Patent Publication Number: US-7585155-B2

Title: Axial flow fan

Description:
RELATED APPLICATION 
   The present application is based on, and claims priority from, KR Application Number 2004-018645, filed Mar. 19, 2004, the disclosure of which is hereby incorporated by reference herein in its entirety. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates generally to axial flow fans and, more particularly, to an axial flow fan which prevents deformation of blades even when rotated at high speed, thus promoting structural stability, and which achieves high efficiency and satisfactory capacity despite a low rotational frequency. 
   2. Background of the Related Art 
   As well known to those skilled in the art, axial flow fans are used to cool a heat exchanging medium circulating in, for example, a heat exchanger of a vehicle, such as a radiator or a condenser. As shown in  FIG. 1 , such an axial flow fan  10  includes a hub  20  which is coupled to an output shaft  52  of a drive unit  50  such as a motor, a plurality of blades  30  which are radially arranged along a circumferential outer surface of the hub  20 , and a fan band  40  which couples outer ends of the blades  30  together to prevent deformation of the blades  30 . The axial flow fan  10  having the above-mentioned construction is rotated by a rotational force transmitted from the drive unit  50  to the hub  20 , so that air is blown in an axial direction by the rotation of the blades  30  of the axial flow fan  10 . 
   Typically, the axial flow fan  10  is made of synthetic resin and formed as a single body. To efficiently guide air blown by the axial flow fan  10  to a heat exchanger, the axial flow fan  10  is assembled with a shroud  60  which is mounted to the heat exchanger. The shroud  60  to guide blown air includes a blast port having a predetermined size such that the axial flow fan  10  may be rotatably inserted into the shroud  60 . The shroud  60  has a structure capable of supporting therein the motor  50  which is the drive unit. 
   As shown in  FIG. 2 , in each blade  30  of the conventional axial flow fan  10 , both a leading edge (LE), which is an edge of the blade  30  in a rotational direction, and a trailing edge (TE), which is an edge of the blade  30  in a direction opposite the rotational direction, are curved in the direction opposite the rotational direction while extending from a blade root  32 , which is a junction between the hub  20  and the blade  30 , to an intermediate portion of the blade  30 , thus forming a backward sweeping angle. Both the leading edge (LE) and the trailing edge (TE) of the blade  30  are integrated and curved in the rotational direction while extending from the intermediate portion of the blade  30  to the blade tip  34 , which is the junction between the blade  30  and the fan band  40 . 
   Such change of the sweeping angle of the blade  30  serves as an important factor to enhance the performance of the axial flow fan  10 . However, it has been well-known that it is very difficult to achieve satisfactory air blowing efficiency and noise reduction. 
   In consideration of this, several axial flow fans were proposed in Korean Patent Laid-open Publication No. 2002-94183 and No. 2002-94184, which were filed by the inventor of the present invention. 
   As shown in  FIGS. 3 and 4 , an axial flow fan  10   a  of No. 2002-94183 includes a plurality of blades  30   a  each having a wave shape in which the sweeping angles of both a leading edge (LE) and a trailing edge (TE) alternate between forwards and backwards from a blade root  32   a  to a blade tip  34   a . Furthermore, a chord length (CL), which is the length from the leading edge (LE) to the trailing edge (TE) of the blade  30   a  at the same radius, gradually increases from a blade root  32   a  to a blade tip  34   a . In the drawings, the reference character “α” denotes the angle at which each blade  30   a  is disposed with respect to the horizon (H) when the axial flow fan  10   a  is level with the horizon (H). In the drawings, the reference numeral  20   a  denotes a hub, and  40   a  denotes a fan band. 
   As shown in  FIGS. 5 and 6 , an axial flow fan  10   b  of No. 2002-94184 includes a plurality of blades  30   b  each having a wave shape the same as that described for the axial flow fan  10   a  of No. 2002-94183. As well, the chord length (CL) of each blade  30   b  gradually increases from a blade root  32   b  to a blade tip  34   b . Each blade  30   b  has a maximum backward sweeping angle at the blade root  32   b  and has a maximum forward sweeping angle at the blade tip  34   b . In the drawings, the reference numeral  20   b  denotes a hub, and  40   b  denotes a fan band. 
   In the conventional axial flow fans  10   a  and  10   b  having a wave shape, air passing through the axial flow fan  10   a ,  10   b  is dispersed in a region between inflection points in which the direction of the sweeping angle changes. Therefore, concentration of the flowing air is prevented, thus improving air blowing efficiency and reducing noise. 
