USOO5967764A

United States Patent (19) 11 Patent Number: 5,967,764

B00th et al. (45) Date of Patent: Oct. 19, 1999
54 AXIAL FAN WITH SELF-COOLED MOTOR 5,217,353 6/1993 De Filippis ............................. 417/368
5,283,493 2/1994 Hokanson et al. ...................... 310/227
75 Inventors: Jeff D. Booth, Maynard; Robert J. Van 5,645,401 7/1997 Martin et al. ....................... 416/169 A
Houten, Winchester, both of Mass. FOREIGN PATENT DOCUMENTS
73 Assignee: Bosch Automotive Systems 0569738 A1 11/1993 European Pat. Off..
Corporation, Waltham, Mass. 3301918 A1 7/1984 Germany.
3933868 A1 5/1991 Germany.
21 Appl. No.: 08/907,557 Primary Examiner-Charles G. Freay
22 Filed: Aug. 8, 1997 Attorney, Agent, or Firm-Fiah & Richardson P.C.
(51) Int. Cl." ...................................................... F04B 35/04 57 ABSTRACT
52 U.S. Cl. ....................... 417/423.8; 417/368; 417/370; A fan and electric motor combination (or a fan adapted to be
416/169 A used in Such a combination) which provides improved
58 Field of Search ..................................... 417/368, 370, cooling for the motor, using a centrifugal impeller including
417/423.5, 423.7, 423.8, 423.14; 416/169 A, rotating impeller blades. The impeller blades span between
198 R, 175, 201A, 203 an impeller inlet and an impeller outlet, and they rotate to
assist cooling airflow for the motor. Cooling airflow is also
56) References Cited assisted by the position of the impeller in that the impeller
U.S. PATENT DOCUMENTS outlet is positioned upstream of an interSection of the fan
blade trailing edge and the hub. Therefore, cooling airflow
2,294,586 9/1942 Troller ..................................... 417/368 is assisted by at least Some (preferably all) of the pressure
2,661,146 12/1953 Hill et al... ... 417/365 drop acroSS the axial fan. If the impeller outlet is positioned
2,819,675 1/1958 Gilman ..... ... 416/175 Still further upstream, e.g., upstream of an interSection of the
3,731,121 5/1973 Cook et al. ... ... 310/227 fan blade leading edge and the hub, then the motor cooling
4,092,556 5/1978 Mabuchi ................................... 31.0/57 airflow is assisted by all or nearly all of the pressure drop
4,153,389 5/1979 Boyd ........ ... 416/201 A acroSS the axial fan.
4,659,951 4/1987 Angi et al. ................................ 310/62
4,883,982 11/1989 Forbes et al. ................ ... 310/62
5,180,279 1/1993 McLane-Goetz et al. .............. 415/177 12 Claims, 15 Drawing Sheets
U.S. Patent Oct. 19, 1999 Sheet 1 of 15 5,967,764
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U.S. Patent Oct. 19, 1999 Sheet 13 of 15 5,967,764
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AXIAL EAN WITH SELF-COOLED MOTOR through the inside of the motor-i.e., through the casing
inlet, into the inside of motor casing, and through the casing
FIELD OF THE INVENTION outlet to the impeller inlet.
This invention is in the general field of electric motor In one embodiment, the impeller blades are positioned
driven axial fans, particularly fans used in automotive between a forwardly-facing central region of the hub and a
engine cooling applications. bottom plate Spaced axially in front of the forwardly-facing
central hub region. The central hub region Serves as a top
BACKGROUND OF THE INVENTION plate of the centrifugal impeller. Alternatively, there can be
a top plate Separate from the hub and the bottom plate.
Internal motor temperature has a critical effect on the In other embodiments, the fan hub comprises a
performance and durability of electric motors. The internal rearwardly-facing, concave, central region, constructed to
temperature of an electric motor is greater than the ambient Serve as a bottom plate and a top plate Spaced axially
temperature due to the heat generated by the motor. In rearward of the central hub region. The impeller blades are
automotive engine cooling applications where the electric positioned between the rearwardly-facing region and the top
motor is under the hood of the vehicle the problem is made 15 plate. Typically, the impellerblades are connected to the fan
more Severe by the high ambient temperatures produced by hub, so that hub rotation drives the impeller blades.
the vehicle's engine. Certain features may operate to reduce Alternatively, the motor casing may serve as the top plate or
motor temperature rise over ambient temperature rise. a portion of the top plate. In this embodiment, the motor
McLane-Goetz et al. U.S. Pat. No. 5,180,279 disclose a casing may include a flange constructed to Serve at least part
fan which includes a Scoop downstream of an axial fan to of the top plate of the centrifugal impeller.
divert Some of the axial fan airflow across the rear of the
motor.
