG. 21 is a back view of the fan case in FIG. 14;
[0064] FIG. 22 and FIG. 23 are perspective views from different
angles of a fan assembly according to another preferred embodiment
of the present invention;
[0065] FIG. 24 is an exploded perspective view of the fan assembly
shown in FIG. 22;
[0066] FIG. 25 is a perspective view of part of the second fan case
of the fan assembly shown in FIG. 22 as seen from the direction of
arrow C in FIG. 24;
[0067] FIG. 26 is a perspective view showing fan units installed to
the two front sections of the second fan case in the fan case
insertion direction;
[0068] FIG. 27 is a front view showing fan unit installation to the
two front sections of the second fan case in the fan case insertion
direction before the installation is completed;
[0069] FIG. 28 is a front view showing the fan units when
completely installed to the two front sections shown in FIG.
27;
[0070] FIG. 29 is a perspective view of an apparatus in which the
fan assembly shown in FIGS. 22 to 25 is used when the fan assembly
is fully installed to said apparatus;
[0071] FIG. 30 is a front view of an apparatus in which the fan
assembly shown in FIGS. 22 to 25 is used when the fan assembly is
fully installed to said apparatus;
[0072] FIG. 31 is a plan view of an apparatus in which the fan
assembly shown in FIGS. 22 to 25 is used when the fan assembly is
fully installed to said apparatus;
[0073] FIG. 32 is a side view of an apparatus in which the fan
assembly shown in FIGS. 22 to 25 is used when the fan assembly is
fully installed to said apparatus;
[0074] FIG. 33 is a perspective view showing the second fan case
200B of the fan assembly installed to the apparatus shown in FIG.
29 withdrawn from said apparatus;
[0075] FIG. 34 is a front view showing the second fan case 200B of
the fan assembly installed to the apparatus shown in FIG. 29
withdrawn from said apparatus;
[0076] FIG. 35 is a plan view showing the second fan case 200B of
the fan assembly installed to the apparatus shown in FIG. 29
withdrawn from said apparatus;
[0077] FIG. 36 is a side view showing the second fan case 200B of
the fan assembly installed to the apparatus shown in FIG. 29
withdrawn from said apparatus;
[0078] FIG. 37 and FIG. 38 are perspective views from different
directions of a fan unit according to the related art; and
[0079] FIG. 39 is an exploded perspective view of the fan unit
shown in FIG. 37 and FIG. 38.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0080] The preferred embodiments of the present invention are
described below with reference to the accompanying figures. FIG. 1
is an exploded perspective view of a fan unit according to a
preferred embodiment of the present invention, and FIG. 2 is an
assembly diagram of this fan unit.
[0081] As shown in these figures, this fan unit 100 comprises a fan
housing frame 110, a printed circuit board 130, fan 150, and fan
housing cover 170.
[0082] The printed circuit board 130 is housed in the fan housing
frame 110 with circuit board card edge 131 protruding forward in a
specific insertion direction S from an opening 111 in the box frame
110. The fan 150 is then placed in the box frame 110, and the cover
170 is then fastened to the box frame 110 with the printed circuit
board 130 and fan 150 housed thereinside.
[0083] Tabs 171 (see FIG. 1) and 172, and claw 173 are formed on
the fan housing cover 170. Matching engaging holes 112, recess 113,
and hole 114 are formed in the fan housing frame 110. The cover 170
is thus fastened to the box frame 110 by fitting tabs 171 into
matching engaging holes 112 in the box frame 110, and then swinging
the cover 170 to the box frame 110 as though closing a door with
the tabs 171 and holes 112 acting as a hinge so that tab 172 of
cover 170 fits into recess 113 of box frame 110, and engaging claw
173 of cover 170 fits into and engages hole 114 in box frame 110.
