HVAC DELIVERY SYSTEM IN HIGH VOLUME LOW-SPEED FAN

Abstract

An HVAC delivery system to supply air from an HVAC system in proximity to a fan blade. A fan blade for use in a high volume, low-speed fan, wherein the fan blade includes a body portion, a leading edge portion and a trailing portion. The leading edge portion of the fan blade includes a series of steps extending along the length of the leading edge. The fan distributes airflow from the HVAC delivery system.

Claims

1. A combination ceiling fan and HVAC delivery system comprising: a mounting apparatus; a motor mounted to said mounting apparatus; an gear mechanism coupled to said motor; a plurality of fan blades forming a centerline, the fan blades engage the gear mechanism to rotate the fan blades around the centerline; each of the fan blades having a body portion, a top portion, a leading edge portion and a trailing portion; wherein the leading edge portion of the fan blade is configured to include a plurality of steps extending along a length of the leading edge portion of each fan blade; an HVAC delivery system mounted within the fan having an HVAC inlet positioned to accommodate an HVAC system and an HVAC outlet positioned at, or in close proximity to the centerline of the fan, wherein the HVAC outlet supplies air from the HVAC system in an impact area of the fan blades.

2. The combination fan and HVAC delivery system of claim 1 further comprising an air exchanger configured to distribute air at a location above the plane formed by the plurality of fan blades.

3. The combination fan and HVAC delivery system of claim 1 further comprising an air exchanger configured to distribute air at a location below the plane formed by the plurality of fan blades.

4. The combination fan and HVAC delivery system of claim 1 further comprising an air exchanger configured to distribute air at a location above and below the plane formed by the plurality of fan blades.

5. The combination fan and HVAC delivery system of claim 1 wherein the fan comprises a high volume, low speed fan.

6. The combination fan and HVAC delivery system of claim 5 further comprising an air exchanger configured to distribute air at a location above the plane formed by the plurality of fan blades.

7. The combination fan and HVAC delivery system of claim 5 further comprising an air exchanger configured to distribute air at a location below the plane formed by the plurality of fan blades.

8. The combination fan and HVAC delivery system of claim 5 further comprising an air exchanger configured to distribute air at a location above and below the plane formed by the plurality of fan blades.

9. A combination ceiling fan and HVAC delivery system comprising: a mounting apparatus; a motor mounted to said mounting apparatus; an gear mechanism coupled to said motor; a plurality of fan blades forming a centerline, the fan blades engage the gear mechanism to rotate the fan blades around the centerline, said fan blades further forming a plane; an HVAC delivery system mounted within the fan having an HVAC inlet positioned to accommodate an HVAC system and an HVAC outlet positioned in close proximity to supply air from the HVAC system to the impact area of the fan blades.

10. The combination fan and HVAC delivery system of claim 9 further comprising an air outlet configured to distribute air at a location above the plane formed by the plurality of fan blades.

11. The combination fan and HVAC delivery system of claim 9 further comprising an air outlet configured to distribute air at a location below the plane formed by the plurality of fan blades.

12. The combination fan and HVAC delivery system of claim 9 further comprising an air outlet configured to distribute air at a location above and below the plane formed by the plurality of fan blades.

13. The combination fan and HVAC delivery system of claim 9 wherein the fan comprises a high volume, low speed fan.

14. The combination fan and HVAC delivery system of claim 13 further comprising an air outlet configured to distribute air at a location above the plane formed by the plurality of fan blades.

15. The combination fan and HVAC delivery system of claim 13 further comprising an air outlet configured to distribute air at a location below the plane formed by the plurality of fan blades.

16. The combination fan and HVAC delivery system of claim 13 further comprising an air outlet configured to distribute air at a location above and below the plane formed by the plurality of fan blades.

17. The combination fan and HVAC delivery system of claim 14, wherein the HVAC outlet is positioned at or close proximity to the centerline of the fan.

18. The combination fan and HVAC delivery system of claim 15, wherein the HVAC outlet is positioned at or close proximity to the centerline of the fan.

19. The combination fan and HVAC delivery system of claim 16, wherein the HVAC outlet is positioned at or close proximity to the centerline of the fan.

