Patent Description:
A motor fan (throughout the description referred to as "fan motor") is a sort of an actuator that generates a rotational force. The fan motor generates a suction force by rotation of a fan (e.g., impeller) connected to a rotating shaft of a motor. Fan motors are used for various devices. Fan motors are used for home appliances such as cleaners, air conditioners, etc., cars, etc. For example, when a fan motor is used for a cleaner, air sucked by the fan motor flows into a filter of the cleaner.

Generally, a fan motor consists of a motor and an impeller connected to a rotating shaft of the motor. And, a diffuser may be provided between the motor and the impeller.

Once the motor rotates, the impeller connected to the rotating shaft is rotated as well. By rotation of the impeller, air is sucked in a direction of the impeller. The air coming out of the impeller is guided by a diffuser and then discharged in a direction of the motor.

Problems of a fan motor of the related art are described as follows.

First of all, problems of an impeller of the related art are described.

An impeller may include a hub and a multitude of blades provided to the hub. However, as the related art employs a centrifugal impeller, a centrifugal flow is generated from the impeller.

In the related art, a hub line of the impeller extends in a diameter direction, whereby a flow coming out of the impeller is discharged in the diameter direction. Therefore, the flow passing through the impeller is rapidly turned at almost <NUM> degrees and goes in a diffuser direction.

Generally, a flow path loss is heavy in an area where a flow is rapidly turned and flow path efficiency is poor. Yet, as described above, since the flow is rapidly turned in the related art impeller, a flow path loss is heavy and flow path efficiency is poor.

Problems of a diffuser of the related are described in the following.

A diffuser may include a hub and a multitude of vanes provided to the hub. Yet, as an axial flow diffuser is used in the related art, an axial flow is generated from the diffuser.

In the related art, the vanes are provided to the hub in an axial direction. Hence, a flow coming out of an impeller is rapidly turned to enter the vanes. This is because the flow comes out of the impeller in an approximately diameter direction and because the vanes of the diffuser are provided in an axial direction. Therefore, the related art diffuser has a heavy flow path loss and poor flow path efficiency.

Meanwhile, there exists a section (hereinafter referred to as `vaneless section') in which no vane of a diffuser is present between an impeller and the diffuser, and such a vaneless section is long. However, the vaneless section fails to guide a flow due to absence of vanes. Therefore, in vaneless section of a related art fan motor, a flow path loss is heavy and flow path efficiency is poor.

Meanwhile, in the related art, a length of a vane of a diffuser is short. However, if the length of the vane of the diffuser is short, a flow cannot be guided effectively. Therefore, the related art diffuser has a small diffuser effect and poor flow path efficiency.

As described above, a related art fan motor has a heavy flow path loss in a diffuser. Therefore, the related art fan motor disadvantageously has poor flow path efficiency and lowered total efficiency of the fan motor. Moreover, as a fan motor is downsized and tends to have ultra-high speed, it is further necessary to reduce a flow path loss and improve flow path efficiency.

The above-described fan motor of the related art is disclosed in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, etc..

<CIT> discloses a small size light weight efficient fan motor for a vacuum cleaner and obtain a small size efficient vacuum cleaner.

Accordingly, embodiments of the present disclosure are directed to a fan motor and manufacturing method thereof that substantially obviate one or more problems due to limitations and disadvantages of the related art. The present invention is defined by independent claims <NUM> and <NUM>, the dependent claims <NUM>-<NUM> describe embodiments of the present invention.

One object of the present disclosure is to provide a fan motor having an impeller and manufacturing method thereof, by which a flow path loss may be reduced and flow path efficiency may be improved.

Another object of the present disclosure is to provide a fan motor having a diffuser and manufacturing method thereof, by which a flow path loss may be reduced and flow path efficiency may be improved.

Another object of the present disclosure is to provide a fan motor and manufacturing method thereof, by which a vaneless section between an impeller and a diffuser may be minimized.

Another object of the present disclosure is to provide a fan motor and manufacturing method thereof, by which a vane length of a diffuser may be maximized.

Another object of the present disclosure is to provide a fan motor and manufacturing method thereof, by which efficiency of the fan motor may be improved.

Another object of the present disclosure is to provide a fan motor having an easily manufactured diffuser and manufacturing method thereof.

Further object of the present disclosure is to provide a fan motor and manufacturing method thereof, by which a flow may be guided efficiently.

Additional advantages, objects, and features of the disclosure will be set forth in the disclosure herein as well as the accompanying drawings. Such aspects may also be appreciated by those skilled in the art based on the disclosure herein.

According to an embodiment of the present disclosure, an impeller is a diagonal flow type. Hence, in the impeller, a flow path loss may be reduced and flow path efficiency may be improved.

According to the invention, the diffuser includes a diagonal flow type. Hence, in the diffuser, a flow path loss may be minimized but flow path efficiency may be maximized.

According to the invention, a diagonal flow vane is provided to a vaneless section. Hence, the vaneless section between an impeller and the diffuser may be minimized. Hence, a flow path loss may be minimized but flow path efficiency may be maximized.

