PRIORITY

This application claims benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 63/436,331, filed Dec. 30, 2022, which is expressly incorporated by reference herein and made a part hereof.

BACKGROUND

A ventilation fan having a scroll formed to define an interior space, an inlet opening into the interior space, and an outlet spaced apart from the inlet, a fan wheel coupled to the scroll and arranged to lie within the interior space, and a motor configured to drive rotation of the fen wheel about a rotation axis, wherein the fan wheel includes a wheel hub coupled to the motor, a plurality of peripheral fan blades coupled to an outer edge of the wheel hub and spaced apart circumferentially about the rotation axis, and a plurality of impeller fan blades coupled to the wheel hub and located radially between the rotation axis and the plurality of peripheral fan blades. Each of the impeller fan blades can be spaced apart from the rotation axis and arranged along a plane that does not pass thorough the rotation axis. Each plane can be substantially straight and parallel with the rotation axis. Each plane can extend through a tangent point of one of the peripheral blades. Each impeller blade can have an inner end located at a first circumferential location and an outer end located at a second circumferential location offset from the first circumferential location. The outer end of each impeller blade can be formed integrally with a radially inner end of a corresponding peripheral blade. Each of the peripheral blades can have a first, constant height and each of the impeller blades has a second, variable height. The second, variable height can be less than the first, constant height. Each of the impeller blades can have a bottom edge that slopes toward a proximal end of the peripheral blades as the impeller blades extend radially outward away from the rotation axis. Each of the impeller blades can have a bottom edge that slopes toward a distal end of the peripheral blades as the impeller blades extend radially outward away from the rotation axis.

A fan wheel for a ventilation fan, the fan wheel having a wheel hub defining a rotational axis configured to be coupled to a motor; a plurality of peripheral fan blades coupled to an outer edge of the wheel hub and spaced apart circumferentially about the rotational axis; and a plurality of impeller fan blades coupled to the wheel hub and located radially between the rotation axis and the plurality of peripheral fan blades. Each of the impeller fan blades can be spaced apart from the rotation axis and arranged along a plane that does not pass thorough the rotation axis. Each plane can be substantially straight and parallel with the rotation axis. Each plane can extend through a tangent point of one of the peripheral blades. Each impeller blade can have an inner end located at a first circumferential location and an outer end located at a second circumferential location offset from the first circumferential location. The outer end of each impeller blade can be formed integrally with a radially inner end of a corresponding peripheral blade. Each of the peripheral blades can have a first, constant height and each of the impeller blades has a second, variable height. The second, variable height can be less than the first, constant height. Each of the impeller blades can have a bottom edge that slopes toward a proximal end of the peripheral blades as the impeller blades extend radially outward away from the rotation axis.

A fan wheel for a ventilation fan, the fan wheel having a wheel hub defining a rotational axis; a plurality of peripheral fan blades extending from an outer edge of the wheel hub; and a plurality of impeller fan blades coupled to the wheel hub radially inward of the peripheral fan blades.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The accompanying drawings, which are included to provide further understanding and are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and together with the description serve to explain the principles of the disclosed embodiments. In the drawings:

FIG. 1 is a cross-sectional view of one embodiment of the ventilation fan of the present disclosure.

FIG. 2 is a perspective view of a fan wheel of the ventilation fan of FIG. 1.

FIG. 3 is a top plane view of the fan wheel of FIG. 2.

FIG. 4 is an outtake of FIG. 3.

FIG. 5 is a cross-sectional view of the fan wheel of the ventilation fan of FIG. 1.

FIG. 6 is a cross-sectional view of a second embodiment of the ventilation fan of the present disclosure.

FIG. 7 is a perspective view of a fan wheel of the ventilation fan of FIG. 6.

FIG. 8 is a cross-sectional perspective view of the ventilation fan disclosed in FIG. 6.

FIG. 9 is a top plane view of the fan wheel of FIG. 6.

FIG. 10 is an outtake of FIG. 9.

FIG. 11 is a cross-sectional view of the fan wheel of FIG. 6.

FIG. 12 depicts another embodiment of a fan wheel of the present disclosure.

FIG. 13 is a cross-sectional view of another embodiment of the ventilation fan of the present disclosure.

FIG. 14 is a perspective view of a fan wheel of the ventilation fan of FIG. 13.

FIG. 15 is a top plane view of the fan wheel of FIG. 13.