Description

DESCRIPTION OF THE FIGURES

[0026] Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the following drawings:

[0027] FIG. 1 is a perspective view of the fan of the present invention;

[0028] FIG. 2 is a bottom plan view of the fan;

[0029] FIG. 2(a) is a section side elevation view of a fan of the present invention showing the HVAC system integral to the fan;

[0030] FIG. 2(b) is a section side elevation view of a fan of the present invention with the fan moving in the reverse direction, directing air upward toward the ceiling;

[0031] FIG. 3 is a top plan view of a fan blade of the present invention showing the stepped design;

[0032] FIG. 3(a) is a top plan view of an alternative design of the fan blade of the current invention that includes five steps;

[0033] FIG. 4 is a side view of the fan blade of the present invention;

[0034] FIG. 5 is a perspective view of a fan blade of the current invention showing three steps;

[0035] FIG. 5a is a perspective view of an alternate embodiment of the fan blade of the present invention;

[0036] FIG. 6 is graph of air speed versus distance from the center of the fan;

[0037] FIG. 7 is a cutout view of a offset motor gear box;

[0038] FIG. 8 is a side view of a flow diagram where the rotation of the fan blades force air in a downward direction; and

[0039] FIG. 9 is a side view of a flow diagram where the rotation of the fan blades force air in an upward direction.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

[0040] A typical high volume, low-speed fan has between four to eight fan blades. The fan blades are typically between 4-feet to 12-feet in length and have a width of 6 inches. Thus, the total diameter of a typical fan is between 8-feet (96 inches) to 24-feet (288 inches). Non-commercial, or residential fans typically have a span less than 8-feet.

[0041] In the preferred embodiment of the present invention, as shown in FIGS. 1, 2, 2(a) and 2(b), the fan 10 is mounted to a ceiling 20. The fan 10 is mounted to the ceiling 20 using a standard mount such as a universal I-Beam clamp with a swivel. The fan may also be mounted in conjunction with an HVAC system (not shown).

[0042] As shown in FIGS. 1, 2, 2(a) and 2(b), the fan 10 includes an HVAC delivery system 500. The HVAC delivery system 500, comprise a generally hollow section 502 which connects to the HVAC system. In the preferred embodiment, the HVAC delivery system 500 is positioned along in close proximity to the centerline 515 of the fan. Air from the HVAC system is supplied from the HVAC system (not shown) to the hollow section 502 of the HVAC delivery system 500. As shown in FIG. 2(a), the air from the HVAC system passes from the inlet 504 of the HVAC delivery system 500, to the lower outlet or lower exchanger 506 of the HVAC delivery system 500. Air from the HVAC system may also be delivered above the plane formed by the fan blades 30 as shown by an upper air ducts or air exchanger 507. The fan blades 32 act upon the cool air 507 delivered from the outlet 506 and the air ducts 501 of the HVAC delivery system 500 such that air 507 is pushed downward by the fan blades 32 toward the lower segment of a room. The gear mechanism 516 and gear motor 501 of the fan 10 may operate in a reverse manner to pull the air supplied from the outlet 506 of the HVAC delivery system 500 by the movement of fan blades 32. As shown in FIG. 2(b), the air from the HVAC system passes from the inlet of the HVAC delivery system 500, to the lower outlet 506, whereupon the fan blades 32 act upon the warm air 509 delivered from the outlet 506 such that the air 509 is pulled upward toward the ceiling of the room. The air ducts 501 are not shown in FIG. 2(b), but may be employed if so desired.

[0043] The gear motor 501 and gear mechanism 516 is typically an off-set PM electromagnetic motor. The horsepower of the motor varies depending upon the diameter of the entire fan 10. For example, an 8-foot and 12-foot fan typically has a 1 horsepower gear motor 501. The 16-foot fan typically includes a 1.5 horsepower gear motor 501, and a 20-foot and 24-foot fan typically has a 2.0 horsepower gear motor 501. Attached to the gear motor 501 is a fan blade mount/gear 503 that has a centerline 515 at the center of the fan to which the fan blades 32 are mounted. The gear motor 501 operates in cooperation with the gear mechanism 516 and the blade mount/gear 503 to turn the fan blades 32. The gear mechanism 516 may be offset from the centerline 515 of the fan. Alternatively, the gear mechanism 516 may be positioned along the centerline 515 of the fan. FIGS. 2(a) and 2(b) show the gear mechanism 516 in the offset position relative to the centerline 515 of the fan. The position of the HVAC delivery system 500 in proximity to the centerline 515 is the important to the function of the invention.