When the fan housing cover 170 is thus secured to the fan housing
frame 110, it closes fan housing opening 115 in which the printed
circuit board 130 and fan 150 are housed. A fan housing is thus
formed by the fan housing frame 110 and fan housing cover 170. The
printed circuit board 130 and fan 150 are also secured inside the
fan housing as further described below.
[0084] It will be noted that absolutely no tools are required to
house printed circuit board 130 and fan 150 in fan housing frame
110 and install cover 170 to the box frame 110, and assembly is
thus quite simple.
[0085] It should be further noted that the cover 170 fastened to
the box frame 110 can be removed therefrom by pushing with the tip
of a slender tool, such as a flat screwdriver, on the claw 173
[143, sic] fit into hole 114 using a certain degree of force so as
to disengage the claw 173 [143, sic] from the hole 114. The cover
170 can then be swung open using the tabs 171 and holes 112 as a
hinge, and removed from the box frame 110. However, it is typically
not necessary to disassemble the fan unit 100 for maintenance and
replacement, and when replaced the fan unit 100 is replaced as a
single unit.
[0086] The fan housing frame 110 and fan housing cover 170 are both
resin moldings in this exemplary embodiment of the invention.
[0087] The fan 150 comprises a frame 151, a freely rotatable blade
152, and a motor (not shown in the figures) fixed to the frame for
turning the blade 152. The blade 152 is disposed centrally to so
that it is surrounded by frame 151 [150, sic]. A mounting hole 153
is formed in each of the four corners of the frame 151 [150, sic].
These holes 153 are exemplary of an installation member of the
present invention. The frame 151 and blade 152 of this fan 150 are
also resin moldings.
[0088] FIGS. 3 and 4 are perspective views from different angles of
a fan housing assembled from the above-noted fan housing frame 110
and fan housing cover 170. FIG. 5(A) is a front view, (B) is a plan
(top) view, (C) is a left side view, (D) is a right side view, and
(E) is a bottom view of this fan housing.
[0089] FIG. 6 is a perspective view of the box frame 110, and FIGS.
7(A) to (D) are front, top, left, and right sides views of the box
frame 110. FIG. 8 is an enlarged view of the area inside circle R1
in FIG. 7(C), and FIG. 9 is an enlarged view of the part shown in
FIG. 8 when viewed in section through line A-A in FIG. 7(B).
[0090] Arrow S shown in some of these figures indicates the
insertion direction indicated by arrow S in FIG. 2.
[0091] This fan housing frame 110 is described in detail next below
with reference to FIGS. 3 to 9.
[0092] In addition to opening 115 (see FIG. 2) for housing printed
circuit board 130 [120, sic] and fan 150 [130, sic] inside box
frame 110, box frame 110 has a ventilation opening further formed
in the bottom thereof with a finger guard 116 formed in this
ventilation opening. The members of this finger guard 116 are thin
as shown in the figure so that resistance to air flow is low and
noise is kept low. The four engaging protrusions 117 shaped as
shown in an enlarged view in FIG. 8 are formed around the finger
guard 116 as shown in FIG. 7 in the bottom wall of the box frame
110. It should be noted that these engaging protrusions 117 are an
example of the engaging members of the present invention. When the
fan 150 is installed to the box frame 110, these four engaging
protrusions 117 are fit into the four mounting holes 153 formed in
frame 151 of fan 150 (see FIGS. 1 and 2), and thus function to
secure fan 150 inside box frame 110.
[0093] A slotted retainer 118 is formed in the bottom inside wall
of the box frame 110 where the printed circuit board 130 is
located. When the printed circuit board 130 is installed to the box
frame 110, one side 132a thereof as shown in FIG. 1 and FIG. 2 is
fit into this slotted retainer 118 and held with card edge 131
projecting from opening 111 in the insertion direction as indicated
by arrow S.
