Patent ID: 8251674

Claim:
A brushless cooling fan assembly for application in a vehicle cooling system, comprising: an axial fan impeller, the impeller having a center ring, an outer rim and a plurality of blades extending radially from the center ring to the outer rim; a shroud for mounting the fan assembly in the vehicle cooling system, the shroud having a center hub with a hollow core and an outer wall, the outer wall having a base plate mounted outside the outer wall; a brushless direct current (BLDC) motor with a center bore and a periphery, the periphery fused to the center ring of the impeller, the hollow core of the shroud inserted through the center bore of the motor, joining together the motor, the shroud and the impeller, the BLDC motor powering the impeller, creating heat; an electronic controller module, having a housing, the housing having an electronic controller electrically connected to the BLDC motor, for controlling the BLDC motor, the electronic controller module mounted on the base plate on the outer wall to separate the controller from the BLDC motor, for protecting the electronic controller from heat created by the BLDC motor; a heat sink disposed on the housing of the electronic controller, the heat sink mated to the electronic controller to dissipate the heat away from the electronic controller, the heat sink having a plurality of fins, the plurality of fins having a sawtooth surface; and a clip extending substantially above and over the fins of the heat sink, holding the heat sink on the housing and forming a plurality of ducts with the sawtooth surface of the fins.