According to the invention, a diagonal flow vane is provided above an axial flow vane of a diffuser, thereby maximizing an overall length of the vane. Hence, a flow path loss may be minimized but flow path efficiency may be maximized.

According to the invention, a diffuser consists of two parts including a hub and a vane structure. Hence, manufacture of the diffuser is facilitated.

According to the invention, a vane structure is fixed using another part of a fan motor. Hence, assembling is improved.

According to the invention, a vane is provided within a vane body. Hence, a flow is efficiently guided in the vane.

To achieve these objects and other advantages and in accordance with the purpose of the disclosure, as embodied and broadly described herein, a fan motor according to the invention is constructed as defined in independent claim <NUM>.

According to the the invention, the vane body includes a hollow ring wherein the axial flow vane is provided to an inner surface of the ring.

According to the the invention, an indentation is provided to the vane body and wherein a fitted part corresponding to the indentation is provided to the motor bracket.

According to an exemplary embodiment of the present disclosure, the vane body, the axial flow vane and the diagonal flow vane may be integrally provided.

According to an exemplary embodiment of the present disclosure, the vane body, the axial flow vane and the diagonal flow vane may be formed by injection molding.

According to the invention, a hub is provided within the vane body and a shape of a top portion of an outer circumference of the hub may be related to a shape of the diagonal flow vane.

According to an exemplary embodiment of the present disclosure, the indentation may include at least one of a first indentation provided in a circumferential direction or a second indentation provided in an axial direction and the fitted part may include at least one of a first fitted part related to the first indentation and a second fitted part related to the second indentation.

According to an exemplary embodiment of the present disclosure, the motor bracket may include a bearing housing, a support part and a bridge connecting the bearing housing and the support part to each other and the fitted part may be provided to an outside of the support part.

According to an exemplary embodiment of the present disclosure, one end of the second fitted part may be connected to a lateral side of the bridge.

According to an exemplary embodiment of the present disclosure, the impeller is received in an impeller housing and a top portion of the vane body may be supported by an inner surface of the impeller housing.

According to an exemplary embodiment of the present disclosure, a step difference may be provided to the inner surface of the impeller housing and the top portion of the vane body may be supported by the step difference.

According to an exemplary embodiment of the present disclosure, an outer diameter of the vane body may be related to an inner diameter of the impeller housing. The vane body may be fixed in an axial direction in a manner that the impeller housing may be coupled to the motor bracket. According to an exemplary embodiment of the present disclosure, the hub may be coupled to the motor bracket. The hub may be coupled to the bridge of the motor bracket.

In further aspect of the present invention, a method of manufacturing a fan motor according to claims <NUM>-<NUM> is provided, which includes a first step of preparing a vane body having a hollow part and a vane provided to an inner circumference thereof and a second step of assembling a hub to the hollow part of the vane body.

According to an exemplary embodiment of the present disclosure, in the second step, the hub may be coupled to a motor bracket, the vane body may be fixed in a circumferential direction in a manner that a bottom portion of the vane body is fitted to the motor bracket, and the vane body may be fixed in an axial direction in a manner that a top portion of the vane body is supported by an impeller housing.

It is to be understood that both the foregoing general description and the following detailed description of the present disclosure are exemplary and explanatory and are intended to provide further explanation of the disclosure as claimed.

The above and other aspects, features, and advantages of the present disclosure will become more apparent upon consideration of the following description of preferred embodiments, taken in conjunction with the accompanying drawing figures. In the drawings:.

Reference will now be made in detail to a fan motor according to the preferred embodiment of the present disclosure, examples of which are illustrated in the accompanying drawings. Although description will now be given in detail according to exemplary embodiments disclosed herein with reference to the accompanying drawings, the embodiments and drawings are used to help the understanding of the present disclosure.

Moreover, to help the understanding of the present disclosure, s the accompanying drawings may be illustrated in a manner of exaggerating sizes of some components instead of using a real scale.

Thus, the present disclosure is non-limited to the following embodiment, and it is intended that the present disclosure covers the modifications and variations of this disclosure provided they come within the scope of the appended claims.

An overall configuration of a fan motor <NUM> according to an embodiment of the present disclosure is described with reference to <FIG> and <FIG> as follows.

First of all, a motor <NUM> includes a stator <NUM> and a rotor <NUM>. An impeller is coupled to a rotating shaft <NUM> of the rotor <NUM>. Hence, if the motor <NUM> rotates, the impeller <NUM> rotates as well, thereby generating a suction force of sucking air.

A diffuser <NUM>, which as shown in <FIG> is not according to the claimed invention, is provided between the impeller <NUM> and the motor <NUM>. The diffuser <NUM> guides an air flow coming out of the impeller <NUM> toward a direction of the motor <NUM>.

Meanwhile, the motor <NUM> is received in a motor housing <NUM>. A motor bracket <NUM> is provided over the motor housing <NUM>. The impeller <NUM> and the diffuser <NUM> may be received in an impeller housing <NUM>.

The respective components are described in detail as follows.

First of all, the motor housing <NUM> is described.