FIG. 16 is an outtake of FIG. 15.

FIG. 17 is a cross-sectional view of the fan wheel of FIG. 13

DETAILED DESCRIPTION

A ventilation fan 10 is configured to be mounted to a building and is configured to ventilate at least one room of the building. The ventilation fan 10 includes a scroll 12, a fan wheel 14 arranged to lie within an interior space 16 defined by the scroll 12, and a motor 15 configured to drive the fan wheel 14 as shown in FIG. 1. The scroll 12 is also formed to define an inlet 18 opening into the interior space 16 and an outlet 20 spaced apart from the inlet 18 to release air from the scroll 12. The scroll 12 and the fan wheel 14 may both reside within a fan housing (not shown). In some embodiments, the ventilation fan 10 is an exhaust fan for a bathroom and is placed above a ceiling of the bathroom.

The fan wheel 14 is located within the interior space 16 defined by the scroll 12 and is configured to move air through the inlet 18 as suggested in FIG. 1 and expel air through the outlet 20, which is optionally connected to a duct to direct the air away from the ventilation fan 10. In one example, the scroll 12 of the ventilation fan 10 is mounted above a ceiling panel of the building and the fan wheel 14 is configured to withdraw air from the at least one room through an opening in the room. The air drawn in to the ventilation fan 10 follows a flow path F through the interior space 16 defined by the scroll 12. The air may be exhausted to an exterior of the building or conditioned and/or recirculated back into the building.

The motor 15 is optionally mounted to the top wall 12T of the scroll 12 and is configured to drive rotation of the fan wheel 14 about a rotation axis 14A relative to the scroll 12 as shown in FIG. 1. The fan wheel 14 includes a wheel hub 30 coupled to the wheel motor 15, a blade support ring 32, and a plurality of fan blades 34 coupled to the wheel hub 30 and the blade support ring 32. The motor 15 includes a drive shaft 22 that is configured to rotate about the central rotation axis 14A of the fan wheel 14 when the motor 15 is powered on. The wheel hub 30 is fixed to the drive shaft 22 for rotation about the central rotation axis 14A therewith. The blade support ring 32 is configured to support at least some of the fan blades 34 to cause movement of the blades relative to the rotation axis 14A in unison with the wheel hub 30. The plurality of fan blades 34 are arranged circumferentially around the rotation axis 14A and cause movement of the airflow F when the motor 15 drives the fan wheel 14 about the rotation axis 14A.

The plurality of fan blades 34 are shaped and oriented relative to the rotation axis 14A to move air through the inlet 18 when the plurality of fan blades 34 are driven in rotation about the rotation axis 14A by the wheel motor 15. The plurality of fan blades 34 include a plurality of peripheral blades 36 and a plurality of impeller blades 38 as shown in FIG. 2. The plurality of peripheral blades 36 extend vertically between the wheel hub 30 and the blade support ring 32, preferably parallel to the rotation axis 14A. The plurality of impeller blades 38 are coupled to the wheel hub 30 and are arranged radially inward from the plurality of peripheral blades 36 relative to the rotation axis 14A. The plurality of peripheral blades 36 and the plurality of impeller blades 38 cooperate to increase airflow through the scroll 12 or maintain a flow rate through the scroll 12 while decreasing the required torque supplied by the wheel motor 15 and/or revolutions per minute (RPM) of the wheel motor 15 to maintain the same volume of flow. As a result, the sounds levels produced by the fan 10 and/or power consumption of the motor 15 may also be reduced.

The plurality of peripheral blades 36 extend substantially parallel to the rotation axis 14 in a lengthwise direction from the wheel hub 30 to the blade support ring 32 as shown in FIGS. 1 and 2. Each of the peripheral blades 36 have a proximal end 40 fixed to the wheel hub 30 and arranged to lie near the top wall 12T and the motor 15 and a distal end 42 arranged to lie near a bottom wall 12B of the scroll inlet 18. The proximal end 40 of the plurality of peripheral blades 36 are coupled to the wheel hub 30 at a radially outer edge 44 of the wheel hub 30. The distal end 42 of each of the peripheral blades 36 are arranged slightly radially outward of the scroll inlet 18 and are spaced apart from the scroll bottom wall 12B. In some embodiments, each of the plurality of peripheral blades 36 are angled circumferentially relative to the rotation axis 14A as described in a separate U.S. Provisional patent application, titled VENTILATION FAN and filed on the same day as this application, which is expressly incorporated by reference herein in its entirety.