[0044] The preferred embodiment shown in FIGS. 1 and 2 includes five fan blades 30, however, there may be a greater number of fan blades, or there may be less than five fan blades. Each fan blade 30 has a leading edge 32, and a trailing edge 34 and an end cap 36. The fan blade 30 includes a blade body 38. The blade body 38 is typically made of an extruded aluminum alloy, but could be made of a composite metal, carbon fiber material, a graphite material, fiberglass, wood or other similar material. The leading edge 32 of the fan blade has steps 40, 42, 44 (as shown in FIGS. 2 and 3) from the portion of the leading edge 32 fan blade 30 positioned closest to the centerline 15 of the fan blade mount 15.

[0045] The stepped configuration of the leading edge 32 of the fan blade is shown in more detail in FIGS. 2, 3, 4 and 5. The leading edge 32 of the fan blade 30 has a first step 40, a second step 42 and a third step 44. The steps extend from the blade body 38. The leading edge 32 of the fan blade 30, including the first step 40, the second step 42 and the third step 44, are preferably made of an extruded polymer material, such as high-impact polystyrene, but may be constructed of a composite plastic material, graphite, fiberglass, carbon fiber, aluminum or any material having similar features and properties to the identified materials.

[0046] The steps 40, 42 and 44 preferably have generally equal lengths proportional to the length of the blade body 38. Thus, the first step 40 would be approximately ⅓ the total length 39 of the blade body 38. The second step would also be approximately ⅓ the total length 39 of the blade body 38. Likewise, the third step would be approximately ⅓ the total length 39 of the blade body 38. The steps 40, 42 and 44 have a width in a ratio of 3:2:1. Thus, the distance that the first step 40 extends beyond the front edge of the blade body 38 is 3-inches; the distance the second step 42 extends 52 is 2-inches and the third step 44 extends 54 is 1-inch. The ratio of the distance the various steps 40, 42 and 44 extend beyond the front edge of the blade body 38 is 3:2:1. While the preferred embodiment has steps of proportional length and proportional width, it is not a requirement. The important aspect of the step configuration is that the leading edge has multiple steps from the area of the fan blade 30 closest to the hub. The steps decrease the thickness of the blade in each step that proceeds from the hub.

[0047] While the preferred number of steps is three with a ratio of 3:2:1, the number of steps may be more than three, so long as the ratio of length of the steps corresponds to the number of steps and the distances the various steps extend beyond the front edge of the blade body is a ratio equal to the number of steps. FIG. 3(a) shows a blade that has five steps. By way of example, a 20-foot diameter fan would have a fan blade 130 of approximately 10-foot in length 139. The ratio of the steps in the preferred embodiment would be 5:4:3:2:1. Each step 140, 142, 144, 146, and 148 would be approximately 2 feet in length 156. The overall fan width 155 should not exceed 9-inches in the preferred embodiment. A fan blade 30 that exceeds a width of 9-inches may cause an undesirable load to be placed on the motor. It is, of course, possible for the distance to be greater than 9-inches if one chooses to construct a fan using a non-conventional fan motor. In the above example of the 5 step fan blade, the distance from the front edge of the fan body 38 to the leading edge of the step 40 should not necessarily exceed 3 inches. In the embodiment of a 5 step fan blade (FIG. 3(a)), the distance of the first step 50 would be approximately 3-inches. Each step would then decrease by 6/10 of an inch.

[0048] FIG. 4 is a side view of one of the preferred embodiments of the fan blade of the present invention which has 3 steps. The blade 30 includes a leading edge 32. The leading edge 32 includes a series of steps 40, 42 and 44. The distance between the first step 40 and the second step 42 of the leading edge 32 is shown as 56. Likewise, the distance between the second step 42 and the third step 44 is shown as 58. The blade 30 has an upper portion 35 and a lower portion 37. The blade 30 also has a rearward portion 34. The steps 40, 42 and 44 along the leading edge 32 of the blade 30 provides vortex along the edge of the steps 60 and 62. The vortex created at the edges of the steps 60 and 62 create a greater turbulent airflow below the fan. The vortex created at the edges of the steps 60 and 62 also provide for greater airflow velocity in the area near the centerline 15 of the fan.

