초록 ▼

A fan assembly with an impeller and shroud for application in a vehicle cooling system. The fan is powered by an external rotor brushless direct current (BLDC) motor having an electronic controller positioned away from the BLDC on an outer shroud wall with a plurality of ducts drawing an airflow fro

A fan assembly with an impeller and shroud for application in a vehicle cooling system. The fan is powered by an external rotor brushless direct current (BLDC) motor having an electronic controller positioned away from the BLDC on an outer shroud wall with a plurality of ducts drawing an airflow from a static lower pressure created by the impeller, the airflow streaming over a heat sink disposed on the controller, exiting through a shroud. The static lower pressure air is pulled by a centrifugal fan and skewed magnets inside the motor through a plurality of ducts in a shroud hub, cooling the BLDC, maintaining low resistance for high efficiency. The BLDC is integrated into the assembly, having a stator fixed in the shroud hub and a rotor directly fused to the impeller, the shroud and impeller forming the BLDC motor without a housing, allowing the motor to easily dissipate heat.

대표청구항 ▼

1. A brushless cooling fan assembly for application in a vehicle cooling system, the assembly comprising: an axial fan impeller having a center ring, an outer rim and a plurality of blades fully extending radially from the center ring to the outer rim;a shroud for mounting the fan assembly in the ve

1. A brushless cooling fan assembly for application in a vehicle cooling system, the assembly comprising: an axial fan impeller having a center ring, an outer rim and a plurality of blades fully extending radially from the center ring to the outer rim;a shroud for mounting the fan assembly in the vehicle cooling system, the shroud having a center hub with a hollow core and an outer wall with a base plate mounted outside the outer wall, the shroud having an air duct exiting to the blades;a brushless direct current (BLDC) motor with a center bore and a periphery fused to the center ring of the impeller, the hollow core of the shroud inserted through the center bore of the motor to operably couple the motor, the shroud and the impeller as one functional unit, the BLDC motor powering the impeller and thereby creating heat, the impeller rotating with respect to the shroud and the motor and thereby creating static pressure; andan electronic controller module having a housing, the housing having an electronic controller electrically connected to the BLDC motor, the controller controlling the BLDC motor, the controller generating heat during operation, the electronic controller module mounted on the base plate on the outer wall to separate the controller from the BLDC motor in order to protect the electronic controller from heat created by the BLDC motor, the unit including the controller,wherein the module having a heat sink disposed on the housing, the sink mated to the controller to dissipate heat away from the controller, the sink in fluid communication with the duct,wherein the pressure facilitates air flow from the sink through the duct to the blades and thereby cooling the module. 2. The brushless cooling fan assembly as described in claim 1, wherein the heat sink has a plurality of fins, the plurality of fins having a sawtooth surface. 3. The brushless cooling fan assembly as described in claim 2, wherein the electronic controller module has a clip extending substantially above and over the fins of the heat sink, holding the heat sink on the housing and forming a plurality of ducts with the sawtooth surface of the fins. 4. The brushless cooling fan assembly as described in claim 1, wherein the sink has a plurality of fins, the flow occurs past the fins, the shroud having a plurality of hollows configured to be selectively filled with a plurality of fillings in order to balance the impeller. 5. The brushless cooling fan assembly as described in claim 1, wherein the BLDC motor having internal operational components, the hub having a cooling passageway configured for air flow, the passageway in fluid communication with the components and ambient air,wherein during rotation of the impeller, the passageway facilitates air flow to the components in order to convection cool the components. 6. The brushless cooling fan assembly as described in claim 1, wherein the BLDC motor is an external rotor BLDC motor, at least one of the blades has an airfoil design. 7. The brushless cooling fan assembly as described in claim 1, further comprising a fan located between the BLDC motor and the blades, the motor having an air outlet in fluid communication with ambient air, the fan draws cooler air from front of the BLDC motor and dissipates heat from the BLDC motor by focused convection of the cooler air through the BLDC motor out through the outlet. 8. The brushless cooling fan assembly as described in claim 1, wherein the module including a potentiometer configured for operable coupling with a fan speed controller in a vehicle control system. 9. A brushless cooling fan assembly for aftermarket customization of a vehicle cooling system, the assembly comprising: an axial fan impeller having a center ring, an outer rim and a plurality of blades fully extending radially from the center ring to the outer rim;a shroud for mounting the fan assembly in the vehicle cooling system, the shroud having a center hub with a hollow core and an outer wall with a base plate mounted outside the outer wall, the shroud having an air duct exiting to the blades;a brushless direct current (BLDC) motor with a center bore and a periphery fused to the center ring of the impeller, the hollow core of the shroud inserted through the center bore of the motor to operably couple the motor, the shroud and the impeller as one functional unit, the BLDC motor rotating the impeller and thereby creating heat, the impeller rotating with respect to the shroud and the motor and thereby creating static pressure; andan electronic controller module having a housing, the housing having an electronic controller electrically connected to the BLDC motor to control the BLDC motor, the controller generating heat during operation, the module having a heat sink disposed on the housing, the heat sink having a plurality of fins, the heat sink mated to the electronic controller to dissipate the heat away from the electronic controller, the electronic controller module mounted on the base plate on the outer wall to separate the controller from the BLDC motor in order to protect the electronic controller from heat created by the BLDC motor, the unit including the controller, the sink in fluid communication with the duct,wherein the pressure facilitates air flow from the sink through the duct to the blades and thereby cooling the module. 10. The brushless cooling fan assembly as described in claim 9, wherein the electronic controller module has a clip extending substantially above and over the fins of the heat sink, holding the heat sink on the housing and forming a plurality of ducts with the sawtooth surface of the fins.