COMPACT VANE-AXIAL FAN WITH MODULAR COMPONENTS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/551,428 (filed Feb. 8, 2024). The aforementioned application is hereby incorporated by reference in its entirety.

BACKGROUND

Vane-axial fans are used in various applications and industries, including heating, ventilation, and air conditioning (HVAC) systems. Vane-axial fans typically consist of a housing with a rotating impeller (e.g., a rotor) and with downstream, stationary vanes, which can help direct airflow. In addition, some conventional fans can be associated with lower efficiency and louder noise.

BRIEF DESCRIPTION OF DRAWINGS

Subject matter of the present disclosure associated with a compact vane-axial fan with modular components is described in detail below with reference to these figures.

FIG. 1 depicts a perspective of an inlet side of a first vane-axial fan based on an example of this disclosure.

FIG. 2 depicts a perspective of an outlet side of the first vane-axial fan, in accordance with examples of this disclosure.

FIG. 3 depicts an exploded view of the first vane-axial fan, in accordance with examples of this disclosure.

FIG. 4 depicts a cross section associated with FIG. 3, in accordance with examples of this disclosure.

FIG. 5 depicts another cross section of the first vane-axial fan, in accordance with examples of this disclosure.

FIG. 6 depicts another cross section of the first vane-axial fan, with the housing omitted to not obstruct the view of the impeller, vane insert, and stator assembly, in accordance with examples of this disclosure.

FIG. 7 depicts a perspective of an inlet side of a second vane-axial fan based on an example of this disclosure.

FIG. 8 depicts a perspective of an outlet side of the second vane-axial fan, in accordance with examples of this disclosure.

FIG. 9 depicts an exploded view of the second vane-axial fan, in accordance with examples of this disclosure.

FIG. 10 depicts a cross section associated with FIG. 9, in accordance with examples of this disclosure.

FIG. 11 depicts another cross section of the second vane-axial fan, in accordance with examples of this disclosure.

FIG. 12 depicts yet another cross section of the second vane-axial fan, in accordance with examples of this disclosure.

FIG. 13 depicts a cross section of the second vane-axial fan with a different configuration of the impeller, vane insert, and stator assembly, in accordance with examples of this disclosure.

FIG. 14 depicts an exploded view of a third vane-axial fan based on an example of this disclosure.

FIG. 15 depicts a cross section associated with FIG. 14, in accordance with examples of this disclosure.

FIG. 16 depicts an exploded, cross-sectional view of a fourth vane-axial fan based on an example of this disclosure.

FIG. 17 depicts an exploded, cross-sectional view of a fifth vane-axial fan based on an example of this disclosure.

DETAILED DESCRIPTION

This detailed description is related to a compact vane-axial fan with modular components, which is associated with improved efficiency and can operate with a variety of differently configured impellers and vanes to allow for customization to a particular application. The fan can include a base set of components, including a fan housing with motor and stator (e.g., with or without stator vane), and in some examples, the base set of components can be modularly assembled with an impeller and a vane insert, which is positioned inline between the impeller and the stator. Stated differently, the same base set of components can be used with different sets of impellers and vane inserts, such that the same base set of components could be installed in two or more different use scenarios, while the impeller and vane insert can be switched to achieve desired performance objectives and functionality (e.g., specific to the use scenario).

In examples, the configuration(s) of the impeller, the vane insert, and/or the stator contribute to a compact design. In addition, configurations of the impeller and the vane insert can be tailored to one another to contribute to improved performance. Furthermore, a variety of different combinations of impellers and vane inserts can be selectively assembled with the base set of components to tailor fan operations for a use case and still achieve high efficiency. In some examples, the variety of different combination of impellers and vane inserts can decrease noise associated with the fan. As such, the vane-axial fane of the present disclosure is customizable to the needs of the user.

In examples of the present disclosure, a vane-axial fan can be used in any system configured to move some volume of air, such as for conditioning purposes or ventilation/venting (e.g., heating, ventilation, and/or cooling (HVAC) system). In some instances, a vane-axial fan can be housed in a cabinet or other structure with one or more surrounding walls. In some instances, a vane-axial fan can be free-standing, without being housed in a cabinet.

In contrast to the present invention, conventional vane-axial fans tend to be less versatile, less efficient, and noisier. In some instances, vanes of many conventional vane-axial fans are often fixed and not interchangeable. Furthermore, in many conventional vane-axial fans, the impeller is mounted further away from the motor, which can contribute to a less compact overall assembly. In some examples, conventional vane-axial fans can include a control ring that is intended to prevent airflow losses when the fan gets deadheaded, keeping the static pressure and stall factor level. However, the control ring by itself can fail to provide desired efficiencies and is less customizable to correspond with impeller blade configurations.

In contrast to conventional solutions, the vane-axial fan described herein is more compact, more efficient, more versatile, and can be less noisy. For example, instead of including an external motor that sits down below the impeller like many conventional vane-axial fans, the vane-axial fan described herein includes an external rotor that is positioned closer to the center of the impeller, pushed forward instead of sitting down below. Not only does this design allow the impeller to be positioned deeper on the mounting surface, but this design saves overall space, allowing the vane-axial fan to be more compact than conventional designs.

