U.S. patent application number 15/937982 was filed with the patent office on 2019-03-28 for axial fan.
The applicant listed for this patent is Nidec Corporation. Invention is credited to Kazuhiro INOUCHI, Junya MATSUYAMA, Tatsuya TATARA.
Application Number | 20190093662 15/937982 |
Document ID | / |
Family ID | 64379953 |
Filed Date | 2019-03-28 |
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United States Patent
Application |
20190093662 |
Kind Code |
A1 |
INOUCHI; Kazuhiro ; et
al. |
March 28, 2019 |
AXIAL FAN
Abstract
An axial fan includes a rotor portion including a shaft arranged
to extend along a central axis extending in a vertical direction; a
stator portion arranged radially opposite to the rotor portion; and
an impeller hub fixed to the rotor portion, and arranged to be
capable of rotating integrally with the rotor portion. The impeller
hub is an injection molded article, and includes a hub top plate
portion arranged to extend perpendicularly to an axial direction; a
hub tubular portion being tubular, and arranged to extend axially
downward from an outer edge of the hub top plate portion; a
plurality of blades arranged in a circumferential direction on an
outer surface of the hub tubular portion; and an inner fixing
portion arranged radially inward of the hub tubular portion. The
rotor portion includes a rotor tubular portion being tubular and
arranged to extend in the axial direction. The inner fixing portion
includes a first region arranged radially opposite to an outer
surface of the rotor tubular portion with a gap therebetween, and
having a weld defined in a radially inner surface thereof; and a
second region arranged to be in contact with at least a portion of
the outer surface of the rotor tubular portion.
Inventors: |
INOUCHI; Kazuhiro; (Kyoto,
JP) ; TATARA; Tatsuya; (Kyoto, JP) ;
MATSUYAMA; Junya; (Kyoto, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nidec Corporation |
Kyoto |
|
JP |
|
|
Family ID: |
64379953 |
Appl. No.: |
15/937982 |
Filed: |
March 28, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04D 25/0613 20130101;
F04D 29/646 20130101; F04D 29/329 20130101; F04D 25/08 20130101;
F04D 29/263 20130101; F04D 29/522 20130101; F04D 25/0606
20130101 |
International
Class: |
F04D 25/06 20060101
F04D025/06; F04D 25/08 20060101 F04D025/08; F04D 29/26 20060101
F04D029/26; F04D 29/52 20060101 F04D029/52; F04D 29/64 20060101
F04D029/64 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 28, 2017 |
JP |
2017-187689 |
Claims
1. An axial fan comprising: a rotor portion including a shaft
arranged to extend along a central axis extending in a vertical
direction; a stator portion arranged radially opposite to the rotor
portion; and an impeller hub fixed to the rotor portion, and
arranged to be capable of rotating integrally with the rotor
portion; wherein the impeller hub is an injection molded article,
and includes: a hub top plate portion arranged to extend
perpendicularly to an axial direction; a hub tubular portion being
tubular, and arranged to extend axially downward from an outer edge
of the hub top plate portion; a plurality of blades arranged in a
circumferential direction on an outer surface of the hub tubular
portion; and an inner fixing portion arranged radially inward of
the hub tubular portion; the rotor portion includes a rotor tubular
portion being tubular and arranged to extend in the axial
direction; and the inner fixing portion includes: a first region
arranged radially opposite to an outer surface of the rotor tubular
portion with a gap therebetween, and having a weld defined in a
radially inner surface thereof; and a second region arranged to be
in contact with at least a portion of the outer surface of the
rotor tubular portion.
2. The axial fan according to claim 1, wherein the inner fixing
portion includes a plurality of the second regions; and the
plurality of second regions are arranged at regular intervals in
the circumferential direction.
3. The axial fan according to claim 1, wherein the inner fixing
portion is tubular, extending in the axial direction.
4. The axial fan according to claim 1, wherein the hub top plate
portion includes a gate mark defined in an upper or lower surface
thereof; the inner fixing portion includes: a first wall portion
arranged radially outside of the gate mark; and a second wall
portion arranged circumferentially adjacent to the first wall
portion; and the first wall portion includes the second region.
5. The axial fan according to claim 1, wherein the hub top plate
portion includes a gate mark defined in an upper or lower surface
thereof; the inner fixing portion includes: a first projecting
portion arranged to project radially inward from an inner surface
of the hub tubular portion; and a second projecting portion
arranged to project radially inward from the inner surface of the
hub tubular portion to a greater extent than the first projecting
portion; a shortest circumferential distance between the first
projecting portion and the gate mark is greater than a shortest
circumferential distance between the second projecting portion and
the gate mark; and the second projecting portion is arranged to be
in radial contact with the outer surface of the rotor tubular
portion.
6. An axial fan comprising: a rotor portion including a shaft
arranged to extend along a central axis extending in a vertical
direction; a stator portion arranged radially opposite to the rotor
portion; and an impeller hub fixed to the rotor portion, and
arranged to be capable of rotating integrally with the rotor
portion; wherein the impeller hub is an injection molded article,
and includes: a hub top plate portion arranged to extend
perpendicularly to an axial direction; a hub tubular portion being
tubular, and arranged to extend axially downward from an outer edge
of the hub top plate portion; a plurality of blades arranged in a
circumferential direction on an outer surface of the hub tubular
portion; and an inner fixing portion arranged radially inward of
the hub tubular portion; the hub top plate portion includes a
plurality of gate marks arranged in the circumferential direction
in an upper or lower surface thereof; the rotor portion includes a
rotor tubular portion being tubular and arranged to extend in the
axial direction; and at least a portion of an outer surface of the
rotor tubular portion is arranged to be in contact with an inner
surface of a portion of the inner fixing portion which lies in a
region between a middle position between each gate mark and a
circumferentially adjacent one of the gate marks and a middle
position between the gate mark and another circumferentially
adjacent one of the gate marks.
7. The axial fan according to claim 6, wherein the gate marks are
arranged at regular intervals in the circumferential direction.
8. The axial fan according to claim 6, wherein at least a portion
of a region of contact between an inner surface of the inner fixing
portion and the outer surface of the rotor tubular portion is
arranged radially outside of the gate mark and on an imaginary line
joining the gate mark and the central axis.
9. The axial fan according to claim 6, wherein the inner fixing
portion is tubular, extending in the axial direction.
10. The axial fan according to claim 6, wherein the inner fixing
portion includes: a first wall portion including a region
overlapping with the gate mark when viewed in a radial direction;
and a second wall portion arranged circumferentially adjacent to
the first wall portion; and the rotor tubular portion is arranged
to be in contact with an inner surface of the first wall
portion.
11. The axial fan according to claim 6, wherein the inner fixing
portion includes: a first projecting portion arranged to project
radially inward from an inner surface of the hub tubular portion;
and a second projecting portion arranged to project radially inward
from the inner surface of the hub tubular portion to a greater
extent than the first projecting portion; a shortest
circumferential distance between the first projecting portion and
the gate mark is greater than a shortest circumferential distance
between the second projecting portion and the gate mark; and the
second projecting portion is arranged to be in radial contact with
the outer surface of the rotor tubular portion.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to Japanese
Patent Application No. 2017-187689 filed on Sep. 28, 2017. The
entire contents of this application are hereby incorporated herein
by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present disclosure relates to an axial fan.
