FAN BLADE AND BLADE HUB ASSEMBLY
The present invention provides an improved blade and blade hub assembly. According to a first preferred embodiment, the present invention provides an apparatus for attaching light-weight foam blades onto an injection molded hub to be used in an unguarded fan assembly. According to a further preferred embodiment, the present invention preferably further provides a foam blade design in which the more centrally located portion of the blade is inserted into slots that are molded into an injection molded hub. According to a further preferred embodiment, the slots of the present invention preferably keep the blade in a desired camber and support the blade in the proper angle and orientation.
1 . A fan assembly for creating and directing a flow of air, wherein the fan assembly comprises:
a first fan blade, a second fan blade and a third fan blade; wherein each of the first, second and third fan blades comprise:
an insertion edge; wherein the insertion edge comprises a flat insertion surface; wherein the flat insertion surface comprises a plurality of securing holes; and
a fan blade body;
a fan hub assembly, wherein the fan hub assembly comprises:
a front nose cone;
a rear supporting shell, wherein the rear supporting shell comprises a curved inner housing surface; wherein the curved inner housing surface comprises:
a first fan blade insertion aperture, a second fan blade insertion aperture and a third fan blade insertion aperture; and
a plurality of securing pins, wherein each securing pin comprises:
an insertion pin; and
a plurality of supporting ribs; wherein the supporting ribs extend from the insertion pin to the curved inner housing surface;
wherein at least a first group of three securing pins are formed on the curved inner housing surface adjacent to the first fan blade insertion aperture; wherein at least a second group of three securing pins are formed on the curved inner housing surface adjacent to the second fan blade insertion aperture; wherein at least a third group of three securing pins are formed on the curved inner housing surface adjacent to the third fan blade insertion aperture;
wherein the first blade is inserted through the first blade aperture and the first group of three securing pins are inserted through the first blade securing holes; wherein the plurality of supporting ribs of the first group of three securing pins align the first blade into a first thrust orientation;
wherein the second blade is inserted through the second blade aperture and the second group of three securing pins are inserted through the second blade securing holes; wherein the plurality of supporting ribs of the second group of three securing pins align the second blade into a second thrust orientation; and
wherein the third blade is inserted through the third blade aperture and the third group of three securing pins are inserted through the third blade securing holes; wherein the plurality of supporting ribs of the third group of three securing pins align the third blade into a third thrust orientation;
wherein the first, second and third thrust orientations are angled to form and direct a single, uniform column of air.
2 . The fan assembly of claim 1 , wherein the first, second and third fan blades are tilted towards the nose cone.
3 . The fan assembly of claim 1 , wherein the first, second and third fan blades are tilted away from the nose cone.
4 . The fan assembly of claim 1 , wherein the fan blades are formed of injection molded materials.
5 . The fan assembly of claim 4 , wherein the fan blades are formed of materials selected from the group of materials comprising: Polypropylene (PP), High Density Polyethylene (HDPE), Low Density Polyethylene (LDPE), ABS Plastics, Acrylic, Polyurethane (PU), Nylon (PA), and Thermoplastic Elastomer (TPE).
6 . The fan assembly of claim 4 , wherein the fan blades are formed of materials selected from the group of materials comprising: Thermoplastic Polyurethane Elastomer Engineering Thermoplastic, Polycarbonate (PC), Polystyrene (PS), High Impact Polystyrene (HIPS), Polybutylene Terephthalate (PBT), Polyetherimide (PEI), and Polyphenylene Sulfide (PPS).
7 . The fan assembly of claim 1 , wherein the fan blades are formed of a light-weight foam material.
8 . The fan assembly of claim 7 , wherein the fan blades are formed closed cell material.
9 . The fan assembly of claim 7 , wherein the fan blades are formed of open cell material.
10 . The fan assembly of claim 7 , wherein the fan blades are formed of materials selected from the group of materials comprising: Crosslinked Polyethylene, ethylyene-vynyl acetate (EVA), Volara, FloTex, and Neoprene
11 . The fan assembly of claim 7 , wherein each securing pin is heat staked to secure each blade to the hub assembly.