In examples of the present disclosure, the positioning of the vanes directly adjacent the impeller (e.g., without a control ring in between) can lend to a more compact design of the presently described vane-axial fan. Instead of including a control ring, the present solution achieves improved performance with various other features, such as with impeller-vane alignment. Some examples of the present disclosure address stall issues by handling roughly a 30-50% stall factor while still maintaining fine function (e.g., no decrease in power and/or efficiency), showcasing improved performance without having to integrate a 1½ to 2 inch gap between the leading or upstream edges of the blades (e.g., and vanes) and a leading or upstream edge of the shroud and without utilizing a control ring. In examples, this functionality is achieved by the present design, which includes leading edges of vanes of the vane insert (e.g., and blades of the impeller) that are positioned closer to the leading edge of the shroud, because the present design ensures that the direction of the airflow as it comes off the faces of the impeller blades aligns with the direction of the airflow as it engages the vanes of the vane insert. The airflow path, as it comes off of the impeller blades, flows more directly (e.g., as compared to prior solutions) into the vanes of the insert, as compared to when a gap is included (e.g., such as a 1½ to 2 inch gap between the blades and the vanes and/or between the blades and a leading edge of the shroud) in which there are more opportunities for the airflow to get trapped in the gap.

Moreover, when a conventional vane-axial fan stalls out, it typically pulls more energy (e.g., greater than 10% normal energy) and pushes less air. In contrast, if the present vane-axial fan stalls, the fan may still draw more energy (e.g., less than 10% normal energy), but the fan does not lose airflow while maintaining roughly 30-50% static change. Thus, the present vane-axial fan maintains its power (e.g., its output) at this condition, but conventional vane-axial fans typically lose power during these conditions.

In at least some examples, while the vanes of conventional vane-axial fans are typically fixed and not interchangeable, the vanes of the present solution include module components that are interchangeable depending on the desired output of a user. For example, vane inserts and impellers can be interchanged to achieve greater efficiency, less noise production, lower stall, and more. In addition to the versatility of the present design, the present vane-axial fan also includes more blades (e.g., vanes) than conventional solutions, which allows the present vane area to be smaller, leading to a more compact and efficient design. In addition to having more blades in general, the present disclosure also incorporates more efficient secondary blades. Secondary blades (e.g., blades located on the stator instead of the impeller or vane insert) of conventional solutions typically are not angled, which can allow exhaust air to expand by about 20-21 degrees. In contrast to conventional vane-axial fans, the secondary blades of the present solution are angled (e.g., inward towards the axis) such that the expansion of the exhaust is reduced, improving the efficiency (e.g., as compared to conventional solutions). As such, because the present solution boasts more blades and includes angled secondary blades, the present design reduces the air expansion as compared to previous designs.

Referring now to FIG. 1 through FIG. 6, a first vane-axial fan 100 is depicted based on examples of this disclosure. The fan 100 includes a housing 110 (or casing) that circumferentially aligns with a stator 112. In addition, the fan includes a motor 114 (e.g., internal motor or axially aligned motor). Alternatively, the fan 100 can include a belt-drive arrangement (e.g., external motor). In at least some examples, the same concepts apply to the fans with either an internal motor (e.g., such as motor 114) or an external motor (e.g. such as a belt-drive arrangement). Stated differently, at least some of the features of the fan 100, such as the impeller 116, the vane insert 118, and/or the stator 112 can be used with a belt-drive motor or other eternal motor. In at least one example, any one or more of the housing 110, the stator 112, and the motor assembly 114 can be part of a base set of components that can be operatively coupled with additional fan components, which can be tailored and customized for a given use case or application. Additional components can also be included in the base set of components, such as a mounting plate 120.

In at least some examples, the fan 100 can include an impeller 116 and a vane insert 118 that can be assembled with the base set of components (e.g., the housing 110, the stator 112, the motor assembly 114, and the mounting plate 120). The impeller 116 and the vane insert 118 are one example, and the fan 100 can include other impellers and/or vane inserts having different configurations, which can be tailored or customized for a particular use case or application.

The fan 100 can be assembled in various manners. For example, the stator 112 (e.g., stator vane) can be affixed to a base 122 of the motor assembly 114 (e.g., as indicated by the reference line 124 in FIG. 4 showing alignment of mounting apertures). In operation (e.g., when the impeller 116 is rotating via the motor 114), the base 122 and the stator 112 attached to the base 122 can remain in a fixed position. In at least some examples, the vane insert 118 can be fastened to the stator 112 (e.g., as indicated by the reference line 126), and similar to the stator 112 and the base 122, the vane insert 118 can also remain stationary and fixed relative to the rotation of the impeller 116. In examples, the impeller 116 can be fastened (e.g., as indicated by the reference line 128) to a mounting flange 130 (e.g., radial mounting flange) of the motor assembly 114, and the rotation of the mounting flange 130 can operationally rotate the impeller 116.

In at least some examples, the stator 112 can be fastened to the housing 110 and to the mounting plate 120 (e.g., as indicated by the reference line 132). The various parts can be assembled in various orders. In some examples, the stator 112, the vane insert 118, the impeller 116 and the motor assembly 114 can be removably coupled together in a first subassembly. The impeller 116 and the vane insert 118 can then be moved through the central opening of the mounting plate 120, so that the mounting plate 120 is flush with the outer, radial flange 134 of the stator 112. The housing 110 can then be maneuvered into position around the impeller 116 and the vane insert 118 and fastened to the mounting plate 120 and the stator 112 (e.g., via the flange 134).

In some examples, the housing 110 can include a single piece. In other examples, the housing 110 can include multiple pieces (e.g., reference view 111). Whether the housing 110 includes a single piece or multiple pieces, the inlet-side edge of the housing 110 includes a bell inlet lip 108.