[0094] A cantilevered beam-shaped operating lever 119 extending to
the back relative to the insertion direction S is formed at an
outside wall of the box frame 110. An engaging protrusion 120 for
preventing removal of the fan unit 100 from the fan case when the
fan unit 100 is installed to a fan case for housing the fan unit
100 is formed at a point between the ends of the operating lever
119. This protrusion 120 is further described in detail below.
[0095] A handle 121 is also disposed to this box frame 110 to make
it easier to install the fan unit 100 to the fan case and remove it
therefrom.
[0096] The letters AIR and an arrow are also formed as surface
markings in the box frame 110 as shown in the top views in FIG.
5(B) and FIG. 7 (B), and the bottom view in FIG. 5(E). The
direction indicated by this arrow is the direction in which the fan
installed in this fan housing pushes air, that is, the direction of
air flow.
[0097] As also shown in the top views in FIG. 5(B) and FIG. 7(B),
and the bottom view in FIG. 5(E), L-shaped guide channels 122 and
123 are formed to the box frame 110. These L-shaped guide channels
122 and 123 are formed in the outside wall of sides 124 and 125,
which are coplanar to the direction of air flow AIR and insertion
direction S, of box frame 110. The guide channels 122 and 123 each
comprise a first channel part 122a and 123a, and a second channel
part 122b and 123b. The sides 124 and 125 each have two edges 124a,
124b and 125a, 125b substantially parallel to the insertion
direction S. The first channel part 122a and 123a of guide channels
122 and 123 extends from one edge 124a, 125a toward the other edge
124b, 125b to the middle part of sides 124 and 125. The second
channel part 122b and 123b of guide channels 122 and 123 extends in
the insertion direction S from the end of the corresponding first
channel part. The function of these guide channels 122 and 123 is
also further described below.
[0098] FIG. 10 is a perspective view of the fan housing cover 170.
FIGS. 11(A) to (D) are front, top, left, and right sides views of
the cover 170. FIG. 12 is an enlarged view of the area inside
circle R2 in FIG. 11(D), and FIG. 13 is an enlarged view of the
part shown in circle R3 in FIG. 11(A).
[0099] The fan housing cover 170 is described in detail below with
reference to FIGS. 3 to 5, and FIGS. 10 to 13.
[0100] A ventilation opening is formed in the middle of cover 170
with a finger guard 174 formed in the opening. Similarly to the
finger guard 116 disposed to box frame 110, the members of this
finger guard 174 are thin as shown in the figure so that resistance
to air flow is low and noise is kept low.
[0101] An engaging protrusion 175 shaped as shown in the enlarged
view in FIG. 12 is formed to the inside wall of the cover 170. As
are engaging protrusions 117 of the box frame 110, these engaging
protrusion 175 are exemplary of the engaging members of the present
invention. Further similarly to the engaging protrusions 117 of box
frame 110 (see FIG. 7(C)), engaging protrusion 175 fits into
mounting hole 153 in fan 150 (see FIGS. 1 and 2) and functions to
fasten the fan 150 inside the fan housing.
[0102] A forked retainer 176 for holding side 132b of printed
circuit board 130 (see FIGS. 1 and 2) is also formed on the inside
wall of the cover 170. Note that this side 132b of printed circuit
board 130 is the side opposite side 132a held by the slotted
retainer 118 (see FIG. 7(C)) of box frame 110. In conjunction with
slotted retainer 118 of box frame 110, the forked retainer 176
works to hold the printed circuit board 130 inside the fan
housing.
[0103] It will thus be obvious that box frame 110 and cover 170 in
conjunction with each other have a structure for fixing the printed
circuit board 130 and fan 150 inside the fan housing.
[0104] The cover 170 is also fixed to the box frame 110 as
described above.
[0105] A fan unit 100 according to this preferred embodiment of the
invention is configured so that it can be easily assembled without
using any screws or similar fasteners and without using any tools,
and thus facilitates cost reduction.
