Rotor hub assembly, electric fan

Abstract

The invention relates to a rotor hub assembly for an electric fan, in particular for a radiator fan of a motor vehicle, comprising a hub cup, which rotates during operation and which has air outlet guides on the inside of the hub cup, which air outlet guides are arranged and shaped in such a way that the air outlet guides guide and accelerate cooling air, wherein a magnetic return cup is arranged inside the hub cup, which return cup has air passage openings, which, together with the air outlet guides, form continuous air outlets for a cooling air flow from the pressure side to the vacuum side of the fan. The invention further relates to an electric fan having such a rotor assembly.

Claims

1. A rotor hub arrangement for an electric fan, comprising a hub cup which rotates during operation and comprises air escape guides on the inside thereof which are arranged and shaped in such a way that they guide and accelerate cool air, wherein a feedback cup is arranged inside the hub cup and comprises air passage openings which, together with the air escape guides, form continuous air outlets for a cool airflow from the pressure side to the underpressure side of the fan, wherein the air escape guides comprise ribs extending between the base of the hub cup and the feedback cup and the ribs extend in an arc shape in the radial and circumferential direction.

2. The arrangement of claim 1, wherein the air passage openings and air escape guides are formed in such a way that at least some of the cool air is released in the radial direction.

3. The arrangement of claim 1, wherein the air escape guides are formed in the manner of an impeller.

4. The arrangement of claim 1, wherein the ribs extend in the radial direction.

5. The arrangement of claim 1, wherein the feedback cup is made of a metal material or wherein the hub cup is made of a non-metal material.

6. The arrangement of claim 1, wherein the feedback cup is coupled to the hub cup for conjoint rotation in a predetermined position relative to the hub cup.

7. The arrangement of claim 1, wherein the feedback cup comprises a base which has a circumferential shoulder orientated towards the hub cup, the air passage openings being arranged in the region of the shoulder or extending radially outwards from the shoulder.

8. The arrangement of claim 1, wherein each air outlet comprises a recess which forms a blade face of the air escape guide extending towards circumferential wall of the hub cup.

9. The arrangement of claim 1, wherein the air outlet is formed having an axial elevation, orientated circumferentially in the direction of rotation with respect to the air outlet, and an axial depression orientated circumferentially counter to the direction of rotation with respect to the air outlet.

10. The arrangement of claim 1, wherein the feedback cup comprises a plurality of different types and sizes of cavities which enlarge radially at a constant opening angle or clearances for forming spokes.

11. The arrangement of claim 1, wherein cavities are formed in the centre of the base of the feedback cup as axial air passage openings, and cavities are provided in the centre of the base of the hub cup and are formed as axial air escape guides and which, together with the axial air passage openings, form continuous axial air outlets for releasing cool air in the axial direction.

12. An electric fan comprising an electric motor, having a pressure side and an underpressure side, wherein the fan comprises a rotor hub arrangement for an electric fan, comprising a hub cup which rotates during operation and comprises air escape guides on the inside thereof which are arranged and shaped in such a way that they guide and accelerate cool air, wherein a feedback cup is arranged inside the hub cup and comprises air passage openings which, together with the air escape guides, form continuous air outlets for a cool airflow from the pressure side to the underpressure side of the fan and wherein the fans is formed and configured so as to convey air from the underpressure side to the pressure side.

13. The fan of claim 12, wherein an inlet opening is provided on the pressure side for the cool airflow from the pressure side to the underpressure side.

14. A rotor hub arrangement for an electric fan, comprising a hub cup which rotates during operation and comprises air escape guides on the inside thereof which are arranged and shaped in such a way that they guide and accelerate cool air, wherein a feedback cup is arranged inside the hub cup and comprises air passage openings which, together with the air escape guides, form continuous air outlets for a cool airflow from the pressure side to the underpressure side of the fan, wherein the air escape guides each form a substantially radially orientated air outlet in the hub cup and the air outlet is formed countersunk in a depression in a base of the hub cup or is formed in a clearance in the circumferential wall of the hub cup.