2. Description of the Related Art
[0003] In a known fan, an impeller is attached to a rotor yoke. The
impeller includes an impeller cup including a tubular lateral wall
portion in the shape of a truncated cone, and a plurality of blades
arranged in an annular shape and arranged to project from an outer
circumferential surface of the lateral wall portion of the impeller
cup. In addition, inside of the lateral wall portion of the
impeller cup, an annular member is defined concentrically and
integrally with the lateral wall portion of the impeller cup. A
plurality of support members are arranged in a circumferential
direction between an inner circumferential surface of the lateral
wall portion of the impeller cup and an outer circumferential
surface of the annular member. Further, a plurality of ribs are
arranged to project radially inward from the annular member. When
the rotor yoke is press fitted to the impeller cup, a radially
outward stress is applied to each rib. A radially outward
press-fitting stress thus acting on each rib at the time of the
press fitting is absorbed by the annular member as a
circumferential force, resulting in a reduced load on the impeller
cup.
SUMMARY OF THE INVENTION
[0004] In recent years, there has been a demand for a high air
volume fan motor capable of continuously operating under a high
temperature condition. The flexural modulus of elasticity tends to
decrease under the high temperature condition, and it is therefore
desirable to choose a material having a high flexural modulus of
elasticity to prevent a deformation of an impeller blade portion.
In addition, a demand for higher air volumes requires the fan motor
to rotate at a high speed, and therefore, an impeller cup and a
rotor yoke need to be securely fixed to each other to maintain
balance of an impeller even when the fan motor is rotating at a
high speed under the high temperature condition. Meanwhile, in the
case where the impeller cup is made of a material having a high
flexural modulus of elasticity, a thermal stress caused by a
difference in thermal expansion between the impeller cup and the
rotor yoke tends to become significantly high when a significant
decrease in ambient temperature occurs. Moreover, when a
significant increase in the ambient temperature occurs, a
difference in the thermal expansion between the impeller cup and
the rotor yoke may cause a reduction in strength with which the
impeller cup and the rotor yoke are fixed to each other.
Accordingly, there is a demand for a fan motor capable of
continuously operating with stability with the ability to prevent a
significantly high thermal stress from acting on an impeller or a
rotor yoke, and to maintain secure fixing of the impeller and the
rotor yoke to each other, even when a change in ambient temperature
occurs.
[0005] An axial fan according to a preferred embodiment of the
present disclosure includes a rotor portion including a shaft
arranged to extend along a central axis extending in a vertical
direction; a stator portion arranged radially opposite to the rotor
portion; and an impeller hub fixed to the rotor portion, and
arranged to be capable of rotating integrally with the rotor
portion. The impeller hub is an injection molded article, and
includes a hub top plate portion arranged to extend perpendicularly
to an axial direction; a hub tubular portion being tubular, and
arranged to extend axially downward from an outer edge of the hub
top plate portion; a plurality of blades arranged in a
circumferential direction on an outer surface of the hub tubular
portion; and an inner fixing portion arranged radially inward of
the hub tubular portion. The rotor portion includes a rotor tubular
portion being tubular and arranged to extend in the axial
direction. The inner fixing portion includes a first region
arranged radially opposite to an outer surface of the rotor tubular
portion with a gap therebetween, and having a weld defined in a
radially inner surface thereof; and a second region arranged to be
in contact with at least a portion of the outer surface of the
rotor tubular portion.
[0006] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view illustrating an axial fan
according to a preferred embodiment of the present disclosure.
[0008] FIG. 2 is a plan view of the axial fan illustrated in FIG.
1.
[0009] FIG. 3 is a vertical sectional view of the axial fan
illustrated in FIG. 1.
[0010] FIG. 4 is a perspective view of a housing according to a
preferred embodiment of the present disclosure.
[0011] FIG. 5 is a perspective view of a stator portion according
to a preferred embodiment of the present disclosure.
[0012] FIG. 6 is a perspective view of a rotor yoke according to a
preferred embodiment of the present disclosure.
[0013] FIG. 7 is a perspective view of an impeller according to a
preferred embodiment of the present disclosure.
[0014] FIG. 8 is a perspective view of the impeller illustrated in
FIG. 7 as viewed from below.
[0015] FIG. 9 is a plan view of the impeller illustrated in FIG.
7.
[0016] FIG. 10 is a bottom view of the impeller illustrated in FIG.
7.
[0017] FIG. 11 is a plan view illustrating a circumferential
development of a blade attached to an impeller hub according to a
preferred embodiment of the present disclosure.
[0018] FIG. 12 is a diagram depicting circumferential developed
blades according to a preferred embodiment of the present
disclosure superimposed on each other, the circumferential
developed blades being circumferential developments of
circumferential sections of the blade taken at different radial
positions.
[0019] FIG. 13 is a schematic bottom view illustrating an
arrangement of an inner fixing portion according to a preferred
embodiment of the present disclosure.
[0020] FIG. 14 is a vertical sectional view of an impeller used in
an axial fan according to another preferred embodiment of the
present disclosure.
[0021] FIG. 15 is a schematic bottom view of one of first wall
portions included in the impeller illustrated in FIG. 14.
[0022] FIG. 16 is a bottom view of an impeller used in an axial fan
according to yet another preferred embodiment of the present
disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Hereinafter, preferred embodiments of the present disclosure
will be described in detail with reference to the accompanying
drawings. It is assumed herein that, regarding an axial fan A, a
direction parallel to a central axis C1 of the axial fan A is
referred to by the term "axial direction", "axial", or "axially",
that directions perpendicular to the central axis C1 of the axial
fan A are each referred to by the term "radial direction",
"radial", or "radially", and that a direction along a circular arc
centered on the central axis C1 of the axial fan A is referred to
by the term "circumferential direction", "circumferential", or
"circumferentially". It is also assumed herein that, regarding the
axial fan A, an axial direction is a vertical direction, and that a
side on which an air inlet 16 of a housing 10 is arranged with
respect to an impeller 40 is defined as an upper side. The shape of
each member or portion and relative positions of different members
or portions will be described based on the above assumptions. It
should be noted, however, that the above definition of the vertical
direction and the upper and lower sides is made simply for the sake
of convenience in description, and is not meant to restrict
relative positions or directions of different members or portions
of the axial fan A when in use. It is also assumed herein that an
upstream side and a downstream side are defined with respect to a
direction in which an air flow caused by rotation of the impeller
40 passes.
[0024] FIG. 1 is a perspective view illustrating an axial fan A
according to a first preferred embodiment of the present
disclosure. FIG. 2 is a plan view of the axial fan A illustrated in
FIG. 1. FIG. 3 is a vertical sectional view of the axial fan A
illustrated in FIG. 1.
[0025] Referring to FIGS. 1 to 3, the axial fan A according to the
present preferred embodiment includes a housing 10, a stator
portion 20, a rotor portion 30, and an impeller 40. The stator
portion 20 is fixed to the housing 10. The rotor portion 30 is
arranged to be capable of rotating with respect to the stator
portion 20, and includes a portion arranged radially outside of the
stator portion 20 with a gap therebetween. The impeller 40 is
attached to the rotor portion 30.
[0026] The housing 10 will now be described below with additional
reference to FIG. 4. FIG. 4 is a perspective view of the housing
10. In the perspective view illustrated in FIG. 4, a shaft 31,
which will be described below, of the rotor portion 30 is also
depicted.
