High efficiency forward curved impeller and method for assembling the same

1. A fan blade for a fan impeller, said fan blade coupled to a front endring and a rear endring defining a blade span therebetween, said fan blade comprising:

a first portion;

a second portion positioned on a first side of said first portion;

a third portion positioned on a second side of said first portion;

a leading edge defining a leading edge blade angle; and

a trailing edge defining a trailing edge blade angle, wherein said leading edge blade angle and said trailing edge blade angle are constant within said first portion and said leading edge blade angle and said trailing edge blade angle vary continuously within each of said second portion and said third portion, wherein said leading edge and said trailing edge define a chord length therebetween, said chord length is constant over said blade span.

2. The fan blade in accordance with claim 1 , wherein said fan blade is configured to rotate about an axis, said trailing edge and the axis define an outer radius, said outer radius is constant over said blade span.

3. The fan blade in accordance with claim 1 , wherein said fan blade is configured to rotate about an axis, said leading edge and the axis define an inner radius, said inner radius varies continuously within each of said second portion and said third portion.

4. The fan blade in accordance with claim 3 , wherein said inner radius is constant within said first portion.

5. The fan blade in accordance with claim 3 , wherein said inner radius decreases continuously along a length of said second portion.

6. The fan blade in accordance with claim 3 , wherein said inner radius decreases continuously along a length of said third portion.

7. A fan impeller comprising:

a front endring;

a rear endring; and

a plurality of fan blades coupled between said front endring and said rear endring, each fan blade of said plurality of fan blades defining a blade span, between said front endring and said rear endring, at least one of said plurality of fan blades comprising:

a first portion;

a second portion positioned on a first side of said first portion;

a third portion positioned on a second side of said first portion;

a leading edge defining a leading edge blade angle; and

a trailing edge defining a trailing edge blade angle, wherein said leading edge blade angle and said trailing edge blade angle are constant within said first portion and said leading edge blade angle and said trailing edge blade angle vary within said second portion and said third portion, wherein said leading edge and said trailing edge define a chord length therebetween, said chord length is constant over said blade span.

8. The fan impeller in accordance with claim 7 , wherein said fan impeller is configured to rotate about an axis, said trailing edge and the axis define an outer radius, said outer radius is constant over said blade span.

9. The fan impeller in accordance with claim 7 , wherein said fan impeller is configured to rotate about an axis, said leading edge and the axis define an inner radius, said inner radius varies continuously within each of said second portion and said third portion.

10. The fan impeller in accordance with claim 9 , wherein said inner radius is constant within said first portion.

11. The fan impeller in accordance with claim 9 , wherein said inner radius decreases continuously along a length of said second portion.

12. The fan impeller in accordance with claim 9 , wherein said inner radius decreases continuously along a length of said third portion.

13. The fan impeller in accordance with claim 7 , wherein said fan impeller defines a blade solidity, the blade solidity is defined as a ratio of a chord length of said at least one fan blade of said plurality of fan blades to a pitch of said at least one fan blade of said plurality of fan blades, wherein the blade solidity is constant over said blade span.

14. A method of assembling a fan impeller, said method comprising:

providing a front endring and a rear endring; and

coupling a plurality of fan blades to the front endring and the rear endring, each fan blade of the plurality of fan blades defining a blade span, between the front endring and the rear endring, at least one of the plurality of fan blades comprising:

a first portion;

a second portion positioned on a first side of the first portion;

a third portion positioned on a second side of the first portion;

a leading edge defining a leading edge blade angle; and

a trailing edge defining a trailing edge blade angle, wherein the leading edge blade angle and the trailing edge blade angle are constant within the first portion and the leading edge blade angle and the trailing edge blade angle vary continuously within each of the second portion and the third portion, wherein the fan impeller defines a blade solidity, the blade solidity is defined as a ratio of a chord length of the at least one fan impeller to a pitch of the at least one fan impeller, wherein the blade solidity is constant over the blade span.

15. The method in accordance with claim 14 , wherein the leading edge and the trailing edge define a chord length therebetween, the chord length is constant over the blade span.

16. The method in accordance with claim 14 , wherein the fan impeller is configured to rotate about an axis, the trailing edge and the axis define an outer radius, the outer radius is constant over the blade span.

17. The method in accordance with claim 14 , wherein the fan impeller is configured to rotate about an axis, the leading edge and the axis define an inner radius, the inner radius varies continuously within each of the second portion and the third portion.

18. The method in accordance with claim 17 , wherein the inner radius is constant within the first portion.