Description

CONTENTS OF THE DRAWINGS

(1) In the following, the present invention is described in greater detail with reference to the embodiments set out in the schematic figures of the drawings, in which:

(2) FIG. 1 shows a feedback cup known to the applicant;

(3) FIG. 2 is a perspective view of a rotor hub arrangement or an electric fan according to the invention, in which the hub cup is not yet assembled;

(4) FIG. 3a is a partial perspective view of the fan according to FIG. 2 when assembled;

(5) FIG. 3b is a sectional view of the fan of FIG. 3a along the section plane illustrated therein;

(6) FIG. 4a is a perspective front view of a hub cup in a first embodiment;

(7) FIG. 4b is a perspective rear view of the hub cup;

(8) FIG. 5a is a front view of a feedback cup;

(9) FIG. 5b is a cross section of a feedback cup according to FIG. 5a along the section plane illustrated therein;

(10) FIG. 6 is a partial view of the rear view according to FIG. 4b of the hub cup of FIGS. 4a and 4b;

(11) FIG. 7 is a partial view of a perspective rear view of a hub cup according to a second embodiment;

(12) FIG. 8a is a partial view of a perspective front view of a hub cup according to a third embodiment;

(13) FIG. 8b is a cross section of a fan comprising a hub cup according to FIG. 8a in the section plane illustrated therein;

(14) FIG. 9a is a perspective front view of a partial view of a fan having a hub cup according to a fourth embodiment;

(15) FIG. 9b is a cross section of the fan of FIG. 9a in the section plane illustrated therein.

(16) The accompanying figures of the drawings are intended to provide further understanding of the embodiments of the invention. They illustrate embodiments and serve, in combination with the description, to explain principles and concepts of the invention. Other embodiments and many of the stated advantages can be seen by referring to the drawings. The elements of the drawings are not necessarily shown to scale with respect to one another.

(17) In the figures of the drawings, identical, functionally equivalent and equivalently operating elements, features and components are provided with the same reference signs in each case, unless stated otherwise.

DESCRIPTION OF EMBODIMENTS

(18) FIG. 1 shows a feedback cup 4, known internally to the applicant, of a cooling fan 30, by means of which a cool airflow is produced in the electric motor by exploiting the pressure gradient between the pressure side and the underpressure side of the fan. The underpressure side is generally also referred to as the suction side, since the air is drawn in to a certain extent as a result of the pressure gradient. For this purpose, a predetermined short-circuit airflow through the electric motor is made possible. Openings 21 are provided in a central region of the base 17 of the feedback cup. These are formed in the centre, in other words close to the axis of rotation, as eight slot openings for the short-circuit airflows. Aside from three attachment points 18 comprising threaded holes and the slot openings 21, the base 17 has a substantially closed surface. In an associated hub cup (not shown), corresponding openings would be provided in the centre for releasing the short-circuit airflow.

(19) FIG. 2 shows an electric fan 30 or a rotor hub arrangement 1 according to the present invention. The electric fan 30 comprises an electric motor 31, which, among other things, contains a feedback cup 4. Air passage openings 5 are provided in the feedback cup 4. Electric motors of the construction shown comprise a feedback cup 4 of this type as rotors or armatures rotating about the axis of rotation 34, to which feedback cup in particular permanent magnets (not shown) are fixed. Electromagnets are provided on the stator in a manner known per se. This is preferably an external rotor motor.

(20) The electric motor 31 further comprises a base holder 33, for example made of aluminium or an alloy containing aluminium, which is provided for structurally attaching the fan 30 to a fan case of a motor vehicle. The base holder 33, which preferably carries the electronics and the power switch, is preferably formed as an injection-moulded aluminium cover. The base holder 33 comprises, on the outside thereof, a plurality of rib-like fins 37 protruding from the base holder 33. These fins 37 serve to increase the surface of the base holder 33, which acts as a cooling body, so as to increase the cooling performance.

(21) Between the base holder 33 and the feedback cup 4, an inlet slit 32 for admitting cool air is provided. Using three attachment points 18 provided on each of the feedback cup and the hub cup, the hub cup 2 is axially attached to the feedback cup. For example, in this case three fixing points are provided, at each of which a fixing means (not shown) can be attached.

(22) The hub cup 2 comprises air escape guides 3, which, when assembled, form air outlets 6 together with the air passage openings 5. To cool the electric motor 31, cool air flows through the inlet slit 32 into the electric motor and flows through the feedback cup 4 or the electronics, power switch, windings and electric motor provided therein, the cool air re-escaping from the electric motor 31 or the rotor hub arrangement 1 through the air outlets 6. This is shown in greater detail in FIG. 3b.