   However, in the conventional axial flow fans  10   a  and  10   b , because the chord length (CL) gradually increases from the blade root  32   a ,  32   b  to the blade tip  34   a ,  34   b , the blade tip  34   a ,  34   b  is structurally unstable. Accordingly, when the axial flow fan  10   a ,  10   b  is rotated at high speed, deformation of the blades  30   a ,  30   b  may occur. Particularly, the deformation of the blade tips  34   a ,  34   b  hampers the noise reducing function of the axial flow fan  10   a ,  10   b.    
   Furthermore, in the case of the axial flow fan  10   b  of No. 2002-94184, the angle (α 1 ) between a line (L 0 ), passing through both the center (O) of the hub  20   b  and an intersection point between the blade root  32   b  and a mid-chord line (ML), which connects middle points between the leading edge (LE) and the trailing edge (TE) of the blade  30   b , and a line (L 1 ), passing through both the center (O) of the hub  20   b  and an intersection point between the mid-chord line (ML) and the blade tip  34   b , is smaller than an angle (α 2 ) between the line (L 0 ) and a line (L 2 ), passing through both the center (O) of the hub  20   b  and a first inflection point (P 1 ), defined at a first valley on the mid-chord line (ML), and is smaller than an angle (α 3 ) between the line (L 0 ) and a line (L 3 ), passing through both the center (O) of the hub  20   b  and a second inflection point (P 2 ) defined at a second valley on the mid-chord line (ML) (α 1 &lt;α 2 , α 3 ). In other words, the difference in width between each valley and opposite ends of the mid-chord line (ML) is large, and the forward sweeping angle of the blade tip  34   b  is excessively large. Thus, the conventional axial flow fan  10   b  must be increased in rotational frequency to achieve satisfactory capacity. As a result, there is difficulty in reducing noise occurring during the rotation of the axial flow fan  10   b.    
   SUMMARY OF THE INVENTION 
   Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide an axial flow fan which prevents the deformation of blades even when rotated at high speed, thus promoting structural stability, and which achieves high efficiency and satisfactory capacity despite a low rotational frequency. 
   In order to accomplish the above object, the present invention provides an axial flow fan, including: a hub; and a plurality of blades arranged along a circumferential outer surface of the hub in a radial direction such that a direction of a sweeping angle of each of the plurality of blades alternately changes in a region between a blade root and a blade tip. A chord length, which is a length from a leading edge to a trailing edge of the blade, gradually reduces from the blade root to an intermediate portion of the blade and has a minimum value at a predetermined position on the intermediate portion of the blade, while the chord length gradually increases from the predetermined position of the intermediate portion of the blade having the minimum value to the blade tip. A second inflection point, defined at a second valley spaced apart from the blade root by a predetermined distance on a mid-chord line connecting middle points between the leading edge and the trailing edge, is placed ahead of a first inflection point, defined at a first valley formed between the blade root and the second valley on the mid-chord line, based on a first line passing through both a center of the hub and an intersection point between the mid-chord line and the blade root, in a direction of rotation. 
   In the present invention, when an outer radius of the hub is designated by “Rh”, and a distance between the center of the hub and the blade root is designated by “Rt”, and a distance between the center of the hub and an arbitrary position on the mid-chord line is designated by “r”, the chord length may have the minimum value at a predetermined position satisfying an equation (r−Rh)/(Rt−Rh)=0.2˜0.6. 
   Furthermore, an angle between the first line, passing through both the center of the hub and the intersection point between the mid-chord line and the blade root, and a second line, passing through both the center of the hub and an intersection point between the mid-chord line and the blade tip, may be greater than an angle between the first line and a third line, passing through both the center of the hub and the first inflection point and is greater than an angle between the first line and a fourth line, passing through both the center of the hub and the second inflection point. 
   The angle between the first line, passing through both the center of the hub and the intersection point between the mid-chord line and the blade root, and the third line, passing through both the center of the hub and the first inflection point, may be less than ½ of the angle between the first line and the second line, passing through both the center of the hub and the intersection point between the mid-chord line and the blade tip. 
   The axial flow fan may further include a fan band to integrally couple the blade tips of the plurality of blades together. 