For motors in which at least part of the motor casing
rotates with the fan hub, the impellerblades may be attached
DeFilippis U.S. Pat. No. 5,217,353 discloses a centrifugal to the motor casing. For motors in which the motor casing
blower motor having a Stationary motor casing with holes is stationary, the assembly may include a Seal (e.g., an
for taking in air from the outside and for ventilating the 25
extension from the hub toward the casing, or an extension
interior of the motor; the motor also has a rotary part with from the casing toward the hub, or both) to reduce a gap
holes which act as outlet ducts for the internal motor between the casing and the hub.
ventilation. A rotatable motor driveplate may be connected to the
Ribs of the fan driven by the motor which are primarily motor, and at least a portion of the impeller blades may be
Structural can have the additional benefit of cooling the attached to that driveplate, so that the motor drives the
motor. impeller blades. The driveplate may serve as either the top
SUMMARY OF THE INVENTION
plate or the bottom plate. The driveplate may include a Seal.
The impellerblades and the driveplate may be made of metal
One aspect of the invention features a fan and electric 35 to improve heat transfer from the motor to the cooling
motor combination (or a fan adapted to be used in Such a airflow.
combination) which provides improved cooling for the The fan and impeller blades may be formed of injection
motor. This aspect of the invention generally features a molded plastic material. In Some cases, the fan and impeller
centrifugal impeller comprising an inlet, an outlet, and blades are molded as a Single unit. The fan, impeller blades
rotating blades. The inlet is positioned to receive the motor 40 and either the top plate, the bottom plate, or both, can be
cooling airflow. The rotating blades cause the pressure at the molded as a single unit. In another case, the impeller blades
impeller outlet to be greater than at the inlet. The pressure of and either the top plate, the bottom plate, or both, can be
the motor-cooling airflow is further increased by positioning molded as a Single unit.
the impeller outlet upstream of an interSection of the fan The above-described fan and motor combinations may be
blade trailing edge and the hub (here upstream is interpreted 45 used to move air through an adjacent heat eXchanger in a
in terms of the general, bulk airflow regardless of local vehicle.
anomalies). Therefore, at least Some (preferably all) of the The above-described fan/motor combinations may be
preSSure rise acroSS the axial fan is added to the pressure rise assembled by attaching the motor to the fan.
of the impeller. If the impeller outlet is positioned still Other features and advantages will be apparent from the
further upstream, e.g., upstream of an interSection of the fan 50 following description and from the claims.
blade leading edge and the hub, then the pressure rise of the
impeller is increased by all or nearly all of the pressure rise BRIEF DESCRIPTION OF THE DRAWINGS
acroSS the axial fan. The resulting preSSure rise overcomes FIGS. 1A and 1B are diagrammatic representations of an
the pressure losses of the motor-cooling flow path, and
results in greater motor-cooling airflow. 55
axial cooling fan for an electric motor.
In referring to axial flow fans, we recognize that the FIG. 1C is an exploded view of the fan of FIGS. 1A and
general flow of air through axial fans may be entirely axial 1B, showing the bottom plate and impeller blades Separated
or the flow may be mixed, in which case there may be a from the rest of the assembly for illustration purposes.
Significant component of radial flow. FIG. 1D is an enlarged view of the motor casing and hub
of FIG. A.
Typically, but not inevitably, the motor will include an 60
outer casing. The invention provides Some advantage for FIG. 1E is a diagrammatic representation of an axial
motorS having a Sealed outer casing, in that the impeller cooling fan for an electric motor for pushing air through a
generates motor-cooling airflow along the outside of the heat eXchanger.
motor casing. The invention is particularly advantageous for FIG. 1F is a diagrammatic view of a Sealed motor casing.
motorS having a casing with at least one casing inlet and at 65 FIG. 2 is a diagrammatic view of an axial cooling fan
least one casing outlet positioned near the impeller inlet, So having the impellerblades integrally connected with the hub
that rotation of the impeller assists motor-cooling airflow of the axial fan.