[0106] It will also be noted that this fan unit 100 has finger
guards 116 and 174 in both ventilation openings on both sides in
the direction of air flow through a fan housing comprising box
frame 110 and cover 170. Contact between a finger and the fan 150
is thus prevented, and the fan unit 100 can be safely handled even
when the fan 150 is turning at high speed.
[0107] Yet further, the box frame 110 and cover 170 of this fan
unit 100 are resin moldings, lightweight, and electrically
insulated, and are therefore electrically safe to handle even when
a live power supply is maintained.
[0108] Because they are resin moldings, the finger guards 116 and
174 can also be thinly formed, thus assuring a wide air flow
channel, reducing resistance to air flow, and keeping noise to a
low level.
[0109] FIG. 14 and FIG. 15 are perspective views from different
angles of a fan assembly according to a preferred embodiment of the
present invention. FIG. 16 is an exploded perspective view of this
fan assembly, and FIG. 17 is a plan view of the fan case of this
fan assembly. FIG. 18 is a section view through line B-B in FIG.
17. FIG. 19 is an enlarged view of the area in oval R4 in FIG. 18.
FIG. 20 is a perspective view from the back of the fan case, and
FIG. 21 is a back view of the fan case.
[0110] As shown in FIG. 16, this fan assembly comprises two fan
units 100 as described above, a fan case 200 for holding these two
fan units 100 stacked together in the direction of air flow, and
two connectors 300 to which a card edge 131 of printed circuit
board 130 in the two fan units 100 is inserted. It should be noted
that these two fan units 100 are fan units as described above with
reference to FIGS. 1 to 13, and further description thereof is thus
omitted below.
[0111] Fan case 200 has a means for securing these two connectors
300 as further described below. The two fan units 100 are housed in
the fan case 200 by sliding them into the fan case 200 in insertion
direction S. This action of installing a fan unit 100 into the fan
case 200 also fits the card edge 131 of printed circuit board 130
in the fan unit 100 into the corresponding connector 300 fixed to
fan case 200.
[0112] Ventilation openings 201 and 202 are formed in the walls of
the fan case 200 in the direction of air flow. The two fan units
100 housed in the fan case 200 thus move air in the direction of
air flow by means of the two fans 150 (see FIG. 1 and FIG. 2)
housed in the two fan units 100.
[0113] By thus locating two fan units 100 in line in the direction
of air flow in this fan assembly, air flow can be maintained even
if one of the two fan units 100 fails, and an abnormal rise in the
internal temperature of the device in which the fan assembly is
installed can thus be prevented.
[0114] A removal prevention tab 203 is disposed to the fan case 200
for each fan unit 100 installed therein. When a fan unit 100 is
slid in the insertion direction S for installation to the fan case
200, the engaging protrusion 120 formed on the operating lever 119
of the fan unit 100 rides passed the removal prevention tab 203 and
thus holds the fan unit 100 secure inside the fan case 200. Once
thus installed, the fan unit 100 cannot be removed from the fan
case 200 by simply pulling out on the fan unit 100 because the
removal prevention tab 203 interferes with movement of the
protrusion 120 in the direction opposite the insertion direction S.
and thus prevents fan unit 100 removal. As a result, unintentional
removal of the fan unit 100 from the fan case 200 is prevented.
[0115] The fan unit 100 can be easily intentionally removed from
the fan case 200 by depressing operating lever 119. This causes the
operating lever 119 to bend and changes the position of the
protrusion 120 on the operating lever 119, thereby disengaging the
protrusion 120 and the removal prevention tab 203 [403, sic] and
removing the interference therebetween so that the fan unit 100 can
be slid out from the fan case 200.
[0116] Connector 300 is removably fixed to the fan case 200. The
mechanism for thus fitting a connector 300 to the fan case 200 is
described next below.
[0117] As shown in FIG. 16, this connector 300 comprises a main
body 310 and first and second arms 320 and 330 extending to both
sides from the body 310. An opening 311 to which card edge 131 of
printed circuit board 130 of fan unit 100 is inserted is disposed
in the body 310. A forward projecting engaging protrusion 321 is
formed to the first arm 320.