[0049] The pitch P of the blade 30 is approximately 22°. The design of the steps 40, 42 and 44 along the leading edge 32 of the blade 30 permits for the blade to accommodate up to a 22° pitch. Conventional HVLS fans typically have a pitch for the blade between 10°-15°. The stepped design of the leading edge of the fan blade allows for a pitch between 18° to 22° to be implemented without increasing the strain of the motor. The increased pitch promotes more downward airflow.

[0050] The steps 40, 42 and 44 along the leading edge 32 of the fan blade 30 have edges 60 and 62, respectively. The edges 60 and 62 of the preferred embodiment have a recessed or Z-shaped configuration. This configuration is for aesthetic purposes. As shown in FIG. 5(a), the steps 240, 242 and 244 have edges 260 and 262 that are at approximately a 90° angle to the leading edge 232 of the fan blade 230. The configuration of the edges 260 and 262 does not affect the function of the fan blade 230.

[0051] An actual embodiment of the preferred invention, without the HVAC delivery system 500, was tested at a warehouse facility in Beaver Dam, Wis. The height of the facility was twenty-five feet from the floor to the ceiling. The high volume, low-speed fan was a 24-foot diameter fan that was mounted twenty feet from the floor—in other words, the fan had approximately a five foot drop from the ceiling. The fan had five blades including three steps on each blade as depicted in FIGS. 3 and 4. The average velocity of the air was measured using a wind velometer gauge. The air velocity was measured at a height of 48-inches above the level of the floor. Measurements were taken at various distances, at approximately three foot intervals, from the centerline 18 of the fan. Measurements were taken at each location using the wind velometer gauge over a time period of approximately thirty seconds. Because the airflow is not constant, the maximum and minimum airflow measurements were recorded over the thirty second period. The maximum and minimum velocity readings over the thirty second period were averaged and are set forth in the chart below:

TABLE-US-00001 Distance from Velocity Center of Fan (Feet) (Miles Per Hour) 3 2.3 6 3.0 9 4.0 12 2.8 15 4.0 20 3.0 23 3.1 26 2.3 30 1.9 33 2.9 36 3.0 42 2.0 46 2.7 50 2.0 53 1.9 58 1.1 62 1.1
FIG. 6 is a graph of the average velocity in MPH of airflow created by the circulation of the fan 10 utilizing the blades 30 of the preferred embodiment at various distances from the centerline 18 of the fan. As shown in FIG. 6, for example, at approximately 8-feet and 16-feet from the centerline 18 of the fan, the average velocity of airflow 48-inches above the ground was 4 miles per hour. The human body typically feels 6° to 10° F. cooler (Relative Temperature) than the ambient temperature of the air when the air is circulating at 4 miles per hour. At airflow at a velocity of 2 miles per hour, the human body fees 3 to 5° cooler than the ambient temperature of the air. The benefit of the fan design is a greater velocity of air circulation is achieved within close proximity to the centerline 14 of the fan.

[0052] The design of the present invention of placing an HVAC delivery system 500 along, or in close proximity to, the centerline 515 of the fan achieves movement of the air exiting the outlet 506 (and air ducts 501) of the HVAC delivery system 500. Cool air 507 (or heated air 509 if the fan is reversed) exiting the upper air exchanger 507 or lower exchanger 506 (and air ducts 501) of the HVAC delivery system 500 along the centerline 505 of the fan is disbursed along the fan blades 32. Thus, the cooled air 507 (or heated air 509) interacts with the airflow created by the fan blades 32 to more evenly disbursed the cooled air 507 (or heated air 509) in the vicinity of the fan.

[0053] The stepped fan blade design has significant airflow coverage and overall air dispersion when used in connection with the HVAC delivery system 500 positioned along the centerline 515 of the fan. The fan of the current invention has minimal airflow dead spots, especially within close proximity to the centerline 515 of the fan 10.

[0054] The fundamental operating principals and indeed many of the engineering criteria of fan blades for high volume low-speed ceiling fans is similar to fan blades used in basically all forms of compressors, fans and turbine generators. In other words, the rotor blades can be used in a huge range of products such as for example, for helicopter blades, car fans, air conditioning units, water turbines, thermal and nuclear steam turbines, rotary fans, rotary and turbine pumps, and other similar applications.

[0055] Although embodiments of the present invention have been described, those of skill in the art will appreciate that variations and modifications may be made without departing from the spirit and scope thereof as defined by the appended claims.