[0027] The housing 10 includes an air channel wall portion 11, a
base portion 12, stationary vanes 13, a bearing holding tube
portion 14, and flange portions 15. The air channel wall portion 11
includes a cylindrical inner surface arranged to extend along the
central axis C1. The impeller 40 is arranged to rotate inside of
the air channel wall portion 11. The air channel wall portion 11 is
a guide arranged to guide an air flow caused by the rotation of the
impeller 40 along the central axis C1. An air inlet 16 is defined
at an axially upper end of the air channel wall portion 11, while
an air outlet 17 is defined at an axially lower end of the air
channel wall portion 11. That is, the rotation of the impeller 40
causes air to be sucked through the air inlet 16, and causes the
air flow, being accelerated or pressurized by the impeller 40, to
be discharged through the air outlet 17.
[0028] The flange portions 15 are arranged to extend radially
outward from each of both axial end portions of the air channel
wall portion 11. Each flange portion 15 includes a fitting hole 151
arranged to pass therethrough in the axial direction. The fitting
hole 151 is used when the axial fan A is attached to a device.
Specifically, a fitting screw, a boss, or the like provided in the
device is inserted into the fitting hole 151 to fix the flange
portion 15 to the device, so that the axial fan A is fixed to the
device. The flange portions 15 are arranged in the form of a square
as illustrated in FIGS. 1, 2, and 4, but may alternatively be
arranged in the form of a circle, a rectangle, or another polygon,
such as, for example, a hexagon. The form of the flange portions 15
may be determined in accordance with the form of a portion(s) of
the device to which the axial fan A is attached.
[0029] The base portion 12 is arranged to hold the stator portion
20. The base portion 12 includes, in a center thereof, a base
through hole 120 (see FIG. 3) arranged to pass therethrough in the
axial direction, and also includes a tubular tube holding portion
121 arranged to project axially upward above a peripheral portion
of the base through hole 120.
[0030] The base portion 12 is arranged at the axially lower end of
the air channel wall portion 11, i.e., at an end of the air channel
wall portion 11 on the downstream side with respect to the air
flow. The base portion 12 is arranged radially inside of the air
channel wall portion 11. The air channel wall portion 11 and the
base portion 12 are radially spaced apart from each other. The
stationary vanes 13 are arranged in a circumferential direction in
a gap between the air channel wall portion 11 and the base portion
12. Each stationary vane 13 is joined to both the air channel wall
portion 11 and the base portion 12. In other words, the base
portion 12 is held by the air channel wall portion 11 through the
stationary vanes 13. The stationary vanes 13 are arranged to
control air flows caused by the rotation of the impeller 40 so that
the air flows will be axially symmetric with respect to the central
axis C1. Accordingly, the stationary vanes 13 are arranged at
regular intervals in the circumferential direction. The base
portion 12 defines a portion of the housing 10, but the base
portion 12 may alternatively be defined by a member separate from
the housing 10.
[0031] The bearing holding tube portion 14 is cylindrical, and the
stator portion 20 is fixed to an outer circumferential surface of
the bearing holding tube portion 14. The bearing holding tube
portion 14 is fixed to the tube holding portion 121 of the base
portion 12 along the central axis C1. The bearing holding tube
portion 14 is arranged to hold a first bearing 141 and a second
bearing 142 with inner circumferential surfaces of an axially upper
end portion and an axially lower end portion, respectively,
thereof. As illustrated in FIG. 3, the first bearing 141 is
arranged on the axially upper end portion, while the second bearing
142 is arranged on the axially lower end portion. The first and
second bearings 141 and 142 are arranged to rotatably support the
shaft 31, which will be described below, of the rotor portion
30.
[0032] The bearing holding tube portion 14 is fixed to the tube
holding portion 121 of the base portion 12 such that the bearing
holding tube portion 14 is coaxial with the central axis C1.
Accordingly, a center of the stator portion 20, which is fixed to
the outer circumferential surface of the bearing holding tube
portion 14, coincides with the central axis C1. In addition, a
center of the shaft 31, which is rotatably supported by the bearing
holding tube portion 14 through the first and second bearings 141
and 142, coincides with the central axis C1. That is, both the
center of the stator portion 20 and a center of the rotor portion
30 coincide with the central axis C1. Thus, a radially outer
surface of each of tooth portions 212, which will be described
below, of the stator portion 20 is arranged radially opposite to an
inner circumferential surface of a rotor magnet 34, which will be
described below, of the rotor portion 30 with a predetermined
distance therebetween.
[0033] Each of the first and second bearings 141 and 142 is a ball
bearing. The shaft 31 is fixed to an inner race of each of the
first and second bearings 141 and 142. The shaft 31 is fixed to the
inner race of each of the first and second bearings 141 and 142
through, for example, insertion and adhesion, press fitting, or the
like, or by other fixing methods. Note that each of the first and
second bearings 141 and 142 is not limited to the ball bearing.
[0034] The stator portion 20 will now be described in detail below
with additional reference to FIG. 5. FIG. 5 is a perspective view
of the stator portion 20. Referring to FIGS. 3, 5, and so on, the
stator portion 20 includes a stator core 21, an insulator 22, and
coils 23. The stator core 21 has electrical conductivity. The
stator core 21 includes an annular core back portion 211 and the
tooth portions 212. The core back portion 211 is annular, and is
arranged to extend in the axial direction. Each tooth portion 212
is arranged to project radially outward from an outer
circumferential surface of the core back portion 211. The number of
tooth portions 212 included in the stator core 21 is two or more.
The tooth portions 212 are arranged at regular intervals in the
circumferential direction.
[0035] The stator core 21 may be defined by laminated
electromagnetic steel sheets, or may alternatively be defined in
one piece by sintering of powder, casting, or the like. The stator
core 21 may be made up of core segments each of which includes one
of the tooth portions 212, or may alternatively be defined by
winding a strip-shaped member. The stator core 21 has, in a radial
center thereof, a through hole arranged to pass therethrough in the
axial direction.
[0036] The insulator 22 is a resin casting. The insulator 22 is
arranged to cover at least each tooth portion 212 of the stator
core 21 in its entirety. A conducting wire is wound around each
tooth portion 212 covered with the insulator 22 to define the
corresponding coil 23. The insulator 22 provides isolation between
the stator core 21 and each coil 23. Although the insulator 22 is a
resin casting in the present preferred embodiment, this is not
essential to the present invention. Other types of insulator that
are able to provide isolation between the stator core 21 and each
coil 23 can be widely adopted as the insulator 22.
[0037] The coil 23 is arranged around each of the tooth portions
212 of the stator core 21. The coils 23 included in the stator
portion 20 can be divided into three groups (hereinafter referred
to as three phases) which differ in timing of supply of an electric
current. The three phases are defined as a U phase, a V phase, and
a W phase, respectively. That is, the stator portion 20 includes
U-phase coils, V-phase coils, and W-phase coils, all of which are
equal in number. Hereinafter, the coils of the three phases will be
simply referred to collectively as the coils 23.
[0038] The stator portion 20 is fixed to the bearing holding tube
portion 14 with a wall surface of the through hole of the stator
core 21 being in contact with the outer circumferential surface of
the bearing holding tube portion 14. The stator core 21 and the
bearing holding tube portion 14 may be fixed to each other through
press fitting, adhesion, or the like, or by other fixing methods.
Various methods by which the stator core 21 can be securely fixed
to the bearing holding tube portion 14 can be widely adopted.