[0118] A connector opening 204 for exposing opening 311 in the body
310 of connector 300 to the inside of the fan case 200, and a slot
205 in which engaging protrusion 321 of first arm 320 is inserted
and guided, are formed in the wall of back 210 of the fan case 200
(see FIGS. 20 and 21) for each connector 300. An arm engaging hole
206 (see FIG. 20) to which second arm 330 of connector 300 is
inserted is further formed crosswise to back wall 210 of fan case
200. A protrusion 207 projecting to the inside of the slot 205 is
further formed in each slot 205 guiding engaging protrusion 321 of
first arm 320.
[0119] To install a connector 300 to fan case 200, the second arm
330 of the connector 300 is inserted to arm engaging hole 206 of
fan case 200, and engaging protrusion 321 of first arm 320 is
inserted to slot 205. The connector 300 is then slid in the
direction further deeply inserting second arm 330 to arm engaging
hole 206. This causes the engaging protrusion 321 on first arm 320
to pass over protrusion 207 projecting inward to slot 205 so that
the engaging protrusion 321 of the first arm 320 is fixed at the
position shown in FIG. 19 engaged by the protrusion 207 in slot
205. If it becomes necessary to remove the connector 300 [320, sic]
from the fan case 200, the connector 300 can be removed by sliding
it in the direction removing the second arm 330 from the arm
engaging hole 206 while applying force sufficient to move the
engaging protrusion 321 of the first arm 320 back over the
protrusion 207 in slot 205.
[0120] It will thus be obvious that a fan case 200 according to
this preferred embodiment of the invention is constructed so that a
connector 300 can reliably be removably installed to the fan case
200 without using any tools. In addition, when the connector 300 is
installed to the fan case 200 and a fan unit 100 is then installed
to the fan case 200, the action of installing the fan unit 100
causes the card edge 131 of the printed circuit board 130 of fan
unit 100 to be fit into and connected to the connector 300.
[0121] This fan assembly can therefore be extremely easily
assembled. In addition, a fan unit 100 can be replaced in the fan
case 200 safely and easily even while current is supplied to the
connector 300.
[0122] FIG. 22 and FIG. 23 are perspective views from different
angles of a fan assembly according to another preferred embodiment
of the present invention. FIG. 24 is an exploded perspective view
of this same fan assembly. FIG. 25 is a perspective view of part of
the second fan case of the fan assembly according to this
embodiment as seen from arrow C in FIG. 24.
[0123] A fan assembly according to this preferred embodiment of the
invention comprises eight fan units 100, first to third fan cases
200A, 200B, and 200C, and eight connectors 300 corresponding to the
eight fan units 100.
[0124] Two fan units 100 are housed in part of first fan case 200A.
Four fan units 100 are housed in second fan case 200B. This second
fan case 200B is removably housed in the first fan case 200A by
sliding the second fan case 200B in insertion direction S to the
first fan case 200A. Two fan units 100 are installed to third fan
case 200C by sliding them in insertion direction S. This third fan
case 200C is supported on and fixed to first fan case 200A.
[0125] It should be noted that this second fan case 200B is
designed to house two fan units 100 stacked vertically to each
other, and two side by side in the insertion direction S. The
second fan case 200B comprises four sections 211, 212, 213, and 214
each holding one fan unit 100. Of these, the two sections 213, 214
at the back in the insertion direction S are designed so that the
fan unit 100 held therein is inserted from the back in the
insertion direction S. Fan units 100 are installed to the two
sections 211, 212 at the front in this same direction S by first
sliding the fan unit 100 into the second fan case 200B in the
direction indicated by arrow D in FIG. 24, and then sliding the fan
unit 100 in the insertion direction S. This installation method is
achieved as described below.
