CABINET COOLING FAN
An electric fan core having a generally rectilinear shape, a positive pressure side, and a vacuum side is disclosed. A fan bracket attached to the positive pressure side of the electric fan core and offset from the fan core thereby defining a gap between the fan core and the fan bracket, the gap having a width less than an amount required to sustain a Venturi effect air intake when the electric fan core is in an operating state is disclosed. A grille attached to the vacuum side of the fan core and having a grille face that is offset from the fan core, the offset being greater than an amount of offset required to reduce turbulence noise from the grille face when the electric fan core is in an operating state is also disclosed.
This application claims the benefit of U.S. provisional patent application No. 60/720,121 filed on Sep. 23, 2005, which is hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTIONThis invention relates to electronics cabinet cooling generally and, more specifically to bracket mounted, electronically controlled cooling fans.
BACKGROUNDElectronic devices typically generate waste heat during operation. If left unattended, the excess heat can cause devices to malfunction and, in some cases, be permanently damaged. The problem is exacerbated by the small form factors and increased performance of many electronic devices. Often, electronics will be stacked together or mounted or placed in cabinets (the personal computer is one example of a cabinet based device). This can lead to additional heating as the amount of ambient air reaching heated components is reduced.
Cooling fans may be added to an electronics cabinet or enclosure to force cooling air to the components. However, typical cooling fans may be inefficient and may not move enough air to produce the desired cooling effect. In addition, known fan designs may be unacceptably noisy and the noise may be amplified by the installation location of the fan or the location of the electronics cabinet in a room. Fans are typically mounted to the cabinet in such a way that noise and vibration are transmitted through the material of the cabinet itself.
Therefore what is needed is a device and method for addressing the above, and related, issues.
SUMMARY OF THE INVENTIONThe present invention disclosed and claimed herein, in one aspect thereof, includes an electronic cooling fan assembly with an electric fan core having a generally rectilinear shape, a positive pressure side, and a vacuum side. A fan bracket attaches to the positive pressure side of the electric fan core and is offset from the fan core thereby defining a gap between the fan core and the fan bracket, the gap having a width less than an amount required to sustain a Venturi effect air intake when the electric fan core is in an operating state. A grille attaches to the vacuum side of the fan core and has a grille face that is offset from the fan core, the offset being greater than an amount of offset required to reduce turbulence noise from the grille face when the electric fan core is in an operating state.
The present invention disclosed and claimed herein, in another aspect thereof, includes a fan mounting bracket for reducing noise and vibration in an enclosure. The bracket has a generally cylindrical shroud having a circumference and first and second ends, the shroud providing first and second mounting tabs substantially on opposite sides of the circumference on the first end, the mounting tabs each defining a fastening hole, the shroud also providing first and second stabilization tabs on substantially opposites side of the circumference on the fist end and being offset approximately 90 degrees from the mounting tabs. The bracket has a mounting flange attached to the second end of the shroud and defining a plane substantially orthogonal to an axis of the shroud, the mounting flange defines a plurality of fan attachment holes. The bracket has a plurality of elastic grommets wherein one of the plurality of elastic grommets is inset into each one of the plurality of fan attachment holes..
The present invention disclosed and claimed herein, in another aspect thereof, includes a method of reducing noise and vibration from a fan core operating to cool a container through an air vent. The method includes attaching a flanged shroud to the fan core with noise and vibration isolating grommets, attaching a grille to the fan core such that a face of the grille is offset from the fan core, the offset being at least a distance necessary to reduce turbulence noise through the grille face, and affixing the shroud to the air vent.
BRIEF DESCRIPTION OF THE DRAWINGSThe present invention is illustrated by way of example and is not limited by the figures of the accompanying drawings, in which like reference numbers indicate similar parts. Moreover, the drawings are not to scale and some features may be enlarged or reduced for illustrative purposes:
The present invention will now be described with reference to the drawings. Referring now to
The fan core 102 may be an off-the-shelf component or may be custom built. In some embodiments a personal computer (“PC”) cooling fan can be employed as a fan core. Generally speaking, the fan core 102 will be an axial, cross-flow type fan. The fan core 102 may also be a tube axial or ducted axial fan. Various physical sizes and air flow ratings may be used for the fan core 102 depending upon the needs of the user and the end application of the fan assembly 100. SilenX Corporation of Santa Fe Springs, Calif. produces a variety of fan cores that may be suitable, including the popular 3.5 inch (92 mm) and 4.5 inch (120 mm) sizes (e.g., part numbers IXP-64-11 and IXP-74-11, respectively). The brands and part numbers are given by way of example only and it is possible to utilize other suitably quiet fan cores with the disclosure provided herein. The fan core 102 will typically provide fan core mounts 104 to be used for attaching the fan to a mounting location (e.g, the fan bracket 116) and/or for attaching the grille 108 or other covering. In the embodiment shown, the fan core 102 provides a total of eight fan core mounts and is generally rectilinear in shape with a fan core mount 104 in each of the four corners on both sides of the fan core 102. Other embodiments may have other shapes or configurations. The fan core 102 will typically have leads 106 to power an electric motor driving the fan blades. As will be described in greater detail below, the fan leads 106 may be attached directly to a suitable power source or may be attached to a thermal switch or to a relay board 140 to provide additional functionality for the fan assembly 100.