The plurality of impeller blades 38 are substantially planar, defining planes 38P, and extend away from the wheel hub 30 substantially parallel to the rotation axis 14A as shown in FIGS. 1 and 2. As depicted in FIG. 3, the planes 38P defined by the impeller blades 38 are spaced apart from and do not pass through the rotation axis 14A. Each of the impeller blades 38 have an inner end 46 positioned near the rotation axis 14A and an outer end 48 positioned at or near the plurality of peripheral blades 36. The inner and outer ends 46, 48 of each corresponding impeller blade 38 are offset circumferentially from one another about the rotation axis 14A.

Each of the peripheral blades 36 is curved to have a concave side 50 and a convex side 52 as shown in FIGS. 3 and 4. The fan wheel 14 is configured to rotate about the rotation axis 14A in a direction toward the concave side 50 so that the plurality of peripheral blades direct a first air flow P radially outward away from the rotation axis 14A during operation.

Each of the impeller blades 38 is substantially straight and extends toward one of the peripheral blades 36 as shown in FIGS. 3 and 4. In the illustrative embodiment, each outer end 48 of the impeller blades 38 is aligned substantially with an inner end 54 of a respective peripheral blade 36. The plane 38P of each impeller blade 38 is aligned substantially with a tangent point on a curvature formed by the concave side 50 of a corresponding one of the peripheral blades 36. In this way, the impeller blades 38 direct a second air flow V away from the rotation axis 14A and toward the concave side 50 of a corresponding peripheral blade 36. Combined first and second air flows P+V result from the plurality of peripheral blades 36 and the plurality of impeller blades 38 cooperating with one another during operation of the ventilation fan 10.

The wheel hub 30 includes a hub base 60 and a shaft mount 62 as shown in FIG. 5. The hub base 60 is coupled to the proximal ends 40 of the plurality of peripheral blades 36. In some embodiments, the hub base 60 is also completely imperforate in that it has no openings extending therethrough toward the motor 15. The shaft mount 62 is coupled to a distal end of the hub base 62 opposite the proximal ends 40 of the peripheral blades 36. The shaft mount 62 is configured to couple the fan wheel 14 to the drive shaft 22 of the wheel motor 15.

Each of the impeller blades 38 is coupled to the hub base 60 and includes a freed edge defining a horizontal bottom edge 70 and a sloped side edge 72 as shown in FIG. 5. The horizontal bottom edge 70 is arranged to lie substantially perpendicular to the rotation axis 14A. The sloped side edge 72 extends upwardly at an angle relative to the rotation axis 14A and away from the bottom edge 70 and the rotation axis 14A. Each of the impeller blades 38 is shaped to increase in height from the hub base 60 as each impeller blade 38 extends from the inner end 46 to an apex 74 located radially outward from the inner end 46. The height of each impeller blade 38 then decreases from the apex 74 to the outer end 48. The bottom edge 70 is offset from the distal end 42 of each peripheral blade 36 such that each impeller blade has a height that is less than each of the peripheral blades 36.

Another embodiment of a ventilation fan 210 is shown in FIGS. 6-11. The ventilation fan 210 includes a scroll 212, a fan wheel 214 arranged to lie within an interior space 216 defined by the scroll 212, and a motor 215 configured to drive the fan wheel 214 as shown in FIG. 6. The scroll 212 is also formed to include an inlet 218 opening into the interior space 216 and an outlet 220 spaced apart from the inlet 218 to release air from the scroll 212. The scroll 212 and the fan wheel 214 may both reside within a fan housing (not shown). In some embodiments, the ventilation fan 210 is an exhaust fan for a bathroom and is placed above a ceiling of the bathroom.

The fan wheel 214 is coupled to the scroll 212 and is configured to displace air into the interior space 216 and through the inlet 218 as suggested in FIG. 6. The air is then expelled through the outlet 220 and is transported away from the ventilation fan 210 by a duct, for example. In one example, the scroll 212 of the ventilation fan 210 is mounted above a ceiling panel of the building and the fan wheel 214 is configured to withdraw air from the at least one room through an opening in the room to the building. The air being withdrawn in to the ventilation fan 210 follows a flow path F through the interior space 216 defined by the scroll 212. The withdrawn air may be exhausted to an exterior of the building or conditioned and/or recirculated back into the building.