[0039] With the stator core 21 being fixed to the bearing holding
tube portion 14, the stator portion 20 is fixed to the base portion
12, i.e., inside of the air channel wall portion 11 of the housing
10. As a result, the tooth portions 212 are arranged at regular
intervals around the central axis C1.
[0040] Referring to FIG. 3, the rotor portion 30 includes the shaft
31, a rotor yoke 33, and the rotor magnet 34. The shaft 31 is
columnar. The shaft 31 is arranged to extend in the axial direction
along the central axis C1. The rotor yoke 33 is made of a
metal.
[0041] The rotor yoke 33 will now be described in detail below with
additional reference to FIG. 6. FIG. 6 is a perspective view of the
rotor yoke 33. Referring to FIG. 6, the rotor yoke 33 includes a
rotor top plate portion 331 and a rotor tubular portion 332. The
rotor top plate portion 331 is arranged to extend radially, and is
in the shape of a disk when viewed in the axial direction. The
rotor top plate portion 331 includes, in a center thereof, a
central through hole 333 arranged to pass therethrough in the axial
direction. The rotor top plate portion 331 includes a plurality
(four in the present preferred embodiment) of positioning holes 334
each of which is arranged to pass therethrough in the axial
direction. First bosses 413, which will be described below, of the
impeller 40 are inserted into the positioning holes 334.
[0042] The rotor tubular portion 332 is tubular, and is arranged to
extend axially downward from a radially outer edge of the rotor top
plate portion 331. The rotor tubular portion 332 is fixed to an
inner fixing portion 43, which will be described below, of the
impeller 40 through press fitting. A coupling portion 32 is
inserted into the central through hole 333.
[0043] The coupling portion 32 is arranged to couple and fix the
rotor top plate portion 331 and the shaft 31 to each other. The
coupling portion 32 includes a coupling hole 321, a yoke fixing
portion 322, and a coupling tube portion 323. The coupling tube
portion 323 is tubular, extending in the axial direction. The yoke
fixing portion 322 is arranged at an axially lower end of the
coupling tube portion 323. The coupling hole 321 is arranged to
pass through the coupling tube portion 323 in the axial
direction.
[0044] An axially upper end portion of the shaft 31 is inserted
into the coupling hole 321. The axially upper end portion of the
shaft 31 is press fitted into the coupling hole 321 to be fixed to
the coupling portion 32. The yoke fixing portion 322 is inserted
into the central through hole 333 of the rotor yoke 33. The yoke
fixing portion 322 includes a cylindrical outer surface arranged to
be in contact with and fixed to a wall surface of the central
through hole 333. The coupling tube portion 323 is inserted into an
axial through hole 414, which will be described below, of the
impeller 40, and is fixed in the axial through hole 414. The
coupling tube portion 323 may be fixed in the axial through hole
414 through, for example, adhesion, welding, or the like, or by
other fixing methods.
[0045] The coupling portion 32 is arranged to fix the shaft 31 and
the impeller 40 to each other, and fix the shaft 31 and the rotor
yoke 33 to each other. In other words, each of the impeller 40 and
the rotor yoke 33 is fixed to the shaft 31 through the coupling
portion 32.
[0046] The rotor magnet 34 is tubular, and includes north and south
poles arranged to alternate with each other in the circumferential
direction. The rotor magnet 34 is fixed with an outer
circumferential surface thereof being in contact with an inner
circumferential surface of the rotor yoke 33. The rotor magnet 34
may be molded in one piece of a resin containing magnetic powder,
or may alternatively be defined by a plurality of magnets arranged
in the circumferential direction and fixed to one another through a
resin or the like. The rotor magnet 34 may be fixed to the rotor
yoke 33 through press fitting, adhesion, or the like, or by other
fixing methods. Various methods by which the rotor magnet 34 can be
securely fixed to the rotor yoke 33 can be widely adopted.
[0047] The shaft 31 is rotatably attached to the bearing holding
tube portion 14 through the first and second bearings 141 and 142
held by the bearing holding tube portion 14. Then, the rotor yoke
33 with the rotor magnet 34 fixed thereto is fixed to the shaft 31
through the coupling portion 32. At this time, the radially inner
circumferential surface of the rotor magnet 34 is arranged radially
opposite to the radially outer surface of each of the tooth
portions 212 of the stator portion 20, which is fixed to the
bearing holding tube portion 14, with a gap therebetween. The base
portion 12, the bearing holding tube portion 14, the stator portion
20, and the rotor portion 30 together define a brushless DC motor
of a so-called outer-rotor type, in which the rotor magnet 34 of
the rotor portion 30 is arranged radially outside of the stator
portion 20. Although the base portion 12 defines a portion of the
housing 10 in the present preferred embodiment, the base portion 12
may alternatively be defined by a member separate from the housing
10. In this alternative case, the motor may be assembled
separately, and be attached to the housing 10.
[0048] Magnetic flux generated as a result of electric currents
being passed through the coils 23 of the stator portion 20 causes
an attractive force or a repulsive force to be applied to the rotor
magnet 34. The attractive force or the repulsive force applied to
the rotor magnet 34 causes the rotor portion 30 to rotate about the
central axis C1 with respect to the stator portion 20. Rotation of
the rotor portion 30 causes the impeller 40 fixed to the rotor
portion 30 to rotate about the central axis C1.
[0049] The impeller 40 will now be described in detail below with
additional reference to FIGS. 7, 8, 9, and 10. FIG. 7 is a
perspective view of the impeller 40. FIG. 8 is a perspective view
of the impeller 40 illustrated in FIG. 7 as viewed from below. FIG.
9 is a plan view of the impeller 40 illustrated in FIG. 7. FIG. 10
is a bottom view of the impeller 40 illustrated in FIG. 7.
[0050] Referring to FIGS. 7 to 10, the impeller 40 includes an
impeller hub 41, a plurality of blades 42, and the inner fixing
portion 43. The impeller 40 is defined by a resin injection molding
process.
[0051] Referring to FIGS. 3, 7, 8, and so on, the impeller hub 41
includes a hub top plate portion 411 and a hub tubular portion 412.
The hub top plate portion 411 is in the shape of a disk, extending
radially. The hub tubular portion 412 is tubular, and is arranged
to extend axially downward from a radially outer edge of the hub
top plate portion 411. The hub top plate portion 411 is provided
with the first bosses 413, the axial through hole 414, and second
bosses 415. The axial through hole 414 is a through hole arranged
to pass through the hub top plate portion 411 in the axial
direction, and arranged in a radial center of the hub top plate
portion 411. The coupling tube portion 323 of the coupling portion
32 is inserted into and fixed in the axial through hole 414. In
other words, the shaft 31 is fixed in the axial through hole 414
through the coupling tube portion 323.
[0052] Each of the first and second bosses 413 and 415 is arranged
to project axially downward from an axially lower surface of the
hub top plate portion 411. Each of the first and second bosses 413
and 415 is made of the same material as that of the hub top plate
portion 411, and is defined integrally with the hub top plate
portion 411. Here, the number of first bosses 413 is four. The
first bosses 413 are inserted into the positioning holes 334 of the
rotor yoke 33. The rotor yoke 33 is thus circumferentially
positioned with respect to the impeller hub 41.