The motor housing <NUM> includes a body <NUM> for receiving the motor <NUM> therein. A coupling part <NUM> extending in a radial direction may be provided to a top side of the body <NUM> of the motor housing <NUM>.

The body <NUM> may have a hollow cylindrical shape overall. An opening <NUM> in a prescribed shape may be provided to a lateral side of the body <NUM>. And, an opening <NUM> may be provided to a bottom side of the body <NUM>. Air flowing into the motor housing <NUM> may be externally discharged through the bottom opening <NUM> of the body <NUM>.

A bearing housing <NUM> (hereinafter referred to as `bottom bearing housing', for clarity) for having a bearing seated therein is provided to the bottom side of the body <NUM>. And, a connecting part <NUM> may be provided to connect the bottom bearing housing <NUM> and the body <NUM> together.

Meanwhile, the opening <NUM> in the prescribed shape may be provided to the coupling part <NUM>. A flow coming out of the diffuser <NUM> may move through the opening <NUM>. A screw fastening recess <NUM> for coupling to the impeller housing <NUM> may be provided to the coupling part <NUM>. And, a screw fastening recess <NUM> for coupling to the motor bracket <NUM> may be provided to the coupling part <NUM>.

Meanwhile, the stator <NUM> may be coupled to an inner surface of the body <NUM> of the motor housing <NUM>. The rotor <NUM> is located around the center of the body <NUM> of the motor housing <NUM>. A bottom side of the rotating shaft of the rotor <NUM> is rotatably supported by the bottom bearing housing <NUM>.

The motor bracket <NUM> is described in the following.

The motor bracket <NUM> may rotatably support a top portion of the rotating shaft of the rotor <NUM>. Moreover, the motor bracket <NUM> may support the diffuser <NUM> by being coupled to the diffuser <NUM>.

Detailed description is made as follows.

A bearing housing (hereinafter referred to as `top bearing housing' for clarity) may be provided around the center of the motor bracket <NUM>. A support part <NUM> supported by the coupling part <NUM> of the motor housing <NUM> may be provided to an outside of the motor bracket <NUM>. The support part <NUM> may correspond to a shape of the coupling part <NUM>. For example, the support part <NUM> may be in a ring shape.

An auxiliary support part <NUM> may be provided inside the support part <NUM>. The auxiliary support part <NUM> may be in a ring shape. A part configured to connect the support part <NUM> and the auxiliary support part <NUM> together may be provided, and a screw fastening recess <NUM> may be provided to this part.

The support part <NUM> may be provided with a screen fastening recess <NUM> corresponding to the screw fastening recess <NUM> of the coupling part <NUM> of the motor housing <NUM>.

A bridge <NUM> may be provided between the top bearing housing <NUM> and the support part <NUM> to connect them together. And, the bridge <NUM> may be provided with a screw fastening recess <NUM> corresponding to the screw fastening recess <NUM> of the diffuser <NUM>. (A specific coupling structure will be described later.

The impeller housing <NUM> is described as follows.

First of all, the impeller housing <NUM> receives the impeller <NUM> and the diffuser <NUM> therein. The impeller housing <NUM> may be approximately configured in a hollow cylindrical shape. An opening <NUM> provided to a top side of the impeller housing <NUM> is an inlet through which air flows in.

The impeller housing <NUM> may have a diameter increasing from top to bottom. A coupling part <NUM> extending in a radial direction may be provided to a bottom side of the impeller housing <NUM>. The coupling part <NUM> of the impeller housing <NUM> may be provided with a screw fastening recess <NUM> corresponding to the screw fastening recess <NUM> of the coupling part <NUM> of the motor housing <NUM>.

The coupling relationship of the respective components will be described as follows.

First of all, the top portion of the rotating shaft <NUM> of the rotor <NUM> is rotatably supported by the top bearing housing <NUM> of the motor bracket <NUM>. The bottom portion of the rotating shaft <NUM> of the rotor <NUM> is rotatably supported by the bottom bearing housing <NUM> of the motor housing <NUM>. The motor bracket <NUM> may be screw-fastened to the top side of the motor housing.

The diffuser <NUM> may be screw-fastened to the top side of the motor bracket <NUM>. And, the impeller <NUM> may be coupled to the top end of the rotating shaft <NUM> of the rotor <NUM>.

Meanwhile, the impeller housing <NUM> and the motor housing <NUM> may be screw-coupled to each other. Hence, the components of the fan motor <NUM> may be received in the impeller housing <NUM> and the motor housing <NUM>.

Alternatively, the impeller housing <NUM> and the motor housing <NUM> may be coupled together by another coupling mechanism. For example, a part A shown in <FIG> shows another coupling mechanism. As shown in the part A of <FIG>, the motor housing <NUM> may be pressed and fitted into the motor housing <NUM> so as to be coupled thereto. In this case, an edge of the coupling part <NUM> of the motor housing <NUM> may be bent downward and then press-fitted into the impeller housing <NUM>.

The impeller <NUM> of the present embodiment is described with reference to <FIG> as follows.

The present embodiment proposes a structure for decreasing a turned angle of a flow coming out of the impeller <NUM> to reduce a flow path loss.