The motor 215 is mounted to the top wall 212T of the scroll 212 and is configured to drive rotation of the fan wheel 214 about a rotation axis 214A relative to the scroll 212 as shown in FIG. 6. The fan wheel 214 includes a wheel hub 230 coupled to the wheel motor 215, a blade support ring 232, and a plurality of fan blades 234 coupled to the wheel hub 230 and the blade support ring 232. The wheel motor 215 includes a drive shaft 222 that is configured to rotate about the central rotation axis 214A of the fan wheel 214 when the wheel motor 215 is powered on. The wheel hub 230 is fixed to the drive shaft 222 for rotation about the central rotation axis 214A therewith. The blade support ring 232 is configured to support at least some of the fan blades 234 to block movement of the blades relative to the rotation axis 214A. The plurality of fan blades 234 are arranged circumferentially around the rotation axis 214A and cause movement of the airflow F when the wheel motor 215 drives the fan wheel 214 about the rotation axis 214A.

The plurality of fan blades 234 are shaped and oriented relative to the rotation axis 214A to displace air through the inlet 218 when the plurality of fan blades 234 are driven in rotation about the rotation axis 214A by the wheel motor 215. The plurality of fan blades 234 include a plurality of peripheral blades 236 and a plurality of impeller blades 238 as shown in FIG. 7. The plurality of peripheral blades 236 extend vertically between the wheel hub 230 and the blade support ring 232 relative to the rotation axis 214A. The plurality of impeller blades 238 are coupled to the wheel hub 230 and are arranged radially inward from the plurality of peripheral blades 236 relative to the rotation axis 214A. The plurality of peripheral blades 236 and the plurality of impeller blades 238 cooperate to increase airflow through the scroll 212 or maintain a flow rate through the scroll 212 while decreasing torque on the wheel motor 215 or revolutions per minute (RPM) of the wheel motor 215. This may also reduce sounds levels produced by the fan 210 and/or reduce power consumption of the motor 215.

The plurality of peripheral blades 236 extend substantially parallel to the rotation axis 214 in a lengthwise direction from the wheel hub 230 to the blade support ring 232 as shown in FIGS. 6 and 7. Each of the peripheral blades 236 have a proximal end 240 fixed to the wheel hub 230 and arranged to lie near the top wall 212T and the wheel motor 215 and a distal end 242 arranged to lie near a bottom wall 212B of the scroll 212 and the inlet 218. The proximal end 240 of the plurality of peripheral blades 236 are coupled to the wheel hub 230 at a radially outer edge 244 of the wheel hub 230. The distal end 242 of each of the peripheral blades 236 are arranged slightly radially outward of the inlet 218 and are spaced apart from the bottom wall 212B. In some embodiments, each of the plurality of peripheral blades 236 are angled circumferentially relative to the rotation axis 214A.

The plurality of impeller blades 238 also extend substantially parallel to the rotation axis 214A away from the wheel hub 230 as shown in FIGS. 7 and 8. The plurality of impeller blades 238 extend away from the rotation axis in a radial direction along respective planes 238P that are spaced apart from and do not pass through the rotation axis 214A. Each of the impeller blades 238 have an inner end 246 positioned near the rotation axis 214A and an outer end 248 positioned at or near the plurality of peripheral blades 236. The inner and outer ends 246, 248 of each corresponding impeller blade 238 are offset circumferentially from one another about the rotation axis 214A.

Each of the peripheral blades 236 is curved to have a concave side 250 and a convex side 252 as shown in FIGS. 9 and 10. The fan wheel 214 is configured to rotate about the rotation axis 214A in a direction toward the concave side 250 so that the plurality of peripheral blades direct a first air flow P radially outward away from the rotation axis 214A during operation.

Each of the impeller blades 238 is substantially straight and extends toward one of the peripheral blades 236 as shown in FIGS. 9 and 10. In the illustrative embodiment, each outer end 248 of the impeller blades 238 is aligned and integral with an inner end 254 of a respective peripheral blade 236. The plane 238P of each impeller blade 238 is aligned substantially with a tangent point on a curvature formed by the concave side 250 of a corresponding one of the peripheral blades 236. In this way, the impeller blades 238 direct a second air flow V away from the rotation axis 214A and toward the concave side 250 of a corresponding peripheral blade 236. Combined first and second air flows P+V result from the plurality of peripheral blades 236 and the plurality of impeller blades 238 cooperating with one another during operation of the ventilation fan 210.