The grille 108 may be attached to one side of the fan core 102. The fan core 102 will typically be configured to move air in the direction of the bracket 116. In such case, the grille 108 will be attached to the vacuum or intake side of the fan core 102. In the embodiment shown, the grille 108 mounts to the fan core 102 via a set of grille mounts 110. The grille 108 is shown with four mounts 110 corresponding to the four fan core mounts 104 on one side of the fan core 102. The grille 108 provides a grille face that covers the blades of the fan core 102 during operation. The grille 108 may be an off-the-shelf grille or may be custom made. The grille 108 may be a wire grille or made from another material. The grille face 112 may be offset from the plane of the grille mounts 110 by the distance shown as F in the drawings. The distance F will allow the fan core 102 to operate with reduced turbulence and noise generated by the airflow through the grille face 112 versus having the grille face 112 flush with the grille mounts 110. In some embodiments, the amount of offset distance F will be approximately one eighth of an inch and can cause a drop in noise of up to 6 to 9 dB versus a flush mount.
The side of the fan core 102 not attached to the grille 108 is attached to the bracket 116. This will typically be the outgoing or positive pressure side of the fan core 102. The bracket 116 provides a face 118 for mounting to the fan core 102 and a shroud 122 for directing airflow. The face 118 is a flange attached to the shroud 122. The shroud 122 and face 118 may be separate components attached together or may be integrated as will be described. The face 118 has four mounts 120 corresponding to the four mounts 104 on the outward side of the fan core 102. The shroud 122 may be substantially circumferential or cylindrical or may have another shape corresponding to the fan core 102. The shroud 122 provides mounting tabs 124 that can be used to secure the fan assembly 100 into a desired location (only one tab 124 is shown in the view of
The fan core 102, the grille 108 and the bracket 116 are connected by a series of fasteners, washers, and grommets. In one embodiment, the grille 108 attaches to the fan core 102 with rivets 114 through the grille mounts 110 and fan core mounts 104. In other embodiments bolts, screws, or other fasteners may be used. The fan core 102 and bracket 116 may attach together with bolts 130 and nuts 132. The bolts 130 may have a standard bolt head or a Philips head to aid in assembly. The nuts 132 may have Nylon inserts or other inserts to prevent untightening or noise from vibration. The bolts 130 pass through the bracket fan mounts 120 and the fan core mounts 104 to join with the nuts 132. In the embodiment shown, there are four bolts 130 and four nuts 132 corresponding to the four sets of bracket fan mounts 120 and fan core mounts 104 on one side of the fan core 102.
A set of grommets 134 may be inserted into the bracket fan mounts 104 prior to assembly. These grommets may be rubber or silicon or another suitable vibration and sound deadening material. One such suitable grommet is made by Gel-Mec UK of the United Kingdom (e.g., part no. 0905-90V). The grommets 134 and bracket fan mounts 120 will typically be sized such that the bracket fan mounts 120 are slightly larger than the grommets 134. The thickness of the face 116 will also typically be slightly thinner than necessary to use the grommets 134. This allows both ease of insertion and self centering of the grommets 134 with the fan assembly 100 mounted in any orientation. Washers 136 may be used where the bolts 130 meet the grommets 134 to allow the bolts 130 to be properly tightened without damaging or overstressing the grommets 134. The washers 136 may be Nylon or another material.
In some embodiments, the fan assembly may be attached to a power supply by the fan leads 106 in order to operate full time. In other embodiments, power may be supplied to the fan via a thermal switch such as the A2R model from Portage Electric Products of North Canton, Ohio. This allows the fan to activate upon a predetermined temperature instead of running all the time. In the embodiment shown in
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The housing 1002 provides one or more isolation pads 1006 located variously throughout the interior of the housing 1002. The pads 1006 may be placed as shown or in other configurations. Typically, the pads 1006 will be placed such that the fan core 102 rests only against the pads 1006 when the assembly 1000 is assembled. These pads 1006 may be silicon, rubber, or another vibration and/or sound dampening material.
In the embodiment shown in
It should be understood that the drawings and detailed description herein are to be regarded in an illustrative rather than a restrictive manner, and are not intended to limit the invention to the particular forms and examples disclosed. On the contrary, the invention includes any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments apparent to those of ordinary skill in the art, without departing from the spirit and scope of this invention, as defined by the following claims. Thus, it is intended that the following claims be interpreted to embrace all such further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments.