The fan 100 can include various features that contribute to improved performance. In at least one example, the impeller 116 includes a shroud 136 (e.g., FIG. 4). In addition, the housing 110 includes a radial wall 138 that circumscribes the shroud 136 when the fan 100 is assembled. In at least some examples, the radial wall 138 includes a shoulder 140 that transitions from a first portion 142 with a first diameter 143 (e.g., FIG. 5) to a second portion 144 with a second diameter 145, which is larger than the first diameter 143 (e.g., the housing 110 comprises a shoulder that transitions from a first narrower portion to a second wider portion). In this respect, the second portion 144 of the radial wall 138 is recessed relative to the first portion 142. In addition, the first diameter 143 is smaller than an outer diameter 146 associated with the shroud 136, while the second diameter 145 is larger than the outer diameter 146 of the shroud 136. As such, the shoulder 140 (e.g., a transitional step or wall extending from the first portion 142 to the second portion 144) allows the impeller 116 to, during fan assembly, slide into the space of the second portion 144 (e.g., within the second diameter 145). In other words, the shroud 136 of the impeller 116 is aligned with the shoulder 140 and positioned within the second wider portion of the housing 110.

In this respect, arrangement of the first portion 142, the shoulder 140, the second portion 144, and the shroud 136 can contribute to better performance due to less bypass associated with impeller 116 airflow/pressure (e.g., where the shroud 136 is at least partially positioned in the recess formed by the second portion 144 and is at least partially obscured by the shoulder 140).

The fan 100 can include other features that reduce bypass. For example, the trailing edge of the shroud 136 of the impeller 116 can include an impeller flange 166 or lip that extends outward and away from a center axis. Similarly, the vane insert 118 can include a vane insert flange 168 or lip (e.g., on the leading edge of the vane insert 118) that extends outward and away from the center axis and that is circumferentially aligned with the impeller flange 166. In some examples, the alignment of the impeller flange 166 with the vane insert flange 168 helps diminish bypass. That is, in some conventional fans, some air can get trapped and/or escape between components, which can contribute to inefficiencies. However, in some cases the impeller flange 166 and the vane insert flange 168 can reduce bypass and increase efficiency.

In examples of the present disclosure, the positioning of the vane insert 118 directly adjacent the impeller 116 (e.g., without a control ring or other structure in between) can lend to a more compact design and achieve improved performance (e.g., as compared with conventional solutions) with various other features, such as with impeller-vane alignment. Some examples of the present disclosure address stall issues by handling roughly a 30-50% stall factor while still maintaining fine function (e.g., no decrease in power and/or efficiency), showcasing improved performance without having to integrate a 1½ to 2 inch gap between the leading edges of the blades (e.g., and vanes) and a leading edge of the shroud 136 and without utilizing a control ring. In some examples, the leading edges of the vanes of the vane insert 118 (e.g., and blades of the impeller 116) are positioned closer to the leading edge of the shroud 136, because the present design ensures that the direction of the airflow as it comes off the faces of the impeller 116 blades aligns with the direction of the airflow as it engages the vanes of the vane insert 118. The airflow path, as it comes off of the impeller 116 blades, flows more directly (e.g., as compared to prior solutions) into the vanes of the vane insert 118, as compared to when a gap is included (e.g., such as a 1½ to 2 inch gap between the blades and the vanes and/or between the blades and a leading edge of the shroud 136) in which case there are more opportunities for the airflow to get trapped in the gap.

In at least some examples, the housing 110 includes an inlet-side edge 148 that is further upstream relative to the impeller 116. In at least some examples, the inlet-side edge includes the bell inlet lip 108 that includes a convex contour 150 or surface (e.g., convex in the axial direction) and that extends radially around the periphery of the inlet-side edge 148. In some examples, the convexly contoured surface can extend to the shoulder 140. The contour of the inlet bell can, in some instances, contribute to improved performance and efficiency by helping to smooth the airflow as it enters the fan, minimize airflow separation at the inlet, and prevent airflow stall.

In at least some examples, the shapes and contours of the impeller 116, the vane insert 118, and the stator 112 can improve efficiency and performance by collectively directing airflow in a desired manner. For example, referring to FIG. 6 (with the housing omitted and a cross section depicted to illustrate some of the more interior structures of the impeller 116, the vane insert 118, and the stator assembly 112), arrows 152 represent a general direction of airflow as it comes off the impeller, and as depicted, the direction can be angled relative to the axial flow direction 154. For example, while the blades of the impeller 116 curve in a first direction, the vanes of the vane insert 118 curve in a second direction opposite or inversely to the first direction, and as the impeller 116 and the vane insert 118 rotate, the curvature of the blades and the vanes, respectively, align with and follow each other, which offsets the stall factor. In some examples (e.g., such as the example depicted in FIG. 5), the contours of the impeller 116 blades and the vane insert 118 vanes align closely. For example, while the blades of the impeller 116 include a given contour extending from the leading edge to the trailing edge, the vanes of the vane insert 118 include an inverse contour extending from the leading edge to the trailing edge. Accordingly, the blades and the vanes are inversed so that they are towards each other, which has the effect of diminishing (e.g., and potentially eliminating) the bypass. In examples, the vane insert 118 includes a contour that contributes to axially aligning the airflow so that it is more aligned with the axial flow direction 154 when the air moves from the trailing edge of the vane insert 118 blades. For example arrows 156 are more aligned in the axial direction with the axial flow direction, as compared with the flow represented by arrows 152. Alignment between the contours of the impeller 116 blades and the vane insert 118 vanes can be described or characterized in various manners. In at least one example, the arrows 152 can represent an orientation or airflow direction that is normal to the face of the impeller 116 blades (e.g., the bottom or underneath side face based on the view in FIG. 6). In addition, the leading portions of the vane insert 118 vanes (oriented closer to the impeller 116 and upstream) can include an angle or contour (e.g., a convex top face) that is generally aligned with the arrows 152. The vane insert 118 vanes can, in some cases, gradually transition from the leading portions to trailing portions that are more downstream and that are more axially aligned. This gradual transition from the leading portions that are aligned in a direction normal (e.g., perpendicular) to the face of the impeller blade 116 to the trailing portions that are more axially aligned can operate to effectively, efficiently, and quietly direct the airflow.