The impeller <NUM> of the present embodiment may be a diagonal flow type. A flow F1 entering the impeller <NUM> through the inlet <NUM> of the impeller housing <NUM> almost follows an axial direction. Yet, a flow F2 coming out of the impeller <NUM> may have a prescribed inclination.

For example, the impeller <NUM> may be configured in a manner that a direction of the flow F2 coming out of the impeller <NUM> has an inclination between a diameter direction (<NUM>°) and the axial direction (<NUM>°). The direction of the flow F2 coming out of the impeller <NUM> may include about <NUM>°.

The impeller <NUM> may include a hub <NUM> and a multitude of blades <NUM> provided to the hub <NUM>. Here, the hub <NUM> may have an approximately circular shape. The blades <NUM> may be provided to a top side of the hub <NUM>.

The direction of the flow F2 coming out of the impeller <NUM> may be set to have a prescribed downward inclination from a radial direction. To this end, the impeller <NUM> may be configured to be inclined further downward from horizontality. For example, in case of viewing a vertical cross-section of the hub <NUM> of the impeller <NUM>, an inclination of a hub top surface 52a and 52b may be configured to have an angle between <NUM>° and <NUM>°, and preferably, <NUM>°. Alternatively, the top surface of the hub <NUM> may be configured to have an inclination getting closer to the axial direction from the top side 52a toward the bottom side 52b. According to this configuration, a flow may be generated in a manner of getting proximate to the axial direction toward an outside from the hub <NUM> (See <FIG>).

With the above configuration, the direction of the flow F2 coming out of the impeller <NUM> may become more slant downward than the diameter direction. Thus, the direction of the flow coming out of the impeller <NUM> may be prevented from being rapidly turned in the diameter direction. Therefore, a flow path loss may be minimized but flow path efficiency may be maximized.

Compared to a flow direction of a centrifugal impeller of the related art, a flow direction of the impeller <NUM> of the present embodiment is considerably inclined downward, i.e., in the axial direction so as to increase a flow rate of the axial direction. Therefore, a flow rate through the fan motor <NUM> increases, whereby a suction capability of the fan motor <NUM> increases.

Compared to a flow rate of a centrifugal impeller of the related art, a flow rate of the impeller <NUM> of the present embodiment is high. According to the comparison with the same reference, the number of blades of the impeller can be reduced. For example, if the number of blades of the centrifugal impeller of the related art is <NUM>, although the number of the blades <NUM> of the impeller <NUM> of the present embodiment is reduced to <NUM>, a sufficient flow rate can be secured.

In addition, if the number of the blades <NUM> of the impeller <NUM> is reduced, the shaft power applied to the impeller <NUM> is reduced. Therefore, since it is possible to reduce the shaft power in the impeller <NUM> of the present embodiment, efficiency of the fan motor <NUM> is raised.

The diffuser, of the fan motor <NUM> is described with reference to <FIG>. As is clear from <FIG>, this diffuser is not according to the claimed invention,.

A diffuser <NUM> of the present embodiment is described as follows.

First of all, a diffuser <NUM> includes a hub <NUM> and a vane <NUM>. Particularly, a multitude of vanes <NUM> may be provided.

The hub <NUM> may be configured in a disk shape. An opening <NUM>, in which the bearing housing <NUM> of the motor bracket <NUM> is inserted, may be provided to the hub <NUM>. A shape of the opening <NUM> of the hub <NUM> may correspond to a shape of the bearing housing <NUM> of the motor bracket <NUM>. Moreover, the hub <NUM> may be provided with a screw fastening recess <NUM> for screw-fastening the motor bracket <NUM> and the hub <NUM> to each other.

Each of the vanes <NUM> includes an axial flow vane <NUM> and a diagonal flow vane <NUM>. The diagonal flow vane <NUM> may play a diffusing role, and the axial flow vane <NUM> may play a role in increasing a flow rate by changing a flow direction into a downward direction.

The diagonal flow vane <NUM> is located above the axial flow vane <NUM>. For example, the axial flow vane <NUM> may be provided to a lateral side <NUM> of the outer circumference of the hub <NUM>. The diagonal flow vane <NUM> is provided to a top side <NUM> of the outer circumference of the hub <NUM>. The diagonal flow vane <NUM> may be in a shape that an angle of a leading edge is inclined.

The axial flow vane <NUM> and the diagonal flow vane <NUM> may be separately provided. Preferably, the axial flow vane <NUM> and the diagonal flow vane <NUM> are connected continuously as a single vane.

In some implementations, generally, a space between the impeller <NUM> and the diffuser <NUM> is a vaneless section having no vane existing therein. Yet, a flow path loss is considerable in the vaneless section. Hence, a size of the diagonal flow vane <NUM> may become a size capable of covering the vaneless section if possible. For example, a top end of the diagonal vane <NUM> may be provided to be substantially adjacent to a bottom side of the impeller <NUM>.