Claims
1. An electronic cooling fan assembly comprising:
- an electric fan core having a generally rectilinear shape, a positive pressure side, and a vacuum side;
- a fan bracket attached to the positive pressure side of the electric fan core and offset from the fan core thereby defining a gap between the fan core and the fan bracket, the gap having a width less than an amount required to sustain a Venturi effect air intake when the electric fan core is in an operating state; and
- a grille attached to the vacuum side of the fan core and having a grille face that is offset from the fan core, the offset being greater than an amount of offset required to reduce turbulence noise from the grille face when the electric fan core is in an operating state.
2. The electronic cooling fan assembly of claim 1, further comprising a set of elastic grommets interposing the fan bracket and the electric fan core.
3. The electronic cooling fan assembly of claim 1, further comprising at least one stress relief cord attached to the fan bracket, the at least one stress relief cord being adapted to retain at least one lead wire in proximity to the electric fan core.
4. The electronic cooling fan assembly of claim 1, wherein the fan bracket has a fan shroud that is substantially cylindrical and defines at least one bendable mounting tab, the at least one mounting tab defining a mounting hole that receives a fastener.
5. The electronic cooling fan assembly of claim 4, wherein the fastener is a captive screw.
6. The electronic cooling fan assembly of claim 5, wherein the shroud further defines at least one bendable stabilization tab, the at least one stabilization tab being offset by approximately 90 degrees on the circumference of the shroud from the at least one stabilization tab.
7. The electronic cooling fan assembly of claim 1, further comprising:
- a switch having a trigger input, an electrical input, and an electrical output;
- wherein the electrical output is connected to the electric fan core and the switch activates the electrical output in response to a predetermine triggering current and voltage on the trigger input.
8. The electronic cooling fan assembly of claim 7, further comprising, a second electrical output that provides power in parallel with the first electrical output.
9. The electronic cooling fan assembly of claim 8, further comprising a second electric fan core connected to the second electrical output.
10. The electronic cooling fan assembly of claim 1, wherein the fan bracket has a two piece construction including a generally cylindrical fan shroud and a flange attached to the fan shroud, the flange being attached to the electric fan core.
11. The electronic cooling fan assembly of claim 1, further comprising a thermal switch configured to selectively activate the electric fan core when an ambient temperate reaches a predetermined threshold.
12. The electronic cooling fan assembly of claim 11, wherein the thermal switch deactivates the electric fan core when the ambient temperature stays below a predetermined minimum threshold for a predetermined amount of time.
13. A fan mounting bracket for reducing noise and vibration in an enclosure, the bracket comprising:
- a generally cylindrical shroud having a circumference and first and second ends, the shroud providing first and second mounting tabs substantially on opposite sides of the circumference on the first end, the mounting tabs each defining a fastening hole, the shroud also providing first and second stabilization tabs on substantially opposites side of the circumference on the fist end and being offset approximately 90 degrees from the mounting tabs;
- a mounting flange attached to the second end of the shroud and defining a plane substantially orthogonal to an axis of the shroud, the mounting flange defines a plurality of fan attachment holes; and
- a plurality of elastic grommets;
- wherein one of the plurality of elastic grommets is inset into each one of the plurality of fan attachment holes.
14. The fan mounting bracket of claim 13, wherein the grommets are sized such that a Venturi effect gap is created when the mounting bracket is attached to a fan core via the fan attachment holes.
15. The fan mounting bracket of claim 13, wherein the shroud and the mounting flange are made substantially from sheet metal.
16. The fan mounting bracket of claim 13, wherein the elastic grommets are substantially made from silicon.
17. A method of reducing noise and vibration from a fan core operating to cool a container through an air vent, the method comprising:
- attaching a flanged shroud to the fan core with noise and vibration isolating grommets;
- attaching a grille to the fan core such that a face of the grille is offset from the fan core, the offset being at least a distance necessary to reduce turbulence noise through the grille face; and
- affixing the shroud to the air vent.
18. The method of claim 17, further comprising securing a power lead to the shroud in proximity to the fan core such that a length of the power lead spanning a distance from the shroud to the fan core is relaxed.
19. The method of claim 17, further comprising selectively engaging the fan core with a thermal switch.
20. The method of claim 17, wherein the step of affixing the shroud further comprises attaching the shroud to the air hole such that the shroud protrudes into the air vent with at least one mounting tab on the shroud being attached to an area surrounding the air vent and at least one stabilizing tab on the shroud being substantially flush against the area surrounding the air vent.
Type: Application
Filed: Sep 25, 2006
Publication Date: Mar 29, 2007
Applicant: RHOADS A/V, L.P. (PLANO, TX)
Inventor: TIM RHOADS (PLANO, TX)
Application Number: 11/534,906
International Classification: F04B 17/00 (20060101);