In some examples, the stator 112 (e.g., the stator rings) can further direct the airflow, as represented by arrows 158, such that when the air exits the trailing edge of the stator 112, the airflow is further aligned in the axial direction. For instances, the stator 112 can include concentric rings 160 (e.g., secondary rings) and radial ribs 162 (e.g., see also FIG. 5). The concentric rings 160 and/or the radial ribs 162 can help further guide or direct the airflow. For example, the concentric rings 160 are slightly angled such that the expansion of air leaving the outlet is reduced (e.g., to about 17-18 degrees), improving efficiency (e.g., as compared to conventional vane axial fans). Accordingly, the concentric rings 160 include a slight angle to accommodate expansion of the air as it exits the trail. In some examples, one or more of the concentric rings 160 tapers in the axial direction as it extends from the upstream edge to the downstream edge. That is, the upstream edge of the ring 160 can have a larger diameter than the downstream edge (e.g., FIG. 5 illustrates an example in which the rings 160 comprise the taper/angle). If the concentric rings 160 were not included, or if the concentric rings 160 were not tapered, the air would tend to expand outwards (e.g., naturally expanding by 20-21 degrees) after leaving the outlet, hitting surfaces above and below the fan, and making the fan less efficient. The inclusion of the concentric rings 160 at a slight angle helps to keep the air from immediately expanding, making the fan more efficient (e.g., as compared to conventional solutions). In some examples, the rings 160 can be perpendicular (not illustrated), instead of tapering.

Various aspects of the impeller 116 (e.g., the blades of the impeller 116), the vane insert 118 (e.g., the vanes of the vane insert 118), and/or the stator 112 (e.g., the concentric rings 160 or secondary blades) can be configured to affect a desired airflow. In at least some examples, while the vanes of conventional vane-axial fans are typically fixed and not interchangeable, the vanes of the present solution include module components that are interchangeable depending on the desired output of a user. For example, the leading edge, trailing edge, inner edge, outer edge, leading face, and trailing face can all be configured. In addition, the impeller 116 and the vane insert 118 can be tailored to correspond with one another to achieve a desired performance associated with the fan. For example, vane inserts and impellers can be interchanged to achieve greater efficiency, less noise production, lower stall, and more. In some examples, a user can optimize the end performance of a fan for efficiency purposes at a specific revolutions per minute (RPM), air flow, and/or static pressure. Thus, the vane-axial fan described herein allows a user to tailor the airflow and blade design to achieve a certain range of performance. For example, if a user desires a quieter running fan, a user can configure the fan to run at 1800 RPM with 1½ inches of static and to push 800 cubic feet per minute (CFM). In another example, if a user desires 2 inches of static, the user can change the components of the fan to achieve 2200 RPM; although this change may drop efficiency from 60% to 40%, this may be the desired airflow of the user.

Furthermore, the set of base components can be universal, such that different impeller and vane insert configurations can be interchangeably removed and installed for specific or targeted use cases. In some examples, it is common amongst all of the potential pairs of impeller and vane insert configurations to have a correspondence between the contours of the impeller blades and the contours of the vanes of the vane inserts. Accordingly, changing one impeller or vane insert for another impeller or vane insert, respectively, entails exchanging the contours associated with the impeller or vane insert for other contours (e.g., different angles) associates with another impeller or vane insert, respectively. In some examples, the number of blades or vanes can be interchangeable for higher or lower airflow and static pressure. For example, the example embodiment illustrated in FIG. 6 is designed for higher airflow and higher static due to the high number of blades (e.g., of the impeller 116) and the number of vanes (e.g., of the vane insert 118). In this example, if a user desired lower airflow while still maintaining higher static, the user could exchange the impeller 116 and/or the vane insert 118 for a differently configured impeller or vane insert. For example, impeller 116 could be exchanged with an impeller with a less number of blades, with blades that are more vertical, and/or blades that are wider (e.g., more vertical from tip-to-tip, from the outside ring to the inner ring of the impeller). Further, the vane insert 118 could be exchanged with a vane insert with vanes that are more vertical, because the user in this case (e.g., desiring lower airflow) want to move less air, meaning that the vanes would be wider in width. In some examples, the straighter (e.g., the more vertical and more aligned) the blades and vanes are, the greater the efficiency is for power. As such, different numbers, lengths, and angles of the blades (e.g. for the impeller) and the vanes (e.g., for the vane insert) can be associated with different impellers and vane inserts and can be interchanged to achieve a desired airflow.

Referring now to FIG. 7 through FIG. 12, another example vane-axial fan 700 is depicted, based on examples of this disclosure, and the fan 700 is compact with modular components. The fan 700 includes some features that are similar to the fan 100, and for brevity, features that are similar might not be described again with respect to the fan 700. But, it is understood that the same description that is associated with the fan 100 can also apply equally to the fan 700. In some examples, the fans 100 and 700 provide similar advantages over conventional solutions, such as modularity, improved efficiency, improved noise reduction, and a universal set of base components. In addition, the fan 100 might be better suited for installation in one use case (e.g., as part of a first system), whereas the fan 700 might be better suited for installation in a different use case (e.g., a second system having a different setup with different access).