[0126] FIG. 26 is a perspective view showing fan units installed to
the two front sections of the second fan case in the insertion
direction S. FIG. 27 is a front view showing fan unit installation
to these sections before the installation is completed, and FIG. 28
is a front view showing the fan units when completely installed to
these front sections.
[0127] Two guide protrusions 222 are formed on the bottom of the
two sections 211, 212 to the front of second fan case 200B in the
direction of arrow S as shown in FIG. 24. As shown in FIG. 25, a
single guide protrusion 221 is also formed in the top of these two
front sections 211, 212.
[0128] As shown in FIGS. 5 (A) and (E), L-shaped guide channels 122
and 123 are formed in fan unit 100. To install a fan unit 100 to
front section 211 or 212, bottom guide protrusions 222 of front
section 211, 212 in second fan case 200B are fit into the first
channel part 123a of guide channel 123, top guide protrusion 221 of
front section 211, 212 is fit into the first channel part 122a of
guide channel 122 of fan unit 100, and the fan unit 100 is then
slid in the direction of arrow D (see FIG. 24). FIG. 27 is a front
view of this position.
[0129] When the guide protrusions 221, 222 advance to the bend in
the L-shaped guide channels 122 and 123 and enter the second
channel part 122b and 123b of guide channels 122 and 123, the fan
unit 100 is slid in the direction of arrow S (the insertion
direction) relative to the fan case 200 to completely house the fan
unit 100 in the corresponding front section 211, 212 of the second
fan case 200B.
[0130] The second sliding step of this operation fits the card edge
131 of printed circuit board 130 of fan unit 100 into the
corresponding connector 300. The protrusion 120 on operating lever
119 of fan unit 100 is also slid passed a removal prevention
protrusion (not shown in the figures) in each front section 211,
212 whereby unintentional removal of the fan unit 100 is prevented.
It should be noted that this removal prevention protrusion is
identical to the removal prevention tab 203 of the fan case 200
described in the preferred embodiment shown in FIG. 16.
[0131] FIG. 29 to FIG. 32 are a perspective view, front view, plan
view, and side view, respectively, of a product in which the fan
assembly shown in FIGS. 22 to 25 is used when the fan assembly is
fully installed to said product. FIG. 33 to FIG. 36 are a
perspective view, front view, plan view, and side view,
respectively, showing the second fan case 200B of the fan assembly
installed to said product being removed therefrom.
[0132] This second fan case 200B can be withdrawn from the product
to a position as shown in FIGS. 33 to 36 (note particularly FIG.
34). When withdrawn to this position the two fan units housed in
the two front sections in the direction of arrow S (insertion
direction) cannot be pulled out to the back (the direction opposite
arrow A) because of the two fan unit housing sections disposed to
this back side. However, by moving the fan unit in the reverse of
the L-shaped movement of the fan unit during installation, the fan
unit can be removed from the second fan case 200B for maintenance
or replacement of the fan units housed at the front in the
insertion direction of the second fan case 200B.
[0133] By thus installing and removing a fan unit to and from the
fan case using an L-shaped movement as described above, a fan unit
can be installed to a fan case or removed therefrom as needed even
when the space available is confined as shown in FIG. 34.
[0134] It will be obvious that a fan assembly according to the
present invention shall not be limited to the two preferred
embodiments described above, and other variations using a
configuration in which the fan unit of the present invention can be
installed and removed in a cassette-like manner will be readily
apparent to one with ordinary skill in the related art.
[0135] As described above, the present invention provides a fan
unit that is easy to assemble, low cost, and extremely safe; a fan
assembly that is easy to assemble and maintain; and an apparatus in
which fan maintenance and replacement are simple.
[0136] Although the present invention has been described in
connection with the preferred embodiments thereof with reference to
the accompanying drawings, it is to be noted that various changes
and modifications will be apparent to those skilled in the art.
Such changes and modifications are to be understood as included
within the scope of the present invention as defined by the
appended claims, unless they depart therefrom.
* * * * *