Borgwarner Inc.

Donald E Buckley

Neil E Robb

Gerard M Light

James R DeBrabander

Jonathan Bradley Stagg

Injection molded ring fan embodiments and methods for making them. The methods influence material flow during the injection molding process such that a major portion of the materials flowing in opposite directions in the outer rings preferably flow past one another, intermix in a swirling relationship, and/or collide at an angle relative to one another. This results in better material mixing or integration of the flow fronts. In one embodiment, the thickness of the outer ring varies in different portions between adjacent fan blades.

Plastic fans having improved fan ring weld line strength

A method to influence material flow during the injection molding of thermoplastic, polymeric ring type fans such that a major portion of the materials flowing in opposite directions preferably flow past one another, or collide at an angle relative to one another, rather than colliding at an 180 degree angle relative to each other to form weld lines. This flow bypassing results in better material mixing or integrating than merely allowing flow fronts to collide and cool. In one embodiment, a portion of the fan's ring is thickened in the weld line area to minimize the amount of material colliding at a 180-degree angle relative to each. Alternatively, at least one appendage could be added to the ring fan that will influence the material flow during molding conditions. Each appendage will be removed prior to introducing the ring fan to a cooling system.

A fan drive assembly including a cooling fan ( ) and a fluid coupling device ( ). The cooling fan includes a fan hub ( ), a spider ( ), and a plurality of fan blades ( ). The coupling device has an output coupling assembly ( ) including a body ( ) and a cover ( ). The body ( ) includes preferably only three mounting portions ( ), each being disposed immediately adjacent an outer periphery of the body. Each of the mounting portions ( ) defines the necessary machining chucking surfaces ( ), and a spider mounting surface ( ) including a pilot surface ( ) engaging the pilot diameter ( ) of the spider ( ). The body ( ) includes cooling fins ( ) covering substantially all of the rearward surface ( ) of the body not covered by the mounting portions. The fan hub ( ) also includes a rearwardly extending air dam portion ( ), limiting localized radial air flow. The fan drive is able to improve the radial air flow through the body cooling fins and achieve substantially greater heat dissipation from the fan drive assembly, thus permitting greater fan speed for a given input speed.

Enhanced fan and fan drive assembly

A fan drive assembly including a cooling fan ( ) and a fluid coupling device ( ). The cooling fan includes a fan hub ( ), a spider ( ), and a plurality of fan blades ( ). The coupling device has an output coupling assembly ( ) including a body ( ) and a cover ( ). The body ( ) includes preferably only three mounting portions ( ), each being disposed immediately adjacent an outer periphery of the body. Each of the mounting portions ( ) defines the necessary machining chucking surfaces ( ), and a spider mounting surface ( ) including a pilot surface ( ) engaging the pilot diameter ( ) of the spider ( ). The body ( ) includes cooling fins ( ) covering substantially all of the rearward surface ( ) of the body not covered by the mounting portions. The fan hub ( ) also includes a rearwardly extending air dam portion ( ), limiting localized radial air flow. The fan drive is able to improve the radial air flow through the body cooling fins and achieve subatantially greater heat dissipation from the fan drive assembly, thus permitting greater fan speed for a given input speed.

A fan drive assembly including a cooling fan (,) and a fluid coupling device (,). The cooling fan includes a fan hub (,), a spider (,), and a plurality of fan blades (,). The coupling device has an output coupling assembly (,) including a body (,) and a cover (,). The body (,) includes preferably only three mounting portions (,), each being disposed immediately adjacent an outer periphery of the body. Each of the mounting portions (,) defines the necessary machining chucking surfaces (,), and a spider mounting surface (,) including a pilot surface (,) engaging the pilot diameter (,) of the spider (,). The body (,) includes cooling fins (,) covering substantially all of the rearward surface (,) of the body not covered by the mounting portions. The fan hub (,) also includes a rearwardly extending air dam portion (,), limiting localized radial air flow. The present invention is able to improve the radial air flow through the body cooling fins and achieve substantially greater heat dissipation from the fan drive assembly, thus permitting greater fan speed for a given input speed.

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Lansing, MI, United States of America

Donald E Buckley