Fan with overmolded blades

Patent metadata

Field	Value
Publication number	US-9523372-B2
Application number	US-201113696672-A
Country	US
Kind code	B2
Filing date	May 6, 2011
Priority date	May 10, 2010
Publication date	Dec 20, 2016
Grant date	Dec 20, 2016

Abstract

A fan member particularly for use in a vehicle cooling system. A formed metal hub member with a plurality of plastic polymer blade members. The blade members are overmolded on the hub member, preferably individually. The plastic polymer material is molded through openings in the hub member to help securely hold the blade members in place.

First claim

What is claimed is:

1. A cooling fan comprising:
a hub that is rotatable about a rotational axis, the hub being formed with a first hub portion, a second hub portion, a third hub portion, a fourth hub portion and a fifth hub portion, the first hub portion having a flat annular shape with first and second axial end surfaces that are disposed opposite one another, the second hub portion being coupled to a radially outer end of the first hub portion and flaring outwardly from the first hub portion in a first direction along the rotational axis, the third hub portion being coupled to a radially outer end of the second hub portion and flaring outwardly from the second hub portion in a second direction along the rotational axis that is opposite the first direction, the fourth hub portion being coupled to a radially outer end of the third hub portion and flaring outwardly from the third portion in the first direction along the rotational axis, the fifth hub portion being coupled to a radially outer end of the fourth hub portion and extending radially outward therefrom, wherein a plurality of first hole sets are formed through the third hub portion and a plurality of second hole sets are formed through the fourth hub portion, each of the first hole sets comprising a plurality of first holes, each of the second hole sets comprising a plurality of second holes, wherein the second and third hub portions intersect on a first axial side of the first hub portion such that the first axial end surface of the first hub portion is disposed along the rotational axis between the second axial end surface and the intersection between the second and third hub portions, wherein the third and fourth hub portions intersect on a second axial side of the hub portion such that the second axial end surface of the first hub portion is disposed along the rotational axis between the first axial end surface and the intersection between the third and fourth hub portions and wherein the fourth and fifth hub portions intersect on the first axial side of the first hub portion; and
a plurality of fan blades, each of the fan blades having a blade portion and a base portion that is coupled to the blade portion, the base portion being overmolded onto the third, fourth and fifth hub portions such that:
portions of the fourth and fifth hub portions over which the base portion extends are encapsulated in a plastic polymer material from which the base portion is formed,
the base portion extends through the plurality of first holes in one of the first hole sets and through the plurality of second holes in one of the second hole sets,
the base portion is received into an annular, generally V-shaped channel defined by the fourth hub portion and a portion of the third hub portion, wherein at least portions of the base portion in the generally V-shaped channel span completely between sides of the V-shaped channel, and
the base portion is disposed over a portion of the third hub portion on a side that is opposite the annular, generally V-shaped channel.

2. The cooling fan of claim 1 , wherein the plastic polymer material comprises polyamide.

3. The cooling fan of claim 2 , wherein the plastic polymer material is polycaprolactam.

4. The cooling fan of claim 1 , wherein the plastic polymer material comprises a filler.

5. The cooling fan of claim 4 , wherein the filler comprises glass.

6. The cooling fan of claim 1 , wherein the fifth hub portion flares outwardly from the fourth hub portion in the first direction along the rotational axis, wherein the fourth and fifth hub portions diverge away from the rotational axis at different angles.

7. The cooling fan of claim 1 , wherein each of the first and second holes has a center point and wherein each of the first holes is paired with a corresponding one of the second holes such a line extending radially from the rotational axis intersects the center points of the paired first and second holes.

8. The cooling fan of claim 1 , wherein a plane extending through first hub portion that is oriented perpendicular to the rotational axis extends through the first and second holes.

9. The cooling fan of claim 1 , wherein the fan blades are discrete structures that are spaced circumferentially around the hub apart from one another.

10. The cooling fan of claim 1 , wherein the fan blades are connected to one another only through the hub.

11. The cooling fan of claim 1 , wherein the hub is formed of metal.

12. The cooling fan of claim 11 , wherein the metal is steel.

13. A method for forming a cooling fan, the method comprising:
providing a fan hub, the hub being formed with a first hub portion, a second hub portion, a third hub portion, a fourth hub portion and a fifth hub portion, the first hub portion having a flat annular shape with first and second axial end surfaces that are disposed opposite one another, the second hub portion being coupled to a radially outer end of the first hub portion and flaring outwardly from the first hub portion in a first direction along the rotational axis, the third hub portion being coupled to a radially outer end of the second hub portion and flaring outwardly from the second hub portion in a second direction along the rotational axis that is opposite the first direction, the fourth hub portion being coupled to a radially outer end of the third hub portion and flaring outwardly from the third portion in the first direction along the rotational axis, the fifth hub portion being coupled to a radially outer end of the fourth hub portion and extending radially outward therefrom, wherein a plurality of first hole sets are formed through the third hub portion and a plurality of second hole sets are formed through the fourth hub portion, each of the first hole sets comprising a plurality of first holes, each of the second hole sets comprising a plurality of second holes, wherein the second and third hub portions intersect on a first axial side of the first hub portion such that the first axial end surface of the first hub portion is disposed along the rotational axis between the second axial end surface and the intersection between the second and third hub portions, wherein the third and fourth hub portions intersect on a second axial side of the hub portion side such that the second axial end surface of the first hub portion is disposed along the rotational axis between the first axial end surface and the intersection between the third and fourth hub portions and wherein the fourth and fifth hub portions intersect on the first axial side of the first hub portion;
molding a plurality of fan blades onto the fan hub, wherein each of the fan blades has a blade portion and a base portion that is coupled to the blade portion, the base portions being molded directly onto the third, fourth and fifth hub portions such that:
portions of the fourth and fifth hub portions over which the base portion extends are encapsulated in a plastic polymer material from which the base portion is formed,
the base portion extends through the plurality of first holes in one of the first hole sets and through the plurality of second holes in one of the second hole sets,
the base portion is received into an annular, generally V-shaped channel defined by the fourth hub portion and a portion of the third hub portion, wherein at least portions of the base portion in the generally V-shaped channel span completely between sides of the V-shaped channel, and
the base portion is disposed over a portion of the third hub portion on a side that is opposite the annular, generally V-shaped channel.

Assignees

• Stagg Jonathan B
• Borgwarner Inc

Inventors

• Stagg Jonathan B

Classifications

• F04D29/023

  especially adapted for elastic fluid pumps · CPC title

• F04D29/329

  Details of the hub · CPC title

• F05D2300/43

  Synthetic polymers, e.g. plastics; Rubber · CPC title

• F05D2230/23

  by permanently joining parts together · CPC title

• B29C45/14336 Primary

  Coating a portion of the article, e.g. the edge of the article (B29C45/14573 and B29C45/14598 take precedence) · CPC title