[0053] Each second boss 415 is arranged to have an axial dimension
smaller than that of each first boss 413. An upper surface of the
rotor top plate portion 331 of the rotor yoke 33 is arranged to be
in contact with an axially lower surface of each second boss 415.
That is, the rotor yoke 33 is axially positioned with respect to
the impeller hub 41 with the upper surface of the rotor top plate
portion 331 being in contact with the axially lower surface of each
second boss 415.
[0054] Referring to FIGS. 7 and 9, a plurality of gate marks 45 are
defined in an upper surface of the hub top plate portion 411 of the
impeller hub 41. Each gate mark 45 is a mark defined at an inlet
(i.e., a gate) defined in a mold (not shown) and through which a
resin is injected into the mold when a resin injection molding
process is performed for the impeller hub 41. The number of gate
marks 45 is four, and the four gate marks 45 are arranged at
regular intervals in the circumferential direction around the
central axis C1.
[0055] When the resin is injected into the mold through a plurality
of gates, a weld, where different flows of the resin meet, is
defined at a middle position circumferentially between
circumferentially adjacent ones of the gates. That is, the weld is
defined at a middle position circumferentially between
circumferentially adjacent ones of the gate marks 45. The weld will
be described in detail below.
[0056] The blades 42 are arranged side by side in the
circumferential direction on an outer surface of the impeller hub
41. In the present preferred embodiment, on the outer surface of
the impeller hub 41, the blades 42 are arranged side by side at
predetermined intervals in the circumferential direction, and are
integrally molded with the impeller hub 41. An upper portion of
each blade 42 is arranged forward of a lower portion of the blade
42 with respect to a rotation direction Rd of the impeller 40 (see
FIG. 2). The upper portion of each blade 42 is arranged forward of
the lower portion of the blade 42 with respect to the rotation
direction Rd.
[0057] The blades 42 will now be described in more detail below
with additional reference to FIG. 11. FIG. 11 is a plan view
illustrating a circumferential development of one of the blades 42
attached to the impeller hub 41.
[0058] Referring to FIG. 11, a radially innermost portion and a
radially outermost portion of the blade 42 will be referred to as
an innermost portion 4201 and an outermost portion 4202,
respectively. As illustrated in FIG. 11, the innermost portion 4201
is distant from a center of the outer surface of the impeller hub
41 by a distance equal to a radius of the outer surface of the
impeller hub 41. A first intermediate portion 4203 and a second
intermediate portion 4204 are defined radially between the
innermost portion 4201 and the outermost portion 4202 of the blade
42. The innermost portion 4201, the first intermediate portion
4203, the second intermediate portion 4204, and the outermost
portion 4202 are equally spaced from one another. In other words,
the first intermediate portion 4203 corresponds to a radially inner
one of two lines that divide the blade 42 into three parts having
the same radial width. In addition, the second intermediate portion
4204 corresponds to a radially outer one of the two lines that
divide the blade 42 into three parts having the same radial
width.
[0059] Referring to FIG. 11, the blade 42 is joined to the impeller
hub 41 at the innermost portion 4201. Meanwhile, radially outside
of the innermost portion 4201 of the blade 42, a forward portion of
the blade 42 with respect to the rotation direction Rd includes a
portion lying forward of a foremost portion of the innermost
portion 4201 with respect to the rotation direction Rd. This
portion is not joined to the impeller hub 41 in a radial direction,
and is therefore low in strength. Accordingly, the forward portion
of the blade 42 with respect to the rotation direction Rd is prone
to being deformed radially outward during the rotation of the
impeller 40. In addition, a rearward portion of the blade 42 with
respect to the rotation direction Rd has a reduced radial dimension
in a section taken along a plane including the central axis C1,
resulting in a reduced section modulus. Accordingly, the rearward
portion of the blade 42 with respect to the rotation direction Rd
is also prone to being deformed radially outward during the
rotation of the impeller 40. Moreover, the rearward portion of the
blade 42 with respect to the rotation direction Rd is a portion
where an air flow caused by the rotation of the impeller 40
separates from the blade 42, and therefore receives an increased
stress. This makes the rearward portion of the blade 42 with
respect to the rotation direction Rd more prone to being deformed
radially outward.
[0060] While the blade 42 is rotating, a section of the blade 42
taken along a plane including the central axis C1 has a greater
section modulus as the radial dimension of the section increases.
Thus, a portion of the blade 42 which is fixed to the impeller hub
41 in a radial direction is not easily deformed radially. This
characteristic is taken into account to determine the shape of the
blade 42.
[0061] A method for determining a portion of the blade 42 which has
a large radial dimension will now be described below with reference
to the accompanying drawings. FIG. 12 is a diagram depicting
circumferential developed blades superimposed on each other. The
circumferential developed blades are circumferential developments
of circumferential sections of the blade 42 taken at different
radial positions.
[0062] FIG. 12 is a diagram depicting circumferential developments
of the innermost portion 4201, the outermost portion 4202, the
first intermediate portion 4203, and the second intermediate
portion 4204 of the blade 42. In each of the developments of FIGS.
11 and 12, an upstream end portion of the innermost portion 4201
with respect to the rotation direction Rd of the impeller 40 is
used as a reference. Referring to FIG. 12, an inner circumferential
developed blade 421 is a circumferential development of the
innermost portion 4201 of the blade 42. Similarly, an outer
circumferential developed blade 422 is a circumferential
development of the outermost portion 4202 of the blade 42, and a
first intermediate circumferential developed blade 423 and a second
intermediate circumferential developed blade 424 are
circumferential developments of the first intermediate portion 4203
and the second intermediate portion 4204, respectively, of the
blade 42.
[0063] The blade 42 is joined to the impeller hub 41 on a rearward
side, with respect to the rotation direction Rd, of a foremost
portion of the inner circumferential developed blade 421 with
respect to the rotation direction Rd. A portion of the blade 42
where all of the inner circumferential developed blade 421, the
outer circumferential developed blade 422, the first intermediate
circumferential developed blade 423, and the second intermediate
circumferential developed blade 424 overlap when viewed in the
radial direction has a large radial dimension, and is therefore not
easily deformed. It is assumed here that the portion of the blade
42 where all of the inner circumferential developed blade 421, the
outer circumferential developed blade 422, the first intermediate
circumferential developed blade 423, and the second intermediate
circumferential developed blade 424 overlap when viewed in the
radial direction is referred to as a first portion 425. After being
determined with the circumferential developments superimposed on
each other, the first portion 425 is transformed from the
development back into a three-dimensional space to determine the
first portion 425 of the blade 42 (see FIGS. 2, 11, and so on). In
each of FIGS. 2 and 11, both ends of the first portion 425 with
respect to the rotation direction are indicated by broken
lines.
[0064] In the blade 42, the first portion 425 is not easily
deformed radially outward during the rotation of the blade 42.
Referring to FIG. 2, when the impeller 40 has been housed in the
air channel wall portion 11 of the housing 10, a gap Gp1 between
the inner surface of the air channel wall portion 11 and a portion
(hereinafter referred to as a "radially outermost portion") of the
first portion 425 of the blade 42 which lies most radially outward
is smaller than a gap Gp2 between the inner surface of the air
channel wall portion 11 and a radially outermost portion of a
portion of the blade 42 on a forward side of the first portion 425
with respect to the rotation direction. In addition, the gap Gp1 is
smaller than a gap Gp3 between the inner surface of the air channel
wall portion 11 and a radially outermost portion of a portion of
the blade 42 on the rearward side of the first portion 425 with
respect to the rotation direction. That is, the radially outermost
portion of the blade 42 is at the shortest distance from the inner
surface of the air channel wall portion 11 in at least a portion of
the first portion 425.