   
     BRIEF DESCRIPTION OF DRAWINGS 
       FIG. 1  is an exploded perspective view showing an assembly of a conventional axial flow fan and a shroud; 
       FIG. 2  is a front view showing a part of the conventional axial flow fan of  FIG. 1 ; 
       FIG. 3  is a front view showing another conventional axial flow fan; 
       FIG. 4  is a sectional view of a blade of the axial flow fan of  FIG. 3  to illustrate the definition of chord length of the blade; 
       FIG. 5  is a perspective view showing a further conventional axial flow fan; 
       FIG. 6  is a front view showing part of the conventional axial flow fan of  FIG. 5 ; 
       FIG. 7  is a front view of an axial flow fan, according to an embodiment of the present invention; 
       FIG. 8  is a front view showing an enlargement of a part of the axial flow fan of  FIG. 7 ; 
       FIG. 9  shows a graph comparing changes of chord lengths of the axial flow fan of the present invention and a conventional axial flow fan; 
       FIG. 10  shows a graph comparing the types of mid-chord lines of the axial flow fan of the present invention and the conventional axial flow fan; 
       FIG. 11  is a graph comparing the rotational frequencies of the axial flow fan of the present invention and the conventional axial flow fan when they output the same air volume; 
       FIG. 12  is a graph comparing the power consumptions of the axial flow fan of the present invention and the conventional axial flow fan when they output the same air volume; and 
       FIG. 13  is a graph comparing noise levels of the axial flow fan of the present invention and the conventional axial flow fan when they output the same air volume. 
   

   DESCRIPTION OF THE ELEMENTS IN THE DRAWINGS 
   
     
       
         
             
           
             
                 
             
           
          
             
               120: hub 
             
             
               130: blade 
             
             
               132: blade root 
             
             
               134: blade tip 
             
             
               140: fan band 
             
             
               CL: chord length 
             
             
               LE: leading edge 
             
             
               ML: mid-chord line 
             
             
               O: center of hub 
             
             
               P1, P2: inflection points 
             
             
               r: distance from center of hub to arbitrary position on mid-chord line 
             
             
               Rh: outer radius of hub 
             
             
               Rt: distance from center of hub to blade tip 
             
             
               TE: trailing edge 
             
             
                 
             
          
         
       
     
   