Meanwhile, the longer a total length of the vane of the diffuser <NUM> becomes, the better the vane gets. This is because a flow coming out of the impeller <NUM> can be guided more effectively if the total length of the vane gets longer. Hence, the total length of the vane of the diffuser <NUM> is preferably set longer. Besides, there is not much clearance under the diffuser <NUM>. Hence, a length of the vane is extended over the diffuser <NUM>.

Yet, in the present embodiment, the diagonal flow vane <NUM> is provided above the axial flow vane <NUM>. Namely, according to the present embodiment, the total length of the vane <NUM> gets longer by the length of the diagonal flow vane <NUM> without extending the length of the axial flow vane <NUM>. Of course, at least one of the length of the axial flow vane <NUM> and the length of the diagonal flow vane <NUM> may be possibly increased.

An operation of the diffuser <NUM> according to the present embodiment is described with reference to <FIG> and <FIG> as follows.

In the present embodiment, the diagonal flow vane <NUM> is located at the portion where the flow F2 coming out of the impeller <NUM> flows into the diffuser <NUM>. Hence, the flow F2 coming out of the impeller <NUM> is first guided by the diagonal flow vane <NUM>, thereby becoming a flow F3a in an inclination direction. Hence, the flow coming out of the impeller <NUM> may move in a direction of the diffuser <NUM> more efficiently without a flow path loss.

Namely, the flow coming out of the impeller <NUM> is naturally discharged downward by the diagonal flow vane <NUM>. Thus, the diagonal flow vane <NUM> restrains a rotation component of the flow and helps the flow to escape efficiently.

In addition, if the impeller <NUM> is a diagonal flow impeller, the flow escaping from the impeller <NUM> in a diagonal flow form may move more naturally along the diagonal flow vane <NUM>. This is because the flow escaping from the impeller <NUM> in a diagonal flow form is naturally accepted by a start point of the diagonal flow vane <NUM>. Moreover, a flow F3 guided to the diagonal flow vane <NUM> is delivered as a flow F3b in a motor direction by the axial flow vane <NUM>.

Therefore, according to the present embodiment, a flow path loss may be minimized and flow path efficiency may be maximized. And, suction capability of the fan motor <NUM> may be raised efficiently.

Moreover, in the present embodiment, the diagonal flow vane <NUM> may be provided above the axial flow vane <NUM>. Therefore, the diagonal flow vane <NUM> may be provided to the vaneless section, thereby minimizing the vaneless section between the impeller <NUM> and the diffuser <NUM>.

In addition, in the present embodiment, a diagonal flow vane is additionally provided above the axial flow vane <NUM>. Therefore, the total length of the vane of the diffuser <NUM> is increased, whereby a significant diffusing effect is obtained.

Operations of the fan motor <NUM> according to the present embodiment are described with reference to <FIG> as follows.

First of all, once the motor <NUM> rotates, the impeller <NUM> connected to the rotating shaft of the motor <NUM> is rotated. If the impeller <NUM> is rotated, air is sucked in through the inlet <NUM> of the impeller housing <NUM>. Namely, a flow F1 in an approximately axial direction is generated.

The air sucked into the impeller housing <NUM> flows in the direction of the impeller <NUM>. Here, the impeller <NUM> of the present embodiment may include a diagonal flow impeller. Hence, the flow F2 coming out of the impeller <NUM> moves downward at a prescribed inclination from a diameter direction. For example, the flow F2 may approximately lie between a radial direction and an axial direction. Namely, a direction of the flow F2 coming out of the impeller <NUM> is not turned rapidly. Thus, according to the present embodiment, a flow path loss is reduced.

The flow F2 coming out of the impeller <NUM> is naturally guided by the diagonal flow vane <NUM> of the diffuser <NUM> first. The flow F3 passing through the diagonal flow vane <NUM> becomes the flow F3B in the approximately axial direction by the axial flow vane <NUM>. Namely, as the air flow is naturally guided in the diffuser <NUM>, a flow path loss is reduced (See <FIG>).

One portion of the flow coming out of the diffuser <NUM> becomes a flow F5 moving into the motor housing <NUM>. The air flowing into the motor housing <NUM> cools down the motor <NUM> and is then externally discharged through the bottom opening <NUM> of the motor housing <NUM>. The other portion of the flow coming out of the diffuser <NUM> becomes a flow F4 directly coming out of the motor housing.

In some implementations, when the fan motor according to the present disclosure is used for a cleaner, both of the flow F5 having passed through the motor housing <NUM> and the flow F4 failing to pass may move to a filter of the cleaner.

In the above-described embodiment, a fan motor having a diagonal flow impeller and an axial-diagonal flow diffuser is taken as an example. Yet, the axial-diagonal flow diffuser is applicable to a fan motor having a centrifugal impeller as well. And, a diagonal flow impeller is usable for a fan motor having an axial flow diffuser as well.

A fan motor 1a according to another embodiment of the present disclosure is described with reference to <FIG>.

The basic principle of the present embodiment is substantially similar to that of the aforementioned embodiment. Yet, the present embodiment differs from the aforementioned embodiment in a structure of a diffuser. For clarity of description, the description of the substantially same components of the aforementioned embodiment will be skipped.