[0065] The distance between the radially outermost portion of the
blade 42 and the inner surface of the air channel wall portion 11
is arranged to gradually increase in a forward direction with
respect to the rotation direction from the first portion 425.
Similarly, the distance between the radially outermost portion of
the blade 42 and the inner surface of the air channel wall portion
11 is arranged to gradually increase in a rearward direction with
respect to the rotation direction from the first portion 425.
[0066] The above arrangement contributes to optimizing a gap
between the inner surface of the air channel wall portion 11 and a
radially outer edge of each blade 42 of the impeller 40 for the
rotation of the impeller 40, and increasing efficiency in air
blowing by the rotation of the impeller 40. The rearward portion of
the blade 42 with respect to the rotation direction is a portion
where an air flow separates from the blade 42, and therefore
receives greater stress than other portions of the blade 42.
Accordingly, it is preferable that the radial distance between the
radially outermost portion of the blade 42 and the inner surface of
the air channel wall portion 11 is greatest at a rearward end
portion of the radially outermost portion of the blade 42 with
respect to the rotation direction.
[0067] Referring to FIG. 2, when the blade 42 is viewed in the
axial direction, the area of the first portion 425 is smaller than
a sum of the area of a portion 426 of the blade 42 on the forward
side of the first portion 425 with respect to the rotation
direction and the area of a portion 427 of the blade 42 on the
rearward side of the first portion 425 with respect to the rotation
direction. The above arrangement allows the gap between the
radially outermost portion of the blade 42 and the inner surface of
the air channel wall portion 11 to be adjusted to achieve further
optimization of the gap.
[0068] Although, in the present preferred embodiment, two portions
(i.e., the first intermediate portion 4203 and the second
intermediate portion 4204) of the blade 42 are adopted as radially
intermediate portions of the blade 42, this is not essential to the
present invention. Only one portion or more than two portions of
the blade 42 may alternatively be adopted as the radially
intermediate portion(s) of the blade 42. In addition, it is
preferable that the portion of the first portion 425 where the
radially outermost portion of the blade 42 is at the shortest
radial distance from the inner surface of the air channel wall
portion 11 is arranged to have a circumferential dimension greater
than a half of the circumferential dimension of the outer
circumferential developed blade 422.
[0069] The inner fixing portion 43 will now be described in detail
below with additional reference to FIG. 13. FIG. 13 is a schematic
bottom view illustrating an arrangement of the inner fixing portion
43. Referring to FIGS. 8, 10, and 13, the inner fixing portion 43
is arranged radially inside of the hub tubular portion 412. The
inner fixing portion 43 includes wall portions 430 arranged in the
circumferential direction. Each wall portion 430 is arranged to
extend axially downward from the lower surface of the hub top plate
portion 411. Each wall portion 430 is molded integrally with the
hub top plate portion 411. The inner fixing portion 43 may be
tubular, extending in the axial direction.
[0070] The wall portions 430 include four first wall portions 431
and four second wall portions 432. Each first wall portion 431
includes an increased thickness portion 433 having a radially inner
surface arranged at a shorter distance from the central axis C1
than any other portion of a radially inner surface of the first
wall portion 431. The four first wall portions 431 are arranged at
regular intervals in the circumferential direction. The rotor
tubular portion 332 is press fitted to the inner fixing portion 43
while being in contact with the inner fixing portion 43, more
specifically, with some of the wall portions 430. Referring to FIG.
13, the radially inner surface of the increased thickness portion
433 is arranged to be in contact with an outer surface of the rotor
tubular portion 332. The rotor tubular portion 332 is press fitted
to the inner fixing portion 43 while being in contact with the
increased thickness portion 433. The distance of the increased
thickness portion 433 from the central axis C1 is arranged to
continuously increase from a circumferential middle of the
increased thickness portion 433 in circumferentially outward
directions.
[0071] In addition, each second wall portion 432 is arranged
circumferentially between adjacent ones of the first wall portions
431. The four second wall portions 432 are also arranged at regular
intervals in the circumferential direction. That is, the first wall
portions 431 and the second wall portions 432 are arranged
alternately and at regular intervals in the circumferential
direction.
[0072] A weld 434 is defined in a circumferential middle of a
radially inner surface of each second wall portion 432. The weld
434 is a portion of the second wall portion 432 where flows of the
resin coming from different directions have met, and is therefore
lower in strength than other portions of the second wall portion
432. Accordingly, when the rotor tubular portion 332 is press
fitted to the inner fixing portion 43, more specifically, to some
of the wall portions 430, the radially inner surface of the second
wall portion 432 is arranged opposite to the outer surface of the
rotor tubular portion 332 with a gap therebetween to prevent a
concentration of stress on the weld 434 at the time of the press
fitting or during the rotation of the impeller 40.
[0073] The inner fixing portion 43 includes first regions 4301 each
of which is arranged radially opposite to the outer surface of the
rotor tubular portion 332 with a gap therebetween, and each of
which has the weld 434 defined in a radially inner surface thereof.
The inner fixing portion 43 also includes second regions 4302 each
of which is arranged to be in contact with the outer surface of the
rotor tubular portion 332.
[0074] Each weld 434 is defined at a middle position between
adjacent ones of the gate marks 45. Each second region 4302 is
arranged circumferentially between adjacent ones of the first
regions 4301. Accordingly, each second region 4302 is arranged in a
region between circumferentially adjacent ones of the welds 434.
That is, at least a portion of the outer surface of the rotor
tubular portion 332 is arranged to be in contact with an inner
surface of a portion of the inner fixing portion 43 (i.e., the
second region 4302) which lies in a region between a middle
position between each gate mark 45 and a circumferentially adjacent
one of the gate marks 45 and a middle position between the gate
mark 45 and another circumferentially adjacent one of the gate
marks 45. Each first wall portion 431 is arranged on an imaginary
line VL that joins a corresponding one of the gate marks 45 and the
central axis C1 (see FIGS. 3, 13, and so on). In other words, at
least a portion of the outer surface of the rotor tubular portion
332 is arranged to be in contact with the inner surface of the
portion of the inner fixing portion 43 which lies in the region
between the middle position between each gate mark 45 and a
circumferentially adjacent one of the gate marks 45 and the middle
position between the gate mark 45 and the other circumferentially
adjacent one of the gate marks 45.
[0075] Referring to FIGS. 3, 8, and 10, the impeller hub 41
includes a recessed portion 46 being recessed axially upward from
an axially lower end portion thereof radially between the hub
tubular portion 412 and the wall portions 430. Each wall portion
430 is joined to a radially inner surface of the hub tubular
portion 412 through a joining portion(s) 44 arranged in the
recessed portion 46. Each joining portion 44 is arranged to extend
in the axial direction. The recessed portion 46 is arranged to have
an axial dimension smaller than that of the impeller hub 41.
[0076] Referring to FIG. 10, both circumferential ends of each
first wall portion 431 are joined to the hub tubular portion 412
through the corresponding joining portions 44. A circumferential
middle portion of the first wall portion 431 defines the increased
thickness portion 433. The circumferential middle portion of the
first wall portion 431 and the hub tubular portion 412 are arranged
radially opposite to each other with the recessed portion 46
therebetween. The above arrangement allows the first wall portion
431 to bend. This allows stress to be distributed when the rotor
tubular portion 332 is press fitted to the inner fixing portion 43.