   DETAILED DESCRIPTION OF ONE PREFERRED EMBODIMENT 
   The features and advantages of the present invention will be more clearly understood from the following detailed description. Terms and words used in the specification and claims must be regarded as concepts selected by the inventor as the best method of illustrating the present invention, and must be interpreted as having meanings and concepts adapted to the scope and sprit of the present invention to understand the technology of the present invention. 
   With reference to  FIG. 8 , in the present invention, a leading edge (LE) of a blade  130  denotes an edge of the blade  130  in a rotational direction. A trailing edge (TE) of the blade  130  denotes an edge of the blade  130  in a direction opposite the rotational direction. A chord length (CL) of the blade  130  denotes a length from the leading edge (LE) to the trailing edge (TE) of the blade  130  at the same radius (see,  FIG. 4 ). A mid-chord line (ML) denotes a line connecting middle points between the leading edge (LE) and the trailing edge (TE) of the blade  130 . A blade root  132  denotes a junction of the blade  130  and a hub  120 . A blade tip  134  denotes an outside end of the blade  130 . A forward sweeping angle denotes a sloping angle of the blade toward a rotational direction. A backward sweeping angle denotes a sloping angle of the blade toward a direction opposite to a rotational direction. First and second inflection points (P 1  and P 2 ) denote points at which the sweeping angle of the blade  130  changes from a backward sweeping angle to a forward sweeping angle. 
   As shown in  FIG. 7 , an axial flow fan  100  of the present invention includes the hub  120  and a plurality of blades  130  which are arranged along a circumferential outer surface of the hub  120  in a radial direction such that the direction of the sweeping angle of each of the blades  130  alternately changes in a region between the blade root  132  and the blade tip  134 . In other words, each blade  130  has a wave shape in which the sweeping angle alternately changes between a backward sweeping angle and a forward sweeping angle in the region defined between the blade root  132  and the blade tip  134 . 
   As shown in  FIG. 8 , in the present invention, each blade  130  has a wave shape in which a direction of a sweeping angle of each of the leading edge (LE) and trailing edge (TE) of the blade  130  alternately changes at three inflection points. 
   The chord length (CL) of each blade  130  is gradually reduced from the blade root  132  to an intermediate portion of the blade  130 . If an outer radius of the hub  120  is designated by “Rh”, and the distance between the center of the hub  120  and the blade tip  134  is designated by “Rt”, and the distance between the center of the hub  120  and an arbitrary position on the mid-chord line (ML), connecting the middle points between the leading edge (LE) and trailing edge (TE), is designated by “r”, the chord length (CL) has the minimum value at a predetermined position satisfying an equation (r−Rh)/(Rt−Rh)=0.2˜0.6. Furthermore, the chord length (CL) of the blade  130  gradually increases from the predetermined position of the intermediate portion of the blade  130  having the minimum value to the blade tip  134 . 
     FIG. 9  shows a graph comparing changes of chord lengths (CL) of the axial flow fan  100  of the present invention and a conventional axial flow fan having wave-shaped blades. As shown in  FIG. 9 , the chord length (CL) around the blade root  132  of the blade  130  of the axial flow fan  100  of the present invention is markedly longer than the chord length (CL) around a blade root of the blade of the conventional axial flow fan. Thus, it is to be readily understood that the axial flow fan  100  of the present invention has a stabler structure than the conventional axial flow fan. 
   Preferably, the angle (α 1 ) between a line (L 0 ), passing through both the center (O) of the hub  120  and an intersection point between the mid-chord line (ML) and the blade root  132 , and a line (L 1 ), passing through both the center (O) of the hub  120  and an intersection point between the mid-chord line (ML) and the blade tip  134 , is greater than an angle (α 2 ) between the line (L 0 ) and a line (L 2 ), passing through both the center (O) of the hub  120  and the first inflection point (P 1 ) in the mid-chord line, and is greater than an angle (α 3 ) between the line (L 0 ) and a line (L 3 ), passing through both the center (O) of the hub  120  and the second inflection point (P 2 ) in the mid-chord line. 
   Furthermore, preferably, the angle (α 2 ) between the line (L 0 ) passing through both the center (O) of the hub  120  and the intersection point between the mid-chord line (ML) and the blade root  132 , and the line (L 2 ) passing through both the center (O) of the hub  120  and the first inflection point (P 1 ), is smaller than ½ of the angle (α 1 ) between the line (L 0 ) and the line (L 1 ), passing through both the center (O) of the hub  120  and the intersection point between the mid-chord line (ML) and the blade tip  134 . 
   The line (L 3 ), passing through both the center (O) of the hub  120  and the second inflection point (P 2 ), is defined ahead of the line (L 2 ), based on the line (L 0 ), in the rotational direction. That is, the second inflection point (P 2 ), defined at a second valley spaced apart from the blade root  132  by a predetermined distance on the mid-chord line (ML), is placed ahead of the first inflection point (P 1 ), defined at a first valley formed between the blade root  132  and the second valley on the mid-chord line (ML), based on the line (L 0 ) passing through both the center (O) of the hub  120  and the intersection point between the mid-chord line (ML) and the blade root  132 , in the rotational direction. 