(23) FIG. 3a is a partial view of a perspective front view of a fan 30 according to FIG. 2 when assembled. The upper half of the hub of the fan 30 is shown here. Thick arrows and a thick chain line illustrate the section plane of the cross section of FIG. 3b in this case.

(24) FIG. 3b is the cross section of the fan 30 according to FIG. 3a in the section plane shown therein. The fan 30 has an underpressure side 19 and a pressure side 20. The fan 30 is configured and provided to convey air from the underpressure side 19 to the pressure side 20 during operation. This results in a pressure gradient between the pressure side 20 and the underpressure side 19, which according to the present invention is exploited to accelerate a cool airflow in the form of a short-circuit airflow from the pressure side 20 to the underpressure side 19. In the embodiment shown, the airflow through the hub cup 2 and electric motor 31 of the fan 30 is indicated using wavy arrows 35, 36. From the pressure side 20, the cool airflow enters the electric motor 31 and the rotor hub arrangement 1 at the inlet slit 32. A first cool airflow 35 extends (substantially) in the axial direction A and exits the rotor hub arrangement through an axial air outlet 6 located in the centre of said arrangement. A second cool airflow 36 passes through the air passage opening 5 (substantially) in the axial direction A through the feedback cup 4 into a gap between the feedback cup 4 and the hub cup 2. In this gap, which extends between the base 9 of the hub cup 2 and the feedback cup 4, ribs 8 are located which are formed integrally on the base 9 of the hub cup 2. The ribs 8 comprise an impeller contour which conveys the cool air around the axis of rotation 34 in the radial direction R during operation as a result of the rotation of the rotor arrangement 1. The ribs 8 are thus part of the air escape guides 3. The cool air 36 thus flows (substantially) radially in the direction of the air outlet 6, which is formed by a depression 10 in the base 9 of the hub cup 2 and the air passage opening 5 which extends as far as an edge of the feedback cup 4.

(25) In the embodiment shown, the cool air is thus also conveyed in the radial direction R, in addition to the axial through-flow which takes place as a result of the pressure gradient. Further, the radially conveyed cool air is released substantially in the radial direction, in other words in a direction composed of an axial and a radial direction, the radial component preferably being predominant.

(26) FIG. 4a shows a hub cup 2 according to the embodiment shown in FIG. 2. FIG. 4b is a rear perspective view of the hub cup 2 according to FIG. 4a. The hub cup 2 comprises a base 9 and ribs 8 integrally formed thereon. Further, radially orientated air escape guides 3, to which the ribs 8 belong, are formed close to the transition between the circumferential wall 12 and base 9 of the hub cup. In this embodiment, the ribs 8, which in this case too have an impeller contour, accordingly extend radially. Further, in a central region of the base 9 close to the axis of rotation 34, cavities 25 are provided which form axial air escape guides 3.

(27) FIG. 5a is a front view of a feedback cup 4 according to the embodiment shown in FIG. 2. This comprises, in the centre close to the axis of rotation 34, slots having a constant opening angle and which enlarge in the radial direction. Larger slots 21 and smaller slots 22 are provided in this case. The large slots 21 form axial air passage openings 5. Further, clearances 23 are provided which form spokes 24 in the outer region of the feedback cup 4. These clearances 23 simultaneously form the radial air passage openings 5.

(28) FIG. 5b is a cross-sectional view of the feedback cup 4 according to FIG. 5a, the section plane extending through the centre of the feedback cup in accordance with the thick chain line in FIG. 5a. This figure shows a base 17 of the feedback cup 4, in which a shoulder 7 is provided. The shoulder 7 separates the central region of the base 17 from an outer region of the base 17, the slots 21, 22 being provided in the central region and the clearances 23 or air passage openings 5 being provided in the outer region. Further, the radial direction R is illustrated, in which the air passage openings 5 make it possible for cool air to escape from the centre of the feedback cup. When the rotor hub arrangement is assembled, the air escape guides 3 of the hub cup 2 are arranged so as to be axially offset together with the air passage openings 5 of the feedback cup 4 and the slots 21 are arranged so as to be axially flush with the cavities 25. Thus, air outlets 6, 6 are provided in the radial and the axial direction in each case.

(29) FIG. 6 is a partial view of the hub cup of FIG. 4b. The radial direction R and the circumferential direction U are shown, these each relating to the axis of rotation of the hub cup 2. The view shown serves primarily for direct comparison with the embodiment shown alongside in FIG. 7.