The inner end 246 of each impeller blade 238 is also coupled to and formed integrally with an annular hub ring 264 coupled to the wheel hub 230. Each of the impeller blades 238 contact the annular ring hub 264 at a tangent point on the annular ring hub 264.

The wheel hub 230 includes a hub base 260 and a shaft mount 262 as shown in FIG. 11. The hub base 260 is coupled to the proximal ends 240 of the plurality of peripheral blades 236. In some embodiments, the base hub 260 is also completely imperforate in that it has no openings extending therethrough toward the motor 215. The shaft mount 262 is coupled to a distal end of the hub base 262 opposite the proximal ends 240 of the peripheral blades 236. The shaft mount 262 is configured to couple the fan wheel 214 to the drive shaft 222 of the wheel motor 215.

Each of the impeller blades 238 is coupled to the hub base 260 and includes a bottom edge 270 that extends upwardly at an angle relative to the rotation axis 214A and from inner end 246 to the outer end 248. The angle may change in some embodiments. For example, the bottom edge 270 may be substantially perpendicular to the rotation axis 214A at the inner and outer ends 246, 248 and may gradually change as the bottom edge 270 extends outwardly away from the rotation axis 214A. Each of the impeller blades 238 may be shaped to increase or decrease in height from the hub base 260 as each impeller blade 38 extends from the inner end 246 to the outer end 248. The bottom edge 270 is offset from the distal end 242 of each peripheral blade 236 such that each impeller blade 238 has a height that is less than each of the peripheral blades 236.

Another embodiment of a fan wheel 314 that is similar to fan wheel 214 is shown in FIG. 12. The disclosure above related to fan wheel 214 is incorporated by reference herein for fan wheel 314 except for the differences discussed below.

The fan wheel 314 includes a wheel hub 330, a blade support ring 332, and a plurality of fan blades 334 coupled to the wheel hub 230 and the blade support ring 232. The plurality of fan blades 334 include a plurality of peripheral blades 336 and a plurality of impeller blades 338 as shown in FIG. 12.

An inner end 346 of each impeller blade 338 is also coupled to and formed integrally with an annular hub ring 364 coupled to the wheel hub 330. Each of the impeller blades 338 contact the annular hub ring 364 at a tangent point on the annular ring hub 364. A distal end 365 of the annular hub ring 364 is substantially aligned with distal ends 340 of each of the peripheral blades 336.

Each of the impeller blades 338 is coupled to a hub base 360 and includes a bottom edge 370. The bottom edge 370 is generally aligned with the distal end 365 of the annular hub ring 364 at the inner end 346 of each of the impeller blades 338. The bottom edge 370 is also generally aligned with a distal end 340 of each of the peripheral blades 336 at the inner end 346 of each of the impeller blades 338.

Another embodiment of a ventilation fan 410 is shown in FIGS. 13-17. The ventilation fan 410 includes a scroll 412, a fan wheel 414 arranged to lie within an interior space 416 defined by the scroll 412, and a motor 415 configured to drive the fan wheel 414 as shown in FIG. 13. The scroll 412 is also formed to include an inlet 418 opening into the interior space 416 and an outlet 420 spaced apart from the inlet 418 to release air from the scroll 412. The scroll 412 and the fan wheel 414 may both reside within a fan housing (not shown). In some embodiments, the ventilation fan 410 is an exhaust fan for a bathroom and is placed above a ceiling of the bathroom.

The fan wheel 414 is coupled to the scroll 412 and is configured to displace air into the interior space 416 and through the inlet 418 as suggested in FIG. 13. The air is then expelled through the outlet 420 and is transported away from the ventilation fan 410 by a duct, for example. In one example, the scroll 412 of the ventilation fan 410 is mounted above a ceiling panel of the building and the fan wheel 414 is configured to withdraw air from the at least one room through an opening in the room to the building. The air being withdrawn in to the ventilation fan 410 follows a flow path F through the interior space 416 defined by the scroll 412. The withdrawn air may be exhausted to an exterior of the building or conditioned and/or recirculated back into the building.