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FIGS. 3A and 3B are diagrammatic views of an axial axial and tangential direction to a generally radial and
cooling fan with impeller blades having an Outer radius tangential direction as it moves from cooling apertures 33
greater than the radius of the bottom plate. through the inlet (I) of impeller blades 24 to the outlet (O)
FIG. 4 is a diagrammatic view of an axial cooling fan of the blades as shown by flow arrows 35. As the air moves
having a motor casing with a flange Serving as the top plate. 5 through impeller blades 24 of the centrifugal blower, it
FIG. 5 is a diagrammatic view of an axial cooling fan with experiences a pressure rise AP.
a rotating motor case. The pressure increase AP through impellerblades 24 and
FIGS. 6A and 6B are diagrammatic views of an axial AP through fan 10 is balanced by a pressure drop AP that
cooling fan having the impeller blades integral with the occurs as the airflow moves through motor 12, entering
fan/motor driveplate attachment. through apertures 31 and exiting through apertures 33, as
shown by the relation
FIG. 6C is a diagrammatic view of a fan/motor combi
nation in which a driveplate Serves as a bottom plate.
FIGS. 7A and 7B are diagrammatic views of an axial When the fan/motor is in operation, the airflow pattern
cooling fan having the impellerblades positioned in a cavity 15 just described continuously cools the interior of motor 12.
formed in the rear of the fan hub. To provide more heat rejection for the internal parts of motor
FIGS. 8A and 8B is a diagrammatic view of an axial 12, and to improve motor performance and durability, a
cooling fan in which impeller outlets are located down Sealing device 40 is employed to ensure that the airflow goes
Stream of the leading edges of the fan blades. through the interior of the motor casing and not along the
FIG. 9 is a diagrammatic view of a fan/motor combination outside of the casing. Sealing device 40 is an extension of
where the motor casing has cooling apertures positioned So hub 20 extending axially towards motor casing top 38,
that cooling air exits radially. defining a clearance gap 42 determined by manufacturing
tolerances and design considerations. The inner radius, from
DESCRIPTION OF THE PREFERRED axis 22, of Sealing device 40 is slightly larger than the
EMBODIMENTS 25 outermost edges of cooling apertures 33 So as not to interfere
In FIGS. 1A and 1B, an axial fan 10 is used to “pull” air with the airflow exiting cooling apertures 33.
through a heat exchanger 11 upstream (from the point of Referring to FIG. 1E, a motor/fan combination is arranged
view of mainstream airflow) of the fan. Fan 10 is driven by to “push air, in the direction indicated by arrows 49,
a motor 12 enclosed in a motor casing 14. Fan 10 includes through heat exchanger 11 downstream (from the point of
a Series of blades 16 integrally connected to a rotating band view of mainstream airflow) of the fan. Motor cooling air
18 and a hub 20 that is structurally reinforced with ribs 21. exits motor casing 14 and enters inlet (I) of impeller blades
Blades 16, each having a leading edge 90 and a trailing edge 24, as shown by arrow 34, and then flows through the
92, extend in a plane generally perpendicular to axis 22 of impeller, exiting at the outlet (O). From the outlet (O), the
the fan and motor. Each blade 16 has a low-pressure Surface cooling airflow enters into the mainstream airflow as indi
13 facing in the general direction of the upstream Side of fan 35 cated by arrow 35. All other identified elements are the same
as those described above with reference to FIG. 1B.
10 and a high pressure Surface (not shown) facing generally Referring to FIG.1F, a sealed motor casing 300 is shown.
towards the downstream side of fan 10.