The first wall portion 431 is made of the resin, while the rotor
tubular portion 332 is made of the metal. Accordingly, an increase
in temperature of the first wall portion 431 and the rotor tubular
portion 332 will cause the first wall portion 431 to experience a
greater thermal expansion than the rotor tubular portion 332.
Provision of the recessed portion 46 between the hub tubular
portion 412 and a radially outer side of the circumferential middle
portion of the first wall portion 431 allows the first wall portion
431 to be deformed radially outward. This contributes to limiting
an increase in stress caused by a difference in thermal expansion
at an area of contact between the first wall portion 431 and the
rotor tubular portion 332.
[0077] A radially outer side of a circumferential middle portion of
each second wall portion 432 is joined to the radially inner
surface of the hub tubular portion 412 through the corresponding
joining portion 44. Each second wall portion 432 is joined to the
radially inner surface of the hub tubular portion 412 through a
single one of the joining portions 44. As mentioned above, the
circumferential middle portion of the second wall portion 432
includes the weld 434. A portion of the second wall portion 432 in
which the weld 434 is defined is joined to the radially inner
surface of the hub tubular portion 412 through the corresponding
joining portion 44, so that an increase in strength of the portion
of the second wall portion 432 in which the weld 434 is defined can
be achieved. In addition, a difference in thermal expansion between
the second wall portion 432 and the rotor tubular portion 332 would
not lead to a significant increase in stress, since the second wall
portion 432 and the rotor tubular portion 332 are radially spaced
apart from each other with the gap therebetween.
[0078] The above arrangement contributes to preventing an increase
in stress on the inner fixing portion 43 (i.e., the wall portions
430) even if the temperatures of the inner fixing portion 43 (i.e.,
the wall portions 430) and the rotor tubular portion 332 become
higher when the axial fan A is running than when the rotor yoke 33
was press fitted to the impeller hub 41. This in turn contributes
to reducing a change in internal stress caused by a temperature
change between the time of manufacture (i.e., the time of the press
fitting) and the time when the axial fan A is running, and thus
allows the impeller 40 to rotate with stability.
[0079] An axial fan according to a second preferred embodiment of
the present disclosure will now be described below with reference
to the accompanying drawings. FIG. 14 is a vertical sectional view
of an impeller 40B used in the axial fan according to the second
preferred embodiment of the present disclosure. FIG. 15 is a
schematic bottom view of one of first wall portions 471 included in
the impeller 40B illustrated in FIG. 14. The axial fan according to
the second preferred embodiment is similar in structure to the
axial fan A according to the first preferred embodiment except in
the structure of the impeller 40B. Accordingly, detailed
descriptions of members of the axial fan according to the second
preferred embodiment other than the impeller 40B are omitted.
[0080] Referring to FIG. 14, the impeller 40B is different in
structure from the impeller 40 according to the first preferred
embodiment in that wall portions 47 are provided in place of the
wall portions 430 of the impeller 40. The wall portions 47 include
the first wall portions 471 and second wall portions 472. Each
second wall portion 472 is substantially identical in structure to
each second wall portion 432 of the impeller 40. That is, each
second wall portion 472 is arranged radially opposite to a rotor
tubular portion 332 with a gap therebetween.
[0081] Referring to FIGS. 14 and 15, each first wall portion 471
includes a rib 473 arranged to project radially inward in a
circumferential middle of a radially inner surface thereof. In the
first wall portion 471, the rib 473 defines an increased thickness
portion. Accordingly, when a rotor yoke 33 has been press fitted to
an impeller hub 41 of the impeller 40B, a radially outer surface of
the rotor tubular portion 332 is in contact with a radially inner
surface of the rib 473.
[0082] In addition, referring to FIG. 14, a gap is defined between
the rib 473 and an axially lower surface of the hub top plate
portion 411. The hub top plate portion 411 includes, in a region
axially opposed to the rib 473, a through hole 48 arranged to pass
therethrough in the axial direction.
[0083] The gap defined between an upper end of the rib 473 and the
hub top plate portion 411 reduces the likelihood that a
press-fitting stress will be transferred to a hub tubular portion
412 of the impeller hub 41 when the rotor yoke 33 is press fitted
to the impeller hub 41. This contributes to preventing a
deformation of the impeller hub 41.
[0084] Provision of the through hole 48 allows the gap between the
rib 473 and the hub top plate portion 411 to be defined using an
insert (i.e., a mold) which is to be drawn in the axial direction
in a resin injection molding process. This allows use of a mold
having a simplified structure.
[0085] The second preferred embodiment is otherwise similar to the
first preferred embodiment.
[0086] An axial fan according to a third preferred embodiment of
the present disclosure will now be described below with reference
to the accompanying drawings. FIG. 16 is a bottom view of an
impeller 40C used in the axial fan according to the third preferred
embodiment of the present disclosure. The axial fan according to
the third preferred embodiment is similar in structure to the axial
fan A according to the first preferred embodiment except in the
structure of the impeller 40C. Accordingly, detailed descriptions
of members of the axial fan according to the third preferred
embodiment other than the impeller 40C are omitted.
[0087] Referring to FIG. 16, the impeller 40C is different in
structure from the impeller 40 in that an inner fixing portion 49
is provided in place of the inner fixing portion 43 of the impeller
40. The inner fixing portion 49 includes first projecting portions
491 and second projecting portions 492. Each of the first and
second projecting portions 491 and 492 is arranged to project
radially inward from a radially inner surface of a hub tubular
portion 412. Each second projecting portion 492 is arranged to
project radially inward to a greater extent than each first
projecting portion 491. Accordingly, when a rotor yoke 33 has been
press fitted to an impeller hub 41, a radially outer surface of a
rotor tubular portion 332 is in contact with a radially inner
surface of each second projecting portion 492.
[0088] Referring to FIG. 16, a weld 494 is defined in a radially
inner surface of each first projecting portion 491. Each second
projecting portion 492 is arranged radially outside of a
corresponding one of gate marks 45. In more detail, each second
projecting portion 492 is arranged on an imaginary line VL that
joins the corresponding gate mark 45 and a central axis C1. In
other words, the shortest circumferential distance between the
first projecting portion 491 and the corresponding gate mark 45 is
greater than the shortest circumferential distance between the
second projecting portion 492 and the corresponding gate mark
45.
[0089] With the above arrangement, the weld 494 is defined in each
first projecting portion 491, on which a stress at the time of the
press fitting will not act. In addition, each second projecting
portion 492, which is arranged to be in contact with the rotor
tubular portion 332, is arranged in the vicinity of the
corresponding gate mark 45, where a high strength is provided. This
contributes to preventing a deformation when the rotor yoke 33 is
press fitted to the impeller hub 41. Each first projecting portion
491 includes a first region 4901 arranged opposite to the radially
outer surface of the rotor tubular portion 332 with a gap
therebetween. Each second projecting portion 492 includes a second
region 4902 arranged to be in radial contact with the radially
outer surface of the rotor tubular portion 332.
[0090] The third preferred embodiment is otherwise similar to the
first preferred embodiment.