In an example, the fan 700 includes a housing 710 that is combined with a stator assembly 712. For example, the housing 710 includes a radial wall 711, which can be connected to (e.g., integrally formed with) the stator assembly 712. In addition, the fan 700 includes a bell inlet lip 708 that attaches to the inlet end of the housing 710 (e.g., to the flange 713, such as with the mounting plate 720 fastened between the flange 713 and the bell inlet lip 708). In addition, the fan includes a motor 714 (e.g., internal motor or axially aligned motor). Alternatively, the fan 700 can include a belt-drive arrangement (e.g., external motor). In at least some examples, the same concepts apply to the fans with either an internal motor (e.g., such as motor 714) or an external motor (e.g. such as a belt-drive arrangement). In at least one example, any one or more of the housing 710 with the stator assembly 712, the bell inlet lip 708, and the motor assembly 714 can be part of a base set of modular components that can be operatively coupled with additional fan components, which can be tailored and customized for a given use case or application. Additional components can also be included in the base set of components, such as a mounting plate 720. In this sense, this set of base components can be universal, based on being compatible with a variety of other fan components, such as the impeller 716 and the vane insert 718.

The fan 700 can be assembled in various manners. For example, the stator assembly 712 can be affixed to a base 722 of the motor assembly 714 (e.g., as indicated by the reference line 724 in FIG. 11 showing alignment of mounting apertures). In operation (e.g., when the impeller 716 is rotating via the motor), the base 722 and the stator assembly 712 attached to the base 722 can remain in a fixed position. In at least some examples, the vane insert 718 can be fastened to the stator assembly 712 (e.g., as indicated by the reference line 726), and similar to the stator assembly 712 and the base 722, the vane insert 718 can also remain stationary and fixed relative to the rotation of the impeller 716. In examples, the impeller 716 can be fastened (as indicated by the reference line 728) to a mounting flange 730 (e.g., radial mounting flange) of the motor assembly 714, and the rotation of the mounting flange 730 can operationally rotate the impeller 716.

In at least some examples, bell inlet lip 708 can be fastened to the housing 710 (e.g., the flange 713) and to the mounting plate 720 (e.g., as indicated by the reference line 732 in FIG. 10). The various parts can be assembled in various orders. In some examples, the stator assembly 712 with the housing 710, the vane insert 718, the impeller 716, and the motor assembly 714 can be removably coupled together in a first subassembly. The impeller 716 and the vane insert 718 can then be moved through the central opening of the mounting plate 720, so that the mounting plate 720 is flush with the outer, radial flange 713 of the housing 710. The bell inlet lip 708 can then be fastened to the mounting plate 720 and the housing 710 (via the flange 713).

In some examples, the bell inlet lip 708 and the mounting plate 720 can be omitted.

The fan 700 can include various features that contribute to improved performance. In at least one example, the impeller 716 includes a shroud 736. In addition, the housing 710 includes the radial wall 711 that circumscribes the shroud 736 when the fan 700 is assembled. In at least some examples, the radial wall 711 includes an inner diameter 745 that is larger than an outer diameter of the shroud 736. In some examples, the inlet bell 708 is associated with an inner diameter 743, which is smaller than the outer diameter associated with the shroud 736. As such, the wall of the bell inlet lip 708 can be at least partially aligned with the shroud 736, as indicated by reference line 741. Alternatively, the shroud 736 could be positioned further radially outward than the wall of the bell inlet lip 708.

In examples, this arrangement of shroud 736 relative to the bell inlet lip 708 can contribute to better performance due to less bypass associated with impeller 716 airflow/pressure. For example, the trailing edge of the shroud 736 of the impeller 716 can include an impeller flange 766 or lip that extends outward and away from a center axis. Similarly, the vane insert 718 can include a vane insert flange 768 or lip (e.g., on the leading edge of the vane insert 718) that extends outward and away from the center axis and that is circumferentially aligned with the impeller flange 766. In some examples, the alignment of the impeller flange 766 with the vane insert flange 768 helps diminish bypass. The inclusion of the impeller flange 766 and the vane insert flange 768 helps to block bypass and improves the efficiency and the static pressure.

Referring to FIG. 12, impeller 716 (e.g., the blades of the impeller 716), the vane insert 718 (e.g., the vanes of the vane insert 718), and/or the stator 712 (e.g., concentric rings 760) can be configured to affect a desired airflow. For example, the leading edge, trailing edge, inner edge, outer edge, leading face, and trailing face can all be configured. In addition, the impeller and the vane insert can be tailored to correspond with one another to achieve a desired performance associated with the fan. For example, it is common amongst all of the potential pairs of impeller and vane insert configurations to have a correspondence between the contours of the impeller blades and the contours of the vanes of the vane inserts. Accordingly, changing one impeller or vane insert for another impeller or vane insert, respectively, entails exchanging the contours associated with the impeller or vane insert for other contours (e.g., different angles) associates with another impeller or vane insert, respectively. In some examples, the number of blades or vanes can be interchangeable for higher or lower airflow and static pressure. For example, the user could exchange the impeller 716 and/or the vane insert 718 for a differently configured impeller or vane insert. For example, impeller 716 could be exchanged with an impeller with a less number of blades, with blades that are more vertical, and/or blades that are wider (e.g., more vertical from tip-to-tip, from the outside ring to the inner ring of the impeller). Further, the vane insert 118 could be exchanged with a vane insert with vanes that are more vertical. As such, different numbers, lengths, and angles of the blades (e.g. for the impeller) and the vanes (e.g., for the vane insert) can be associated with different impellers and vane inserts and can be interchanged to achieve a desired airflow. Furthermore, the set of base components can be universal, such that different impeller and vane insert configurations can be interchangeably removed and installed for specific or targeted use cases.