The motor 415 is mounted to the top wall 412T of the scroll 412 and is configured to drive rotation of the fan wheel 414 about a rotation axis 414A relative to the scroll 412 as shown in FIG. 13. The fan wheel 414 includes a wheel hub 430 coupled to the wheel motor 415, a blade support ring 432, and a plurality of fan blades 434 coupled to the wheel hub 430 and the blade support ring 432. The wheel motor 415 includes a drive shaft 422 that is configured to rotate about the central rotation axis 414A of the fan wheel 414 when the wheel motor 415 is powered on. The wheel hub 430 is fixed to the drive shaft 422 for rotation about the central rotation axis 414A therewith. The blade support ring 432 is configured to support at least some of the fan blades 434 to block movement of the blades relative to the rotation axis 414A. The plurality of fan blades 434 are arranged circumferentially around the rotation axis 414A and cause movement of the airflow F when the wheel motor 415 drives the fan wheel 414 about the rotation axis 414A.

The plurality of fan blades 434 are shaped and oriented relative to the rotation axis 414A to displace air through the inlet 418 when the plurality of fan blades 434 are driven in rotation about the rotation axis 414A by the wheel motor 415. The plurality of fan blades 434 include a plurality of peripheral blades 436 and a plurality of impeller blades 438 as shown in FIG. 14. The plurality of peripheral blades 436 extend vertically between the wheel hub 430 and the blade support ring 432 relative to the rotation axis 414A. The plurality of impeller blades 438 are coupled to the wheel hub 430 and are arranged radially inward from the plurality of peripheral blades 436 relative to the rotation axis 414A. The plurality of peripheral blades 436 and the plurality of impeller blades 438 cooperate to increase airflow through the scroll 412 or maintain a flow rate through the scroll 412 while decreasing torque on the wheel motor 415 or revolutions per minute (RPM) of the wheel motor 415. This may also reduce sounds levels produced by the fan 410 and/or reduce power consumption of the motor 415.

The plurality of peripheral blades 436 extend substantially parallel to the rotation axis 414 in a lengthwise direction from the wheel hub 430 to the blade support ring 432 as shown in FIGS. 13 and 14. Each of the peripheral blades 436 have a proximal end 440 fixed to the wheel hub 430 and arranged to lie near the top wall 412T and the wheel motor 415 and a distal end 442 arranged to lie near a bottom wall 412B of the scroll 412 and the inlet 418. The proximal end 440 of the plurality of peripheral blades 436 are coupled to the wheel hub 430 at a radially outer edge 444 of the wheel hub 430. The distal end 442 of each of the peripheral blades 436 are arranged slightly radially outward of the inlet 418 and are spaced apart from the bottom wall 412B. In some embodiments, each of the plurality of peripheral blades 436 are angled circumferentially relative to the rotation axis 414A.

The plurality of impeller blades 438 also extend substantially parallel to the rotation axis 414A away from the wheel hub 430 as shown in FIGS. 14 and 15. The plurality of impeller blades 438 extend away from the rotation axis in a radial direction along respective planes 438P that are spaced apart from and do not pass through the rotation axis 414A. Each of the impeller blades 438 have an inner end 446 positioned near the rotation axis 414A and an outer end 448 positioned at or near the plurality of peripheral blades 436. The inner and outer ends 446, 448 of each corresponding impeller blade 438 are offset circumferentially from one another about the rotation axis 414A.

Each of the peripheral blades 436 is curved to have a concave side 450 and a convex side 452 as shown in FIGS. 16 and 17. The fan wheel 414 is configured to rotate about the rotation axis 414A in a direction toward the concave side 450 so that the plurality of peripheral blades direct a first air flow P radially outward away from the rotation axis 414A during operation.

Each of the impeller blades 438 is substantially straight and extends toward one of the peripheral blades 436 as shown in FIGS. 15 and 16. In the illustrative embodiment, each outer end 448 of the impeller blades 438 is aligned and integral with an inner end 454 of a respective peripheral blade 436. The plane 438P of each impeller blade 438 is aligned substantially with a tangent point on a curvature formed by the concave side 450 of a corresponding one of the peripheral blades 436. In this way, the impeller blades 438 direct a second air flow V away from the rotation axis 414A and toward the concave side 450 of a corresponding peripheral blade 436. Combined first and second air flows P+V result from the plurality of peripheral blades 436 and the plurality of impeller blades 438 cooperating with one another during operation of the ventilation fan 410.

