Rotary fan with encapsulated motor assembly

Abstract

A fan assembly, such as a rotary axial fan assembly, is disclosed with a shroud that is adapted to be mounted proximate to a heat exchanger. The shroud is sized for conveying a flow of fluid through the heat exchanger and the shroud. A stator fan blade extends inward from the shroud for supporting a hub generally central within the shroud. A motor stator is encapsulated within the hub for receiving a fan rotor and fan blades for forcing the flow of fluid through the heat exchanger and the shroud. The hub may be formed from a thermally conductive material for transferring heat from the motor stator into the flow of fluid for dissipating the heat.

1 . A rotary axial fan assembly comprising: 
 a shroud that is adapted to be mounted proximate to a heat exchanger, the shroud being sized for conveying a flow of fluid through the heat exchanger and the shroud;    at least one stator fan blade extending inward from the shroud;    a hub oriented generally centrally within the shroud, supported by the at least one stator fan blade; and    a motor stator encapsulated within the hub, the motor stator being adapted for receiving a fan rotor for supporting fan blades for forcing the flow of fluid through the heat exchanger and the shroud such that in operation of the fan assembly, heat generated by the motor stator is transferred to the hub and into the flow of fluid for dissipating heat into the flow of fluid.    
   
   
       2 . The rotary axial fan assembly of  claim 1  wherein the hub is formed from a thermally conductive material for transferring heat from the motor stator into the flow of fluid for dissipating the heat into the flow of fluid.  
   
   
       3 . The rotary axial fan assembly of  claim 1  wherein the motor stator further comprises a series of motor windings insert molded into an end cap for contact with the hub for conducting heat from the motor windings to the hub, and wherein the hub is formed from a thermally conductive material for transferring heat from the motor stator into the flow of fluid.  
   
   
       4 . The rotary axial fan assembly of  claim 1  wherein the motor stator is press fit into the hub.  
   
   
       5 . The rotary axial fan assembly of  claim 1  wherein the motor stator is at least partially press fit into the hub.  
   
   
       6 . The rotary axial fan assembly of  claim 1  wherein the hub is formed from a material having a coefficient of thermal conductivity within a range of 10 to 175 Watts per meter*Kelvin.  
   
   
       7 . The rotary axial fan assembly of  claim 1  wherein the hub is formed from an aluminum material.  
   
   
       8 . The rotary axial fan assembly of  claim 1  wherein the hub and the at least one stator fan blade are formed from a thermally conductive material for transferring heat from the motor stator into the flow of fluid.  
   
   
       9 . The rotary axial fan assembly of  claim 1  wherein the hub and the at least one stator fan blade are formed unitarily from an aluminum material.  
   
   
       10 . The rotary axial fan assembly of  claim 1  wherein the motor stator further comprises wiring for powering the motor, wherein the motor wiring is sealed within the hub by the encapsulation of the motor stator.  
   
   
       11 . The rotary axial fan assembly of  claim 1  further comprising a sealant for sealing the connection of the stator and the hub.  
   
   
       12 . The rotary axial fan assembly of  claim 1  wherein the stator is in contact with the hub about the periphery of the stator for uniform heat transfer from the motor stator to the hub.  
   
   
       13 . The rotary axial fan assembly of  claim 1  further comprising a thermally conductive adhesive disposed at the connection of the motor stator and the hub for enhancing heat transfer from the motor stator to the hub.  
   
   
       14 . The rotary axial fan assembly of  claim 1  wherein the at least one stator fan blade further comprises a plurality of radially spaced apart stator fan blades.  
   
   
       15 . The rotary axial fan assembly of  claim 14  wherein the hub, the shroud and the plurality of stator fan blades are cast unitarily from an aluminum material.  
   
   
       16 . The rotary axial fan assembly of  claim 1  wherein the motor stator further comprises a series of motor windings wound about lamination plates and insert molded into an end cap for direct contact of the lamination plates with the hub for conducting heat from the motor windings to the hub, and wherein the hub is formed from a thermally conductive material for transferring heat from the motor stator into the flow of fluid.  
   
   
       17 . The rotary axial fan assembly of  claim 16  wherein the motor stator is press fit into the hub.  
   
   
       18 . The rotary axial fan assembly of  claim 16  wherein the motor stator is at least partially press fit into the hub.  
   
   
       19 . A rotary axial fan assembly comprising: 
 a shroud that is adapted to be mounted proximate to a heat exchanger, the shroud being sized for conveying a flow of fluid through the heat exchanger and the shroud;    a plurality of radially spaced apart stator fan blades extending inward from the shroud; and    a motor stator oriented generally centrally within the shroud, supported by the plurality of stator fan blades, the motor stator being adapted for receiving a fan rotor and fan blades for forcing the flow of fluid through the heat exchanger and the shroud;    wherein the shroud and the plurality of stator fan blades are formed unitarily from a thermally conductive material for transferring heat from the motor stator into the flow of fluid for dissipating the heat into the flow of fluid.    
   
   
       20 . A rotary axial fan assembly comprising: 
 a shroud that is adapted to be mounted proximate to a heat exchanger, the shroud being sized for conveying a flow of fluid through the heat exchanger and the shroud;    a plurality of radially spaced apart stator fan blades extending inward from the shroud; and    a motor stator oriented generally centrally within the shroud, supported by the plurality of stator fan blades, the motor stator being adapted for receiving a motor rotor and fan blades for forcing the flow of fluid through the heat exchanger and the shroud;    wherein the shroud and the plurality of stator fan blades are formed unitarily from a material having a coefficient of thermal conductivity within a range of 10 to 175 Watts per meter*Kelvin.