As can be seen in the example embodiment illustrated in FIG. 13, various aspects of the other impeller 776 (e.g., the blades of the other impeller 776), the other vane insert 778 (e.g., the vanes of the other vane insert 778), and/or the stator 712 (e.g., the concentric rings 760 or secondary blades) can be configured to affect a desired airflow. The vanes of the present solution include module components that are interchangeable depending on the desired output of a user. For example, the leading edge, trailing edge, inner edge, outer edge, leading face, and trailing face can all be configured. In addition, the other impeller 776 and the other vane insert 778 can be tailored to correspond with one another to achieve a desired performance associated with the fan. For example, vane inserts and impellers can be interchanged to achieve greater efficiency, less noise production, lower stall, and more. In the example depicted in FIG. 13, the other impeller 776 blades include a flatter blade angle (e.g., as compared to the blades of impeller 716), and the other vane insert 778 vanes are more vertical (e.g., as compared to the vanes of the vane insert 718). Exchanging the impeller 716 for the other impeller 776, as well as exchanging the vane insert 718 for the other cane insert 718, impacts the airflow of the fan 700. For example, exchanging the impeller 716 for the other impeller 776, which includes a flatter blade angle compared to the impeller 716, decreases the amount of airflow. Furthermore, in the example depicted in FIG. 13, exchanging the vane insert 718 for the other vane insert 778, which includes vanes that are more vertical than the vanes of vane insert 718, increases the static pressure. As such, the modular components of the present disclosure can be configured to affect a desired airflow.

Referring now to FIG. 14 and FIG. 15, another example vane-axial fan 1400 is depicted, based on examples of this disclosure, and the fan 1400 is also compact with modular components. The fan 1400 includes some features that are similar to the fan 100 and the fan 700, and for brevity, features that are similar might not be described again with respect to the fan 1400. But, it is understood that the same description that is associated with the fan 100 and the fan 700 can also apply equally to the fan 1400. In some examples, the fans 100, 700, and 1400 provide similar advantages over conventional solutions, such as modularity, improved efficiency, improved noise reduction, and a universal set of base components. In addition, the fan 1400 might be better suited for installation in one use case (e.g., as part of a first system), whereas the fan 100 or the fan 700 might be better suited for installation in a different use case (e.g., a second system having a different setup with different access).

The fan 1400 includes a housing 1410 (or casing) that circumferentially aligns with a stator 1412 (e.g., see FIG. 15), a motor 1414 (e.g., internal motor or axially aligned motor or an external motor, such as a belt-drive arrangement), an impeller 1416, and a vane insert 1418 that can be assembled with a base set of components (e.g., the housing 1410, the stator 1412, the motor assembly 1414, and a mounting plate 1420). The impeller 1416 and the vane insert 1418 is one example, and the fan 1400 can include other impellers and/or vane inserts having different configurations, which can be tailored or customized for a particular use case or application.

The fan 1400 can be assembled in various manners. For example, the stator 1412 (e.g., stator vane) can be affixed to a base 1422 of the motor assembly 1414 (e.g., as indicated by reference line 1424 showing alignment of mounting apertures). In operation (e.g., when the impeller 1416 is rotating via the motor 1414), the base 1422 and the stator 1412 attached to the base 1422 can remain in a fixed position. In at least some examples, the vane insert 1418 can be fastened to the stator 1412 (e.g., as indicated by reference line 1426), and similar to the stator 1412 and the base 1422, the vane insert 1418 can also remain stationary and fixed relative to the rotation of the impeller 1416.

In examples, the impeller 1416 can be fastened to a motor shaft 1488 (e.g., radial motor shaft that protrudes from the base 1422) of the motor assembly 1414 via attachment of a circular mounting bracket 1464 (e.g., as indicated by the reference line 1494). In examples, the motor shaft 1488 extends through a radial opening of the vane insert 1418. In at least some examples, the circular mounting bracket 1464 is attachable to an inner axial flange 1490 of the impeller 1416 (e.g., as indicated by reference line 1494), and the circular mounting bracket 1464 is attachable to the motor shaft 1488 (e.g., as indicated by reference line 1492). In some examples, the rotation of the motor shaft 1488 (e.g., when operatively attached to the circular mounting bracket 1464) can operationally rotate the impeller 1416.

In at least some examples, the stator 1412 can be fastened to the housing 1410 (e.g., as indicated by the reference line 1432). The various parts can be assembled in various orders. In some examples, the stator 1412, the vane insert 1418, the impeller 1416 and the motor assembly 1414 can be removably coupled together in a first subassembly. The impeller 1416 and the vane insert 1418 can then be moved through the central opening of the mounting plate 1420, so that the circular mounting bracket 1464 can attach to the impeller 1416 and to the motor shaft 1488, holding these components together. The housing 1410 can then be maneuvered into position around the impeller 1416 and the vane insert 1418 and fastened to the mounting plate 1420 and the stator 1412.

The fan 1400 can include various features that contribute to improved performance. The impeller 1416 (e.g., the blades of the impeller 1416), the vane insert 1418 (e.g., the vanes of the vane insert 1418), and/or the stator 1412 can be configured to affect a desired airflow. The impeller and the vane insert can be tailored to correspond with one another to achieve a desired performance associated with the fan (e.g., like the impellers and vane inserts of the fans 100 and 700). The counters, amount, lengths, and angles of the blades (e.g. for the impeller) and the vanes (e.g., for the vane insert) can be associated with different impellers and vane inserts and can be interchanged to achieve a desired airflow.

With reference now to FIG. 16, another example vane-axial fan 1600 is depicted, based on examples of this disclosure, and the fan 1600 is also compact with modular components. The fan 1600 includes some features that are similar to the fans 100, 700, and 1400, and for brevity, features that are similar might not be described again with respect to the fan 1600. But, it is understood that the same description that is associated with the fans 100, 700, and 1400 can also apply equally to the fan 1600. In at least some examples, the fan 1600, and the related disclosure, illustrate and explain that modular features associated with this disclosure, such as a housing, impeller, vane, and stator, can be used across a wide variety of motors, either with or without slight modifications. Among other things, this can contribute to a widely flexible system that is highly effective across a wide variety of use contexts and environments.