(30) FIG. 7 shows the hub cup 2 according to a second embodiment in a view depicted analogously to FIG. 6 of a perspective partial view of the rear face. By contrast with FIG. 6, in this embodiment the air escape guides 3 have a different shape. They comprise inner ribs 8 which extend in an inner region of the hub cup 2 in the manner of an impeller, both in the radial direction R and in the circumferential direction in the shape of a U-curve. As well as the inner ribs, outer ribs 8 are also provided which are located in an outer, circular-ring shaped region of the hub cup 2 and extend substantially radially outwards. When assembled, together with the feedback cup 4, the ribs 8, 8 of the cup hub 2 form an impeller in the region of these air escape guides 3 which accelerates the cool air in the radial direction R during operation.

(31) FIG. 8a is a perspective partial view of a third embodiment of a hub cup. Merely the region of an air escape guide 3 of an air outlet 6 is shown. In the embodiment shown, the air escape guide 3 comprises a recess 13, which is protracted as far as the circumferential wall 12 of the hub cup 2.

(32) FIG. 8b is a cross section through a fan 30 comprising a hub cup 2 of this type according to FIG. 8a. By contrast with the fan 30 shown in FIG. 3b, in this case the air outlet 6 comprises, in the region of the recess 13, an additional blade face which is formed by the recess 13 and can additionally be used or exploited to accelerate the cool air in the radial direction R. Further, the radial path for the cool airflow is completely clear, since the recess 13 extends as far as the circumferential wall 12 of the hub cup. Thus, as indicated by the thick arrow in the radial direction R, the cool airflow can flow out in the radial direction R, radially along the recess 13 past the edge or past the circumferential wall 12 of the hub cup 2.

(33) FIG. 9a is a partial perspective front view of a fan 30 having a hub cup 2 according to a fourth embodiment. Again, only the region of an air escape guide 3 of an air outlet 6 is shown. The fan 30 comprises, on the circumference thereof in the region of the air outlet 6, an elevation 15 which is orientated in the direction of rotation 14 with respect to the air outlet 6 and extends in the axial direction A. Further, an axial depression 16 is provided in addition to the air outlet 6 and orientated circumferentially counter to the direction of rotation 14 with respect to the air outlet 6.

(34) FIG. 9b is a cross-sectional view of the fan 30 according to FIG. 9a in the section plane illustrated therein using a thick chain line. This cross-sectional view illustrates the depression 16 on the hub cup 2. The depression has a formation in the negative shape of a quarter-ellipsoid, and is formed in the base 9 of the hub cup 2. Further, an elevation 15 is illustrated in dashed lines. The dashed lines merely represent the elevation 15, which is not actually visible in the sectional view shown. Said elevation is shown here nevertheless in dashed lines for better comprehension and simpler illustration. The elevation 15 likewise has the shape of a quarter-ellipsoid, a planar face of the quarter-ellipsoid shielding the edge of the air outlet 6 from airflows or disruptive influences on the negative pressure side 19 during operation. Alternatively, it may also have the shape of a hollow quarter-ellipsoid such that the elevation 15 in effect forms a cap over the face of the air outlet 6.

(35) This makes it possible for the cool airflow to flow out undisrupted. Further, the depression 16 on the circumferential side of the air outlet 6 provides an enlarged outflow cross section in the circumferential direction U, and this is favourable in terms of flow and can reduce the outflow resistance at the air outlet 6.

(36) Although the present invention has hitherto been described entirely by way of preferred embodiments, it is not limited thereto, but can be modified in various ways.

LIST OF REFERENCE SIGNS

(37) 1 Rotor hub arrangement 2 Hub cup 3, 3 Air escape guides 4 Feedback cup 5 Air passage openings 6, 6 Air outlets 7 Shoulder 8, 8 Ribs 9 Base of the hub cup 10 Depression 11 Clearance in the circumferential wall of the hub cup 12 Circumferential wall 13 Recess 14 Direction of rotation 15 Elevation 16 Depression 17 Base of the feedback cup 18 Attachment points 19 Underpressure side 20 Pressure side 21 Cavities, slots in the feedback cup 22 Cavities, slots in the feedback cup 23 Cavities, clearances in the feedback cup 24 Spokes 25 Cavities in the hub cup 30 Fan 31 Electric motor 32 Inlet opening, inlet slit 33 Base holder 34 Axis of rotation 35 Cool airflow 36 Cool airflow 37 Fin on the base holder R Radial direction U Circumferential direction