To cool motor 12, multiple (for example, at least 5) In this embodiment, the motor cooling air flows along the
impeller blades 24 are attached to bottom plate 25, and they outside of motor casing 300 in the general direction of arrow
extend between bottom plate 25 and hub 20. Blades 24
40 301. The airflow enters inlet (I) of the impeller and flows
through impellerblades 24, as indicated by arrow 304. Upon
extend generally perpendicularly to axis 22. The combina exiting the outlet (O) of the impeller, the airflow, indicated
tion of hub 20, plate 25, and blades 24 define the flow path by arrow 306, enters the mainstream airflow, flowing in the
of a centrifugal blower, with an inlet radially inward from its general direction of arrow 308.
outlet. In a preferred embodiment, blades 24 and bottom 45 Other embodiments of the invention will now be
plate 25 are molded as one piece as shown in FIG. 1C (parts described. The same element numbers used in FIGS. 1A
are shown in an exploded view with blades 24 Separated through 1D will be used to identify similar elements in
from hub 20 for purposes of clarity), and fan 10 is molded FIGS. 2 through 8.
as another unit.
In FIG. 2, bottom plate 25 is a separately formed piece
Hub 20 is attached to drive plate arms (for example, at 50 and impeller blades 24 are connected integrally with top of
least 3), of which only arm 26 is shown for sake of clarity, fan hub 20 Such that impeller blades 24 and fan 10 are
which are integrally connected with shaft 28. In use, motor molded as a single unit. By having impeller blades 24
casing 14 remains Stationary and motor 12 causes shaft 28 molded together with fan 10, impeller blades 24 provide
to rotate Such that all the other above Stated connected additional structural Support to hub 20. Bottom plate 25 is
elements rotate about axis 22 as a Single unit. 55 shown separated from impeller blades 24 for illustration
Shown in FIG. 1D is the airflow pattern induced by the purposes, in operation, bottom plate 25 would be centered
fan/blower unit. As fan 10 rotates about axis 22, blades 16 relative to hub 20 by a groove 23 and connected to impeller
draw air from the general upstream region (U) of fan 10 and blades 24, for example, by a heat-welding process. In other
they move the air through fan 10 to a general downstream embodiments, bottom plate 25 could be snapped onto hub
region (D) as indicated by arrows 30 (as also shown in FIG. 60 20. The operation of the fan/motor shown in FIG. 2 is
1B). The induced airflow through fan 10 experiences a generally the same as that described in reference to FIGS.
preSSure increase AP. 1A through 1D, except that the airflow, upon exiting cooling
The air is pulled from region (D) through inlet apertures apertures 33, flows through hub holes 53 disposed near the
31 into motor casing 14 as shown by flow arrows 32. The air inlet (I) of impeller blades 24 prior to moving through the
flows through the interior of motor 12, thereby cooling it, 65 blades to the outlet (O) region of the impeller blades.
and is expelled through cooling apertures 33 as indicated by With reference to FIG.3, an illustration of an embodiment
flow arrows 34. The airflow is then turned from a generally is shown in which bottom plate 25 is attached to a set of
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impeller blades 24 integrally molded with fan 10, where In another arrangement, impellerblades 24 and fan/motor
bottom plate 25 does not extend out to the outer radii of driveplate attachment 72 can be made of metal. The metal
impeller blades 24. In addition, top plate 50 formed by hub components act as a heat eXchanger drawing heat from the
20 does not extend inward to the inner radii of impeller motor armature through the shaft and rejecting heat from the
blades 24 thereby leaving an annular gap 52 breached only motor blades to the induced cooling air.
by impeller blades 24. This enables fan 10, impeller blades In the embodiment shown in FIGS. 7A and 7B, impeller
24, and bottom plate 25 to be molded as a single unit. blades 24 are molded integrally to the underside of hub 20
In another embodiment, as shown in FIG. 4, a flange 19 Such that hub 20 Serves as a bottom plate. A Separate annular
connected to motor casing 14 and extending outwardly shaped top plate 82 is attached to the bottom of impeller
towards hub 20 serves as a top plate. Alternatively, the motor blades 24 to form a series of flow paths, each flow path
casing may not have a flange in which the motor casing having two adjacent impellerblades on each Side and having
diameter is large enough So that at least a portion of the hub 20 and top plate 82 as the bottom and top sides,
motor casing Serves as the top plate. When the fan/motor is respectively. This arrangement enables the airflow, having
in operation, air flows through motor casing 14 in the exited the motor casing, to move through the defined flow
direction indicated by arrows 34 through the cooling aper 15 paths and exit through slots 80 disposed around the periph
tures 33. The airflow turns and flows through a series of flow ery of hub 20. The location of slots 80 can be indexed such
paths formed by the combination of flange 19, impeller that each is positioned near the low pressure Surface 13 of a
blades 24 and bottom plate 25, bottom plate 25 being blade 16. The clearance 84 defined by the spacing between
attached to driveplate 27 integrally connected to shaft 28. A the region near the inner radius of top plate 82 and motor
Sealing device is formed by minimizing the gap 41 between casing 14 is minimized to form a Seal to ensure that the
flange 19 and hub 20. airflow moves through the interior of the motor and not
Referring to FIG. 5, an embodiment of the fan/motor is around the outside of the motor casing.