The wheel hub 430 includes a hub base 460 and a shaft mount 462 as shown in FIG. 17. The hub base 460 is coupled to the proximal ends 440 of the plurality of peripheral blades 436. In some embodiments, the base hub 460 is also completely imperforate in that it has no openings extending therethrough toward the motor 415. The shaft mount 462 is coupled to a distal end of the hub base 462 opposite the proximal ends 440 of the peripheral blades 436. The shaft mount 462 is configured to couple the fan wheel 414 to the drive shaft 422 of the wheel motor 415.

Each of the impeller blades 438 is coupled to the hub base 460 and includes a bottom edge 470 that extends downwardly toward the distal ends 442 of the peripheral blades 436 from inner end 446 to the outer end 448 of each impeller blade 438. The bottom edge 470 slopes downwardly at an angle along a majority of its length. The angle may change in some embodiments. For example, the bottom edge 470 may be substantially perpendicular to the rotation axis 414A at the outer ends 448 and may gradually change as the bottom edge 470 extends outwardly away from the rotation axis 414A. Each of the impeller blades 438 may be shaped to increase in height from the wheel hub 430 as each impeller blade extends from the inner end 446 to the outer end 448. The bottom edge 470 is offset from the distal end 442 of each peripheral blade 436 such that each impeller blade 438 has a height that is less than each of the peripheral blades 436. The bottom edge 470 of the impeller blades terminates near the distal ends 442.

In some embodiments, fan wheels feature cutouts between the motor shaft hub and the blades, rather than keeping them disconnected. The present disclosure introduces extended geometry for treating impeller blade profiles in addition to peripheral blades. This can reduce drag on the wheel, and may generate less turbulence. This can also increase airflow per revolution (i.e. lower rpm to deliver equal or greater CFM output). This can also lower motor torque requirements. This can also result in noise reduction.

In some embodiments, the impeller blade profile can be manipulated to direct airflow to designated areas. For example, the impeller blades may be shaped or oriented to direct more air toward the motor for cooling. The present disclosure also provides improved volumetric efficiency (i.e. CFM/Watt), and better sound performance. In some embodiments, the impeller blades provide more control of the air inside the fan, especially at higher RPMs.

The present disclosure can provide suction into or toward the impeller blades, which then direct the air into or toward the outer set of blades to boost fan performance or airflow while minimizing drag and turbulence. In some embodiments, the number of impeller blades and their shapes should be optimized based on each fan platform. Different blade profiles may be advantageous in different situations. In some embodiments, large diameter impellers may be used to minimize drag because the flow has more space to develop inward of the peripheral blades. Smaller diameter impellers may be used where it is desired to move as much air as possible. In some embodiments, the angle of the impeller blades maintain tangency with respect to the peripheral blades.

It should be noted that the various components and features described above can be combined in a variety of ways, so as to provide other non-illustrated embodiments within the scope of the disclosure. As such, it is to be understood that the disclosure is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The disclosure is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation.

Although the present disclosure has been described in the foregoing description by way of illustrative embodiments thereof, these embodiments can be modified at will, without departing from the spirit, scope, and nature of the subject disclosed.

Headings and subheadings, if any, are used for convenience only and do not limit the invention. The word exemplary is used to mean serving as an example or illustration. To the extent that the term include, have, or the like is used, such term is intended to be inclusive in a manner similar to the term comprise as comprise is interpreted when employed as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.

All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. In addition, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

A phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list. The phrase “at least one of” does not require selection of at least one item; rather, the phrase allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, each of the phrases “at least one of A, B, and C” or “at least one of A, B, or C” refers to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.

In one aspect, a term coupled or the like may refer to being directly coupled. In another aspect, a term coupled or the like may refer to being indirectly coupled. Terms such as top, bottom, front, rear, side, horizontal, vertical, and the like refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Thus, such a term may extend upwardly, downwardly, diagonally, or horizontally in a gravitational frame of reference.

The title, background, brief description of the drawings, abstract, and drawings are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that the description provides illustrative examples and the various features are grouped together in various implementations for the purpose of streamlining the disclosure. The method of disclosure is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, as the claims reflect, inventive subject matter lies in less than all features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim standing on its own as a separately claimed subject matter.

The use of the terms “a” and “an” and “the” and “said” and similar references in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. An element proceeded by “a,” “an,” “the,” or “said” does not, without further constraints, preclude the existence of additional same elements. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

Numerous modifications to the present disclosure will be apparent to those skilled in the art in view of the foregoing description. Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the disclosure.