The fan 1600 includes a housing 1610 that circumferentially aligns with a stator 1612, a motor 1614 (e.g., internal motor or axially aligned motor or, in an alternative arrangement, an external motor, such as a belt-drive arrangement), an impeller 1616, and a vane insert 1618 that can be assembled with a base set of components (e.g., the housing 1610, the stator 1612, the motor assembly 1614, and a mounting plate 1620). The impeller 1616 and the vane insert 1618 are one example, and the fan 1600 can include other impellers and/or vane inserts having different configurations, which can be tailored or customized for a particular use case or application, such as modularity, improved efficiency, and improved noise reduction.

The fan 1600 can be assembled in various manners. For example, the stator 1612 (e.g., stator vane) can be affixed to a base 1622 of the motor assembly 1614 (e.g., as indicated by reference line 1624 showing alignment of mounting apertures). In at least some examples, the vane insert 1618 can be fastened to the stator 1612 (e.g., as indicated by reference line 1626). In examples, the impeller 1616 can be fastened to a motor shaft 1688 of the motor assembly 1614 (e.g., located within the motor assembly 1614) via attachment of a circular mounting bracket 1664 (e.g., as indicated by the reference line 1694) to an inner axial flange 1690 of the impeller 1616 (e.g., as indicated by reference line 1694). In some examples, the circular mounting bracket 1664 of fan 1600 has a larger diameter than the circular mounting bracket 1464 of fan 1400. According to examples, the circular mounting bracket 1664 is attachable to the motor shaft 1688. In some examples, the rotation of the motor shaft 1688 (e.g., when operatively attached to the circular mounting bracket 1664) can operationally rotate the impeller 1616. In at least some examples, the stator 1612 can be fastened to the housing 1610.

The various parts can be assembled in various orders. In some examples, the stator 1612, the vane insert 1618, the impeller 1616 and the motor assembly 1614 can be removably coupled together in a first subassembly. The impeller 1616 and the vane insert 1618 can then be moved through the central opening of the mounting plate 1620, so that the circular mounting bracket 1664 can attach to the impeller 1616 and to the motor shaft 1688, holding these components together. The housing 1610 can then be maneuvered into position around the impeller 1616 and the vane insert 1618 and fastened to the mounting plate 1620 and the stator 1612. The impeller and the vane insert can be tailored to correspond with one another to achieve a desired performance associated with the fan (e.g., like the impellers and vane inserts of the fans 100, 700, and 1400).

Referring now to FIG. 17, another example vane-axial fan 1700 is depicted, based on examples of this disclosure, and the fan 1700 is also compact with modular components. The fan 1700 includes some features that are similar to the fans 100, 700, 1400, and 1600, and for brevity, features that are similar might not be described again with respect to the fan 1600. But, it is understood that the same description that is associated with the fans 100, 700, 1400, and 1600 can also apply equally to the fan 1700. In at least some examples, the fan 1700, and the related disclosure, illustrate and explain that modular features associated with this disclosure, such as a housing, impeller, vane, and stator, can be used across a wide variety of motors, either with or without slight modifications. Among other things, this can contribute to a widely flexible system that is highly effective across a wide variety of use contexts and environments.

The fan 1700 includes a housing 1710 that circumferentially aligns with a stator 1712, a motor 1714, an impeller 1716, and a vane insert 1718 that can be assembled with a base set of components. The impeller 1716 and the vane insert 1718 is one example, and the fan 1700 can include other impellers and/or vane inserts having different configurations, which can be tailored or customized for a particular use case or application. For example, the impeller and the vane insert can be tailored to correspond with one another to achieve a desired performance associated with the fan (e.g., like the impellers and vane inserts of the fans 100, 700, 1400, and 1600).

The fan 1700 can be assembled in various manners, and the various parts can be assembled in various orders. For example, the stator 1712 can be affixed to a base 1722 of the motor assembly 1714 (e.g., as indicated by reference line 1724 showing alignment of mounting apertures). In at least some examples, the vane insert 1718 can be fastened to the stator 1712 (e.g., as indicated by reference line 1726). In examples, an inner axial flange of the impeller 1716 can be fastened (as indicated by the reference line 1794) to a mounting flange 1764 (e.g., radial mounting flange) of the motor assembly 1714, and the rotation of the mounting flange 1764 can operationally rotate the impeller 1716. In some examples, the mounting flange 1764 of fan 1700 has a larger diameter than the mounting flanges 130 and 730 of fans 100 and 700, respectively. In at least some examples, the stator 1712 can be fastened to the housing 1710. The impeller 1716 and the vane insert 1718 can be moved through the central opening of the mounting plate 1720, so that the circular mounting bracket 1764 can attach to the impeller 1716, holding these components together. The housing 1710 can then be maneuvered into position around the impeller 1716 and the vane insert 1718 and fastened to the mounting plate 1720 and the stator 1712. According to aspects, the vane-axial fans described herein (e.g., 100, 700, 1400, 1600, and 1700) can be assembled in various manners, and the various parts can be assembled in various orders. However, it will be appreciated by one of ordinary skill in the art that, in some examples, regardless of how each respective fan is assembled (e.g., regardless of how each respective fan connects to its respective motor), the airflow of each respective fan can be configured to affect a desired airflow. For example, the impellers and the vane inserts described herein can be tailored to correspond with one another to achieve a desired performance associated with each respective fan. The counters, amount, lengths, and angles of the blades (e.g. for each described impeller) and the vanes (e.g., for each described vane insert) can be associated with different impellers and vane inserts and can be interchanged to achieve a desired airflow. Furthermore, each fan described herein can be manufactured at different scales (e.g., the same proportions at varying dimensions). For example, the vane-axial fans described herein can be manufactured at varying scales (e.g., larger or smaller in size as compared to other vane-axial fans described herein) for specific use cases associated with varying HVAC systems.