shown in which fan 10, impeller blades 24 and bottom plate Shown in FIGS. 8A and 8B is a motor/fan combination
25 can be connected together to form a Single piece that is where cooling air, flowing in the direction of arrow 93, exits
attached, for example, with Screw 62, to a rotatable outer 25 motor casing 14, flows through impellerblades 24, and exits
motor casing 15. When the fan/motor is in use, fan 10, through impeller outlet (O), where the outlet (O) is located
impeller blades 24, bottom plate 25 and outer motor casing downstream of the leading edges 90 and upstream of the
15 rotate about axis 22 while inner motor casing 17 remains trailing edges 92 of fan blades 16. The other identified
stationary. Air flows in the general direction of arrow 60 into elements are similar to those described above.
the interior of motor 12 through inlet apertures 31 and exits Referring to FIG. 9, motor casing 14 includes cooling
outer motor casing 15 through cooling apertures 33 and apertures 33 located on the Side of motor casing 14 and near
finally moves in a radial and tangential direction through the inlet (I) of impeller blades 24. With this configuration,
impeller blades 24. Similar to that described in a previous motor cooling air exits motor casing 14 through cooling
embodiment (FIG. 1C), sealing device 64 prevents the apertures 33 in a generally radial, as indicated by arrows 34,
airflow from flowing across the outside of motor casing 15 35 and tangential direction. The cooling airflow moves through
and ensures that the flow is directed through the interior of impeller blades 24 and exits the impeller at the outlet (O) of
motor 12, although, unlike that shown in FIG. 1C, hub 20 the impeller blades. As indicated by arrow 35, the cooling
may be in contact with outer motor casing 15. airflow moves from the outlet and enters the mainstream
Alternatively, outer motor casing 15 can be integrally airflow moving in the general direction of arrows 200. This
connected to impeller blades 24, in which bottom plate 25, 40 embodiment may have the additional benefit of reducing the
integral with fan hub 20, is attached to outer motor casing 15 overall package depth by moving the impeller blades to a
with screw 62. position more generally along the Side of the motor casing.
In another arrangement (not shown), the fan/hub/impeller Other embodiments may incorporate one or more of the
combinations shown in FIGS. 1B, 2, and 7 (to be described features described in reference to FIGS. 1 through 9 and are
below), each showing a motor with stationary casing 14, can 45 within the Scope of the following claims.
be used in combination with a motor having the rotatable What is claimed is:
outer motor casing 15. 1. An axial flow fan and motor combination comprising:
In the embodiment shown in FIGS. 6A and 6B, impeller a) a fan hub connected to outwardly extending fan blades,
blades 24 are integral with a fan/motor driveplate attachment the hub and fan blades being rotatable to produce an
72 so that driveplate/impeller blades unit serves as a top 50 airflow from a region upstream of a fan blade leading
plate. Bottom plate 25 is attached to driveplate attachment edge, to a region downstream of a fan blade trailing
72 by a threaded bolt (not shown) placed through hole 70 edge;
and Securely engaged with a threaded portion 74 of the b) an electric motor connected to rotate the fan hub; and
driveplate attachment. A portion of driveplate attachment 72 c) a centrifugal impeller comprising rotating impeller
extends axially towards housing 14 thereby defining a gap 55
71. By minimizing this gap, a Sealing device is formed. In blades, an impeller inlet, and an impeller outlet, the
use, air flows out cooling apertures 33 of motor casing 14 impeller outlet being positioned upstream of an inter
through the flow paths formed by impeller blades 24, bottom Section of the fan blade trailing edge and the hub,
plate 25 and driveplate attachment 72 and out through slots wherein the hub comprises a rearwardly-facing, concave,
76, as indicated by arrow 35. 60 central region, constructed to Serve as a bottom plate,
Referring to FIG. 6C, a fan/motor combination is shown and a top plate Spaced axially rearward of the central
in which a driveplate 400 is integral with impeller blades 24 hub region, the impeller blades being positioned in a
Such that the driveplate/impeller blades unit Serve as a Space between the rearwardly-facing central region and
bottom plate. The airflow moves through motor casing 14 the top plate.