Manufacturing of the diffuser <NUM> of the aforementioned embodiment is not facilitated. For example, injection of the diffuser of the aforementioned embodiment is not facilitated. This is because a diagonal flow vane is provided to a top surface of an outer circumference of a hub in the diffuser of the aforementioned embodiment. The top surface of the outer circumference of the hub is a curved surface and the diagonal flow vane is provided to the curved surface. Thus, it is difficult to manufacture the diffuser <NUM> of the aforementioned embodiment using the injection.

Accordingly, the present embodiment proposes a diffuser of which manufacturing is facilitated. In the present embodiment, it is proposed to separate a diffuser into two parts to facilitate the manufacturing of the diffuser. In the present embodiment, it is proposed to fix the separated two parts without using screws and the like. For example, it is proposed to fix the two parts using peripheral parts of a vane.

A diffuser 6a of the present embodiment is described in detail as follows.

First of all, a diffuser 6a of the present embodiment includes a hub <NUM> and a vane <NUM> separated from the hub <NUM>. In the present embodiment, the hub <NUM> and the vane <NUM> are prepared separately (by injection molding) and then assembled into the diffuser 6a. In the present embodiment, as the vane <NUM> is separated from the hub <NUM>, a contact surface between the vane <NUM> and the hub <NUM> is removed. Hence, the vane <NUM> and the hub <NUM> may be easily manufactured (by injection molding for example).

The hub <NUM> of the present embodiment may be configured in a manner of removing the vane from the hub in the aforementioned embodiment. One example of the hub <NUM> of the present embodiment is described as follows.

The hub <NUM> may include a center part <NUM> and a circumference part <NUM> located on an outer circumference of the center part <NUM>. The center part <NUM> may be in a disk shape and the circumference part <NUM> may be in a cylindrical shape. The center part <NUM> and the circumference part <NUM> may be integrally formed.

The center part <NUM> may be provided with an opening <NUM>. A shape of the opening <NUM> may correspond to a shape of a bearing housing 42a of a motor bracket 4a, and the bearing housing 42a may be inserted in the opening <NUM>. And, the center part <NUM> may be provided with a screw-fastening recess <NUM> for the screw fastening to the motor bracket 42a.

A prescribed step difference <NUM> may exist between the center part <NUM> and the circumference part <NUM>.

A top side of the circumference part <NUM> may be provided as a curved surface. For example, the top side <NUM> of the circumference part <NUM> may be extended in a center direction with a curved surface. A top end portion <NUM> of the top side <NUM> may have a horizontal surface.

The top side <NUM> and/or the top end portion <NUM> of the circumference part <NUM> may play a role in supporting the vane <NUM>, and more particularly, a diagonal follow vane <NUM>. To this end, a curvature of the top side <NUM> and/or the top end portion <NUM> of the hub <NUM> may correspond to a shape of the diagonal flow vane <NUM>.

Generally, a multitude of the vanes <NUM> may be provided. It is preferable to manufacture a multitude of the vanes <NUM> together rather than to manufacture a multitude of the vanes <NUM> individually. To this end, in order to hold a multitude of the vanes <NUM> by a single part or component, a separate part of component is used preferably.

For example, a multitude of the vanes <NUM> may be provided to a body (hereinafter referred to as `vane body') in a prescribed shape. (Both of the vane <NUM> and the vane body <NUM> will be collectively referred to as `vane structure <NUM>'.

The vane body <NUM> includes a hollow member. For example, the vane body <NUM> is a ring shape. The vane <NUM> is provided inside the vane body <NUM>.

The vane <NUM> includes an axial flow vane <NUM> and a diagonal flow vane <NUM>. The shapes of the axial flow vane <NUM> and the diagonal flow shape vane <NUM> in the present embodiment may be substantially identical to those of the axial flow vane and the diagonal flow vane of the aforementioned embodiment.

In some implementations, at least one portion of the axial flow vane <NUM> is connected to an inner surface of the vane body <NUM>. The diagonal flow vane <NUM> may be configured in a manner of being extended from a top side of the axial flow vane <NUM>.

The diagonal flow vane <NUM> may be configured in a manner of being extended from a top end of the axial flow vane <NUM> upward in a center direction of the vane body <NUM>. The diagonal flow vane <NUM> may be connected to the axial flow vane <NUM> without being connected to the vane body <NUM>.

Meanwhile, an indentation <NUM> in a prescribed shape is provided to a bottom side of the vane body <NUM>. The indentation <NUM> may be fitted into a prescribed portion of the motor bracket 4a, thereby playing a role in fixing the vane body <NUM> thereto.

The shape of the indentation <NUM> of the vane body <NUM> is non-limited. For example, the indentation <NUM> may include a first indentation <NUM> provided in a circumferential direction. And, the indentation <NUM> may include a second indentation <NUM> provided in an axial direction.

The indentation <NUM> may include a combination of at least one of the first indentation <NUM> and the second indentation <NUM>. If the indentation <NUM> includes both of the first indentation <NUM> and the second indentation <NUM>, it may have an approximately inverse 'T' shape.