[0091] An axial fan A according to a preferred embodiment of the
present disclosure includes a rotor portion 30 including a shaft 31
arranged to extend along a central axis C1 extending in a vertical
direction; a stator portion 20 arranged radially opposite to the
rotor portion 30; and an impeller hub 41 fixed to the rotor portion
30, and arranged to be capable of rotating integrally with the
rotor portion 30. The impeller hub 41 is an injection molded
article, and includes a hub top plate portion 411 arranged to
extend perpendicularly to an axial direction; a hub tubular portion
412 being tubular, and arranged to extend axially downward from an
outer edge of the hub top plate portion 411; a plurality of blades
42 arranged in a circumferential direction on an outer surface of
the hub tubular portion 412; and an inner fixing portion 43
arranged radially inward of the hub tubular portion 412. The rotor
portion 30 includes a rotor tubular portion 332 being tubular and
arranged to extend in the axial direction. The inner fixing portion
43 includes a first region 4301 arranged radially opposite to an
outer surface of the rotor tubular portion 332 with a gap
therebetween, and having a weld 434 defined in a radially inner
surface thereof; and a second region 4302 arranged to be in contact
with at least a portion of the outer surface of the rotor tubular
portion 332.
[0092] The above structure reduces the likelihood that
press-fitting strength or a stress that acts after press fitting
will cause a deformation or the like of the inner fixing portion
43.
[0093] In the axial fan A having the above-described structure, the
inner fixing portion 43 includes a plurality of second regions
4302, and the plurality of second regions 4302 are arranged at
regular intervals in the circumferential direction.
[0094] With this arrangement, portions of the inner fixing portion
43 to which the rotor tubular portion 332 is press fitted are
evenly distributed in the circumferential direction, allowing
press-fitting stress to be evenly distributed.
[0095] In the axial fan A having the above-described structure, the
inner fixing portion 43 may be tubular, extending in the axial
direction. This arrangement will lead to increased rigidity of the
impeller hub 41, and increased stability of rotation of the
impeller hub 41.
[0096] In the axial fan A having the above-described structure, the
hub top plate portion 411 includes a gate mark 45 defined in an
upper or lower surface thereof. The inner fixing portion 43
includes a first wall portion 431 arranged radially outside of the
gate mark 45, and a second wall portion 432 arranged
circumferentially adjacent to the first wall portion 431. The first
wall portion 431 includes the second region 4302. With this
arrangement, a plurality of wall portions 430 are provided to
achieve a distribution of stress caused by the press fitting.
[0097] In the axial fan A having the above-described structure, the
hub top plate portion 411 includes a gate mark 45 defined in an
upper or lower surface thereof. The inner fixing portion 49 may
include a first projecting portion 491 arranged to project radially
inward from an inner surface of the hub tubular portion 412, and a
second projecting portion 492 arranged to project radially inward
from the inner surface of the hub tubular portion 412 to a greater
extent than the first projecting portion 491. In this case, the
shortest circumferential distance between the first projecting
portion 491 and the gate mark 45 is greater than the shortest
circumferential distance between the second projecting portion 492
and the gate mark 45, and the second projecting portion 492 is
arranged to be in radial contact with the outer surface of the
rotor tubular portion 332. This arrangement reduces the likelihood
that press-fitting strength or a stress that acts after the press
fitting will cause, for example, a deformation of or damage to the
inner fixing portion 49. Further, this structure is simpler than a
double-tube structure and a structure in which a plurality of wall
portions 430 are arranged in the circumferential direction, and
leads to a reduction in production cost.
[0098] An axial fan A according to another preferred embodiment of
the present disclosure includes a rotor portion 30 including a
shaft 31 arranged to extend along a central axis C1 extending in a
vertical direction; a stator portion 20 arranged radially opposite
to the rotor portion 30; and an impeller hub 41 fixed to the rotor
portion 30, and arranged to be capable of rotating integrally with
the rotor portion 30. The impeller hub 41 is an injection molded
article, and includes a hub top plate portion 411 arranged to
extend perpendicularly to an axial direction; a hub tubular portion
412 being tubular, and arranged to extend axially downward from an
outer edge of the hub top plate portion 411; a plurality of blades
42 arranged in a circumferential direction on an outer surface of
the hub tubular portion 412; and an inner fixing portion 43
arranged radially inward of the hub tubular portion 412. The hub
top plate portion 411 includes a plurality of gate marks 45
arranged in the circumferential direction in an upper or lower
surface thereof. The rotor portion 30 includes a rotor tubular
portion 332 being tubular and arranged to extend in the axial
direction. At least a portion of an outer surface of the rotor
tubular portion 332 is arranged to be in contact with an inner
surface of a portion of the inner fixing portion 43 which lies in a
region between a middle position between each gate mark 45 and a
circumferentially adjacent one of the gate marks 45 and a middle
position between the gate mark 45 and another circumferentially
adjacent one of the gate marks 45. Thus, a region where a weld is
unlikely to be defined is made a press-fit region, and this
contributes to securely fixing the rotor tubular portion 332 and
the inner fixing portion 43 to each other.
[0099] In the axial fan A having the above-described structure, the
gate marks 45 are arranged at regular intervals in the
circumferential direction. With this arrangement, stress at the
time of press fitting can be distributed evenly (or substantially
evenly).
[0100] In the axial fan A having the above-described structure, at
least a portion of a region of contact between an inner surface of
the inner fixing portion 43 and the outer surface of the rotor
tubular portion 332 is arranged radially outside of the gate mark
45 and on an imaginary line VL joining the gate mark 45 and the
central axis C1. Thus, a region where a weld is most unlikely to be
defined is made a press-fit region, and this contributes to
securely fixing the inner fixing portion 43 and the rotor tubular
portion 332 to each other, and preventing a deformation of the
inner fixing portion 43.
[0101] In the axial fan A having the above-described structure, the
inner fixing portion may be tubular, extending in the axial
direction. This arrangement will lead to increased rigidity of the
impeller hub 41, and increased stability of rotation of the
impeller hub 41.
[0102] In the axial fan A having the above-described structure, the
inner fixing portion 43 includes a first wall portion 431 including
a region overlapping with the gate mark 45 when viewed in a radial
direction, and a second wall portion 432 arranged circumferentially
adjacent to the first wall portion 431. The rotor tubular portion
332 is arranged to be in contact with an inner surface of the first
wall portion 431. This arrangement allows press-fitting stress to
be distributed.
[0103] In the axial fan A having the above-described structure, the
inner fixing portion 49 may include a first projecting portion 491
arranged to project radially inward from an inner surface of the
hub tubular portion 412, and a second projecting portion 492
arranged to project radially inward from the inner surface of the
hub tubular portion 412 to a greater extent than the first
projecting portion 491. In this case, the shortest circumferential
distance between the first projecting portion 491 and the gate mark
45 is greater than the shortest circumferential distance between
the second projecting portion 492 and the gate mark 45, and the
second projecting portion 492 is arranged to be in radial contact
with the outer surface of the rotor tubular portion 332. This
structure is simpler than a double-tube structure and a structure
in which a plurality of wall portions are arranged in the
circumferential direction, and allows a reduction in the production
cost.
[0104] An axial fan according to a preferred embodiment of the
present disclosure may be used in, for example, a blower apparatus
or the like. The blower apparatus may be used, for example, to cool
an electronic device.
[0105] Features of the above-described preferred embodiments and
the modifications thereof may be combined appropriately as long as
no conflict arises.
[0106] 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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