and impeller blades 24 as indicated by arrow 34. After 65 2. An axial flow fan and motor combination comprising:
exiting the impeller, the airflow then turns and enters the a) a fan hub connected to outwardly extending fan blades,
mainstream airflow as shown by arrow 35. the hub and fan blades being rotatable to produce an
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airflow from a region upstream of a fan blade leading impeller outlet being positioned upstream of an inter
edge, to a region downstream of a fan blade trailing Section of the fan blade trailing edge and the hub,
edge; wherein the motor comprises an outer casing, and
b) an electric motor connected to rotate the fan hub; and 5
wherein at least a portion of the motor Outer casing Serves
c) a centrifugal impeller comprising rotating impeller as a top plate.
blades, an impeller inlet, and an impeller outlet, the 6. The combination of claim 5 in which said motor casing
impeller outlet being positioned upstream of an inter includes a flange, Said flange being constructed to Serve as
Section of the fan blade trailing edge and the hub, the top plate of Said impeller.
wherein the motor comprises an outer casing, and 7. An axial flow fan and motor combination comprising:
wherein at least part of the motor casing is configured to a) a fan hub connected to outwardly extending fan blades,
rotate with the impeller blades and the fan hub. the hub and fan blades being rotatable to produce an
3. The combination of claim 2 wherein said impeller airflow from a region upstream of a fan blade leading
blades are integrally connected to Said motor casing. edge, to a region downstream of a fan blade trailing
4. An axial flow fan and motor combination comprising: 15
edge;
a) a fan hub connected to outwardly extending fan blades, b) an electric motor comprising a shaft and configured to
the hub and fan blades being rotatable to produce an rotate the shaft;
airflow from a region upstream of a fan blade leading c) a centrifugal impeller comprising rotating impeller
edge, to a region downstream of a fan blade trailing blades, an impeller inlet, and an impeller outlet, the
edge; impeller outlet being positioned upstream of an inter
b) an electric motor connected to rotate the fan hub; and Section of the fan blade trailing edge and the hub; and
c) a centrifugal impeller comprising rotating impeller d) a rotatable motor driveplate connected to the motor
blades, an impeller inlet, and an impeller outlet, the shaft and the fan hub, and configured to communicate
impeller outlet being positioned upstream, from the rotational force of the motor shaft to the fan hub.
25 8. The combination of claim 7 wherein said motor com
perspective of motor-cooling airflow generated by the
impeller, of an interSection of the fan blade trailing prises a Stationary outer casing, the combination further
edge and the hub, comprising a Seal between Said driveplate and Said casing.
wherein the motor comprises a Sealed Outer casing, and 9. The combination of claim 7 wherein said driveplate
the impeller generates motor-cooling airflow along the Serves as either a top plate or a bottom plate.
outside of the motor casing. 10. The combination of claim 7 wherein at least a portion
5. An axial flow fan and motor combination comprising: of Said impeller blades are attached to Said driveplate,
whereby motor driveplate rotation drives the impeller
a) a fan hub connected to outwardly extending fan blades, blades.
the hub and fan blades being rotatable to produce an 11. The combination of claim 10 wherein said impeller
airflow from a region upstream of a fan blade leading 35 blades and Said driveplate are made of metal.
edge, to a region downstream of a fan blade trailing 12. The combination as in one of claims 1, 2, 4, 5 and 7,
edge; wherein Said fan, Said impeller blades and either Said top
b) an electric motor connected to rotate the fan hub; and plate, Said bottom plate, or both, are molded as a single unit.
c) a centrifugal impeller comprising rotating impeller
blades, an impeller inlet, and an impeller outlet, the k k k k k