In the following, the motor bracket 4a is described.

The motor bracket 4a of the present embodiment may be basically identical to the former motor bracket of the aforementioned embodiment. Yet, in the present embodiment, a prescribed portion of the motor bracket 4a may be fitted to a prescribed portion of the vane body <NUM>. For example, the motor bracket 4a of the present embodiment may have a portion fitted into the indentation provided to the vane body <NUM>.

The motor bracket 4a may include a bearing housing 42a, a support part 44a and a bridge 46a connecting the bearing housing 42a and the support part 44a to each other.

The bearing housing 42a may be in a shape capable of receiving a bearing provided to a top side of the rotating shaft of the motor. A shape of the support part 44a may correspond to a shape of the coupling part <NUM> of the motor hosing <NUM>. For example, the support part 44a may be in a ring shape. And, the support part 44a may be provided with a screw fastening recess 452a.

The motor bracket 4a may include a fitted part <NUM> fitted into the indentation <NUM> of the vane body <NUM>. The fitted part <NUM> may be provided in a shape corresponding to the indentation <NUM> of the vane body <NUM>. A multitude of the fitted parts <NUM> may be provided in a manner of being spaced apart from each other by a prescribed distance in a circumferential direction.

For example, the fitted part <NUM> may include a first fitted part <NUM> corresponding to the first indentation <NUM> of the vane body <NUM>. The first fitted part <NUM> may be provided in a manner of being extended from the support part 44a in a diameter direction. The first fitted part <NUM> may include a plate-type member having a prescribed small thickness.

The screw fastening recess 452a for the screw coupling to the motor housing <NUM> may be provided to the support part 44a or the first fitted part <NUM>.

The fitted part <NUM> may include a second fitted part <NUM> corresponding to the second indentation <NUM> of the vane body <NUM>. The second fitted part <NUM> may be provided in a manner of being extended from the support part <NUM> in the axial direction. The second fitted part <NUM> may include a plate-type member of small thickness.

The bridge 46a may employ any shape capable of performing a function of connecting the bearing housing 42a and the support part 44a together. For example, the bridge 46a may be in a narrow bar shape.

One side of the bridge 46a may be connected to the bearing housing 42a and the other side may be connected to the support part 44a. Yet, since there is a height difference between the bearing housing 42a and the support part 44a, there may be a height difference between top and bottom ends of the bridge 46a.

For example, the bridge 46a may include a horizontal part <NUM> and a vertical part <NUM>. One side of the horizontal part <NUM> may be connected to the bearing housing 42a and the other side may be connected to the vertical part <NUM>. One side of the vertical part <NUM> may be connected to the horizontal part <NUM> and the other side may be connected to the support part 44a. The horizontal part <NUM> may be provided with the screw fastening recess 466a for the screw coupling to the hub <NUM>.

Meanwhile, one end 454a of the second fitted part <NUM> may be connected to a lateral side of the vertical part <NUM>. If so, the second fitted part <NUM> may bear a rotational force generated by an air flow more effectively.

Namely, the second fitted part <NUM> may greatly receive the rotational force generated by the flow coming out of the impeller <NUM>. Yet, if one end 454a of the second fitted part <NUM> is connected to the lateral side of the vertical part <NUM>, the rotational force generated by the flow coming out of the impeller <NUM> may be supported by the lateral side of the vertical part <NUM> as well.

In addition, a top end <NUM> of the horizontal part <NUM> may extend vertically so as to contact with the lateral side of the bearing housing 42a.

Fixed mechanisms of the hub <NUM> and the vane structure <NUM> are described as follows.

The fixed mechanism of the hub <NUM> is described with reference to <FIG>.

The motor housing <NUM> and the motor bracket 4a may be coupled together. And, the hub <NUM> may be coupled to the motor bracket 4a.

The coupling of the motor bracket 4a and the hub <NUM> is described as follows.

The bearing housing 42a of the motor bracket 4a is inserted in the opening <NUM> of the hub <NUM>. In this state, the hub <NUM> and the motor bracket 4a are assembled by screw fastening. Hence, the hub <NUM> is solidly fixed in the rotation direction and the axial direction.

A rotation-directional (arc-directional) fixed mechanism of the vane structure <NUM> is described with reference to <FIG> and <FIG>.

As described above, in the present embodiment, the vane structure <NUM> may be provided as a member separate from the hub <NUM>. Hence, a mechanism appropriate for fixing the vane structure <NUM> is required. Proposed in the present embodiment is a mechanism of fixing the vane structure <NUM> without using a fastening mechanism such as a screw and the like.

First of all, the impeller <NUM> is rotated at high speed, whereby a flow coming out of the impeller <NUM> has a strong force in a rotation direction. Hence, when the flow coming out of the impeller <NUM> passes through the vane <NUM> of the diffuser 6a, a force applied to the vane <NUM> in the rotation direction is strong. Thus, a force applied to the vane body provided with a multitude of the vanes <NUM> in the rotation direction is strong as well. Accordingly, it is preferable to solidly fixe the vane body <NUM>.