     FIG. 10  shows a graph comparing positions of first and second inflection points (that is, the types of mid-chord lines) of the axial flow fan  100  of the present invention and the conventional axial flow fan having the wave-shaped blades. As shown in  FIG. 10 , a forward side in a rotational direction with respect to the line (L 0 ), passing through both the center (O) of the hub  120  and the intersection point between the mid-chord line (ML) and the blade root  132 , is designated by “+”. A backward side with respect to the line (L 0 ) is designated by “−”. Here, it is to be understood that, in the blade  130  of the axial flow fan  100  of the present invention, the second inflection point (P 2 ) is placed ahead of the first inflection point (P 1 ) in a rotational direction, while, in a blade of the conventional axial flow fan, the second inflection point (P 2 ) is placed behind of the first inflection point (P 1 ) in a rotational direction. Furthermore, it is to be understood that the range of the sweeping angle of the blade  130  of the axial flow fan  100  of the present invention which has an alternately changing direction is lower than that of the blade of the conventional axial flow fan. 
   For stability of the structure of each blade  130  of the axial flow fan  100  of the present invention, the blade tips  134  are integrally coupled together by a fan band  140 . 
   Next, the operation and effect of the axial flow fan  100  of the present invention having the above-mentioned structure will be explained herein below. 
   In the axial flow fan  100  of the present invention, the chord length (CL) around each blade root  132  is longer than that of the intermediate portion of the blade  130 , so that the structural stability of the blade  130  is superior. Therefore, compared with conventional axial flow fans having wave shape blades, deformation around each blade tip  134 , when the axial flow fan  100  is rotated by a motor coupled to the hub  120 , is markedly reduced. Furthermore, in the present invention, the wave shape of the blade  130  is smoother than conventional axial flow fans, and the second inflection point (P 2 ), defined at the second valley of each blade  130 , is placed ahead of the first inflection point (P 1 ), defined at the first valley, in a rotational direction. Accordingly, despite a low rotational frequency, satisfactory capacity is achieved, and occurrence of noise is markedly reduced. 
     FIG. 11  is a graph comparing the rotational frequencies of the axial flow fan  100  of the present invention and a conventional axial flow fan when they output the same air volume. As shown in  FIG. 11 , when the same air volume of 1,602 CMH (cubic meter per hour) is output, the axial flow fan  100  of the present invention has a rotational frequency of 1,983 rpm, while the conventional axial flow fan has a rotational frequency of 2,237 rpm. As such, it is to be understood that the axial flow fan  100  of the present invention is able to have a rotational frequency 12% less than that of the conventional axial flow fan. 
     FIG. 12  is a graph comparing the power consumptions of the axial flow fan  100  of the present invention and a conventional axial flow fan when they output the same air volume. As shown in  FIG. 12 , when the same air volume of 1,602 CMH is output, the power consumption of the axial flow fan  100  of the present invention is 167.6 Watts, while the power consumption of the conventional axial flow fan is 169.1 Watts. As such, it is to be understood that the axial flow fan  100  of the present invention is able to realize power consumption 0.9% less than that of the conventional axial flow fan. 
     FIG. 13  is a graph comparing noise levels of the axial flow fan  100  of the present invention and a conventional axial flow fan when they output the same air volume. As shown in  FIG. 13 , when the same air volume of 1,602 CMH is output, the noise level of the axial flow fan  100  of the present invention is 65.0 dB(A), while the noise level of the conventional axial flow fan is 65.5 dB(A). As such, it is to be understood that the axial flow fan  100  of the present invention is able to reduce noise by 0.5 dB(A) compared with the conventional axial flow fan. 
   Although the axial flow fan  100  of the preferred embodiment of the present invention, in which the direction of the sweeping angle of each blade  130  is alternately changed by the first and second inflection points (P 1 ) and (P 2 ) defined at two valleys between the blade root  132  and the blade tip  134 , has been disclosed for illustrative purposes as an example, the above-mentioned change in the chord length (CL) of each blade and the relationship between the inflection points can be applied to axial flow fans, in which the direction of a sweeping angle of the blade alternately changes at the inflection points defined at three or more valleys of the blade. These axial flow fans also fall within the scope of the present invention. 
   As described above, the present invention provides an axial flow fan in which a chord length (CL) around each blade root is longer than that of an intermediate portion of the blade, so that the structural stability of the blade is superior. Therefore, deformation around the blade tip, when the axial flow fan is rotated, is markedly reduced. Thus, the durability of the axial flow fan is enhanced. 
   Furthermore, in the present invention, the wave shape of each blade is smooth, and a second inflection point, defined at a second valley on a mid-chord line of the blade, is placed ahead of a first inflection point, defined at a first valley on the mid-chord line, in a rotational direction. Accordingly, despite a low rotational frequency, satisfactory blast capacity is achieved, and, as well, the occurrence of noise is markedly reduced. In addition, power consumption is reduced. Thus, the axial flow fan of the present invention enhances air blowing efficiency and prevents a user from experiencing discomfort due to noise.