EXAMPLE CLAUSES

• • A. A vane-axial fan comprising: a housing comprising a radial wall that circumscribes an axis associated with the vane-axial fan; a stator assembly that is coupled to the housing and that comprises one or more rings; an impeller positioned interior to the radial wall; and a vane insert that is removably coupled to the stator assembly and that is positioned interior to the radial wall and between the impeller and the stator assembly.
  • B. The vane-axial fan of Clause A, wherein: the housing further comprises a shoulder that transitions from a first narrower portion to a second wider portion; and the impeller comprises a shroud aligned with the shoulder and positioned within the second wider portion of the housing.
  • C. The vane-axial fan of Clauses A or B, wherein the first narrower portion comprises a bell curve towards the axis.
  • D. The vane-axial fan of any of Clauses A through C, wherein the one or more rings of the stator taper towards the axis.
  • E. The vane-axial fan of any of Clauses A through D, wherein the vane insert comprises vanes comprising a first contour and the impeller comprises blades comprising a second contour, and wherein the first contour comprises a leading edge that corresponds with a trailing edge of the second contour.
  • F. The vane-axial fan of Clause E, wherein the first contour comprises a convex top face oriented towards the impeller and wherein the second contour comprises a convex bottom face oriented towards the vane insert.
  • G. The vane-axial fan of Clause E or Clause F, wherein alignment between the first contour and the second contour offsets a stall factor.
  • H. The vane-axial fan of any of Clauses A through G, wherein: the impeller comprises a first shroud comprising a first lip that is on a trailing edge of the first shroud; the vane insert comprises a second shroud comprising a second lip that is on a leading edge of the second shroud; and the first lip is aligned with the second lip.
  • I. The vane-axial fan of Clause H, wherein alignment of the first lip and the second lip at least partially reduces bypass.
  • J. An system for heating, cooling, and/or venting air, the system comprising: a vane-axial fan comprising: a housing comprising a radial wall that circumscribes an axis associated with the vane-axial fan; a stator assembly that is coupled to the housing and that comprises one or more rings; an impeller positioned interior to the radial wall; and a vane insert that is removably coupled to the stator assembly and that is positioned interior to the radial wall and between the impeller and the stator assembly.
  • K. The system of Clause J, wherein: the housing further comprises a shoulder that transitions from a first narrower portion to a second wider portion; and the impeller comprises a shroud aligned with the shoulder and positioned within the second wider portion of the housing.
  • L. The system of Clauses J and K, wherein the first narrower portion comprises a bell curve expanding away from the housing.
  • M. The system of Clause J, wherein the one or more rings of the stator taper towards the axis.
  • N. The system of Clause J, wherein the vane insert comprises vanes comprising a first contour and the impeller comprises blades comprising a second contour, and wherein the first contour comprises a leading edge that corresponds with a trailing edge of the second contour.
  • O. The system of Clauses J, wherein the first contour comprises a convex top face oriented towards the impeller, wherein the second contour comprises a convex bottom face oriented towards the vane insert, and wherein alignment between the first contour and the second contour at least partially offsets a stall factor.
  • P. The system of Clause J, further comprising a second impeller having one or more properties that are different from the impeller, wherein the second impeller is interchangeable in the system with the impeller.
  • Q. The systems of Clauses J and P, further comprising a second vane insert having one or more properties that are different from the vane inset, wherein the second vane insert is interchangeable in the system with the vane insert.
  • R. The system of Clause J, wherein: the impeller comprises a first shroud comprising a first lip that is on a trailing edge of the first shroud; the vane insert comprises a second shroud comprising a second lip that is on a leading edge of the second shroud; and the first lip is aligned with the second lip, wherein the alignment of the first lip and the second lip at least partially reduces bypass.
  • S. The system of Clause J, wherein: a mounting bracket is attachable to an inner axial flange of the impeller; and the mounting bracket being attachable to a motor shaft extending through a radial opening of the vane insert.
  • T. A method comprising: replacing, in association with a vane-axial fan, a first vane insert with a second vane insert, which has one or more different properties than the first vane insert; and based on replacing the first vane insert with the second vane insert, changing one or more performance characteristics of the vane-axial fan.

As used herein, a recitation of “and/or” with respect to two or more elements should be interpreted to mean only one element, or a combination of elements. For example, “element A, element B, and/or element C” may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. In addition, “at least one of element A or element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Further, “at least one of element A and element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

The present embodiments are described with reference to the drawings in which like elements are referred to by like numerals. The relationship and functioning of the various elements of this disclosure are better understood from the detailed description. However, the embodiments of the disclosure are not limited to the embodiments illustrated in the drawings. It should be understood that in certain instances, details have been omitted which are not necessary for an understanding of the present disclosure, such as conventional fabrication and assembly.

This detailed description is provided in order to meet statutory requirements. However, this description is not intended to limit the scope of the invention described herein. Rather, the claimed subject matter may be embodied in different ways, to include different steps, different combinations of steps, different elements, and/or different combinations of elements, similar or equivalent to those described in this disclosure, and in conjunction with other present or future technologies. The examples herein are intended in all respects to be illustrative rather than restrictive. In this sense, alternative examples or examples can become apparent to those of ordinary skill in the art to which the present subject matter pertains without departing from the scope hereof.

While various embodiments of the invention have been described, the invention is not to be restricted except in light of the attached claims and their equivalents. Moreover, the advantages described herein are not necessarily the only advantages of the invention and it is not necessarily expected that every embodiment of the invention will achieve all of the advantages described.