The vane body <NUM> is fixed by the motor bracket 4a. Yet, in the present embodiment, the vane body <NUM> may be fixed without being screw-fastened to the motor bracket 4a.

Namely, as described above, if the vane body <NUM> is seated on the motor bracket 4a, the fitted part <NUM> of the motor bracket 4a is fitted to the indentation <NUM> of the vane body <NUM>. Thus, although a strong force in the rotation direction is applied to the vane body <NUM>, the fitted part <NUM> of the motor bracket 4a prevents the vane body <NUM> from being rotated. Therefore, the vane body <NUM> is solidly fixed in the rotation direction.

In the above embodiment, the mechanism of fixing the vane structure <NUM> without using a fastening mechanism such as a screw is described, by which the present disclosure is non-limited. And, it is possible to fix the vane structure <NUM> using a fastening mechanism such as a screw.

The axial direction fixed mechanism of the vane structure <NUM> is described with reference to <FIG>.

In the present embodiment, the mechanism of fixing the vane structure <NUM> without using a fastening mechanism such as a screw is proposed.

The vane body <NUM> is supported by the impeller housing <NUM>. And, the vane body <NUM> is supported by the motor bracket 4a. For example, a top portion of the vane body <NUM> may be supported by the impeller housing <NUM>, and a bottom portion of the vane body <NUM> may be supported by the motor bracket 4a.

In this state, the impeller housing <NUM> and another portion (e.g., motor housing <NUM>) of the fan motor are coupled together, whereby the vane body <NUM> may be fixed in the axial direction more solidly.

A portion for supporting the vane body <NUM> may be provided to the impeller housing <NUM>. For example, a prescribed step difference <NUM> may be provided to an inner surface of the impeller housing <NUM>. And, the top portion 82a of the vane body <NUM> may be supported by the step difference <NUM> of the impeller housing <NUM>. Furthermore, an inner diameter of the impeller hosing <NUM> may correspond to an outer diameter of the vane body <NUM>.

The bottom portion of the vane body <NUM> may be supported by the motor bracket 4a. As described above, as the fitted part <NUM> of the motor bracket 4a is fitted to the indentation <NUM> of the vane body <NUM>, the bottom portion of the vane body <NUM> may be supported by the motor bracket 4a more solidly.

In this state, the impeller housing <NUM> is coupled to the motor housing <NUM>. The impeller housing <NUM> may be mutually coupled to the motor housing <NUM> by screw fastening or press fitting.

Namely, in the state that the vane body <NUM> is supported by the impeller housing <NUM>, the impeller housing <NUM> and the motor housing <NUM> are coupled together in the axial direction. If so, a force in the axial direction is applied to the vane body <NUM> supported by the impeller housing <NUM>. Hence, a force in the axial direction is applied to the top side 82a of the vane body <NUM> by the step difference <NUM> of the impeller housing <NUM>. Therefore, the vane body <NUM> may be solidly fixed in the axial direction without a separate fastening mechanism.

In the present embodiment, the step difference <NUM> is provided to the impeller housing <NUM>, and the vane body <NUM> is supported by the impeller housing using the step difference <NUM>, by which the present disclosure is non-limited. Alternatively, the impeller housing <NUM> and the vane body <NUM> may be supported in other ways.

The vane <NUM> is provided to the vane body <NUM>, and more particularly, the diagonal flow vane <NUM> may be seated on the top portion <NUM> of the hub <NUM> so as to be fixed in the axial direction.

According to the present embodiment, the vane <NUM> is located inside the vane body <NUM> in the ring shape. Hence, the air coming out of the impeller <NUM> flows between the inside of the vane body <NUM> in the ring shape and the outside of the hub <NUM>. Hence the air flow may be guided more smoothly.

In the present embodiment, a diffuser having an axial-diagonal flow vane is described.

The above-described embodiments and drawings are used to help the understanding of the present disclosure. It will be appreciated by those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope of the invention which is defined by the appended claims.

Claim 1:
A motor fan, comprising:
a motor housing (<NUM>) receiving a motor (<NUM>) therein;
a motor bracket (4a) disposed on the motor housing (<NUM>);
an impeller (<NUM>) coupled to a shaft (<NUM>) of the motor (<NUM>); and
a diffuser (6a) disposed between the motor (<NUM>) and the impeller (<NUM>), the impeller (<NUM>) being on a top of the motor fan and the diffuser (<NUM>) and the motor (<NUM>) being below the impeller(<NUM>), characterized in that the diffuser (6a) includes a hub (<NUM>) and a vane (<NUM>) separated from the hub (<NUM>), the vane (<NUM>) being provided with a vane body (<NUM>), an axial flow vane (<NUM>) being provided to an inner circumference of the vane body (<NUM>), and a diagonal flow vane (<NUM>) being provided above the axial flow vane,
wherein an indentation (<NUM>) is provided to the vane body (<NUM>) and wherein a fitted part (<NUM>) corresponding to the indentation (<NUM>) is provided to the motor bracket (4a), and
wherein the vane body (<NUM>) comprises a hollow ring and wherein the axial flow vane (<NUM>) is provided to an inner surface of the ring.