Fan blades and associated blade tips
AssigneeAssa Abloy Entrance Systems AB
InventorsL. Blake Whitley, Richard K. Hoofard
Life of this patent
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Abstract
Fans having fan blades with lightweight blade tips are disclosed herein. In one embodiment, for example, each fan blade includes a blade tip attached to an end portion of a main airfoil. The blade tip includes a shaped body that is molded over a support structure to form the shape and exterior surface of the blade tip.
Claims27
A fan blade tip configured to attach to an end portion of a fan blade, wherein the fan blade tip comprises:
- an internal support structure comprising a first material having a first density;
- and
- a shaped body comprising a second material encasing the internal support structure and defining an exterior surface of the fan blade tip, wherein the second material has a second density that is less than the first density, wherein the internal support structure includes a base member and a plurality of elongate support elements projecting outwardly therefrom, wherein the elongate support elements are encased in the second material, and wherein the base member is configured to attach to the end portion of the fan blade.
A fan blade tip configured to attach to an end portion of a fan blade, wherein the fan blade tip comprises:
- an internal support structure comprising a first material having a first density;
- and
- a shaped body comprising a second material encasing the internal support structure and defining an exterior surface of the fan blade tip, wherein the second material has a second density that is less than the first density, wherein the internal support structure includes a plurality of cantilevered support elements projecting outwardly from the end portion of the fan blade, and wherein the cantilevered support elements are encased in the second material.
A fan blade tip configured to attach to an end portion of a fan blade, wherein the fan blade tip comprises:
- an internal support structure comprising a first material having a first density;
- and
- a shaped body comprising a second material encasing the internal support structure and defining an exterior surface of the fan blade tip, wherein the second material has a second density that is less than the first density, wherein the second material forms an airfoil having an inboard chord and an outboard chord, wherein the inboard chord has a first chord length, wherein the outboard chord has a second chord length less than the first chord length, and wherein the second material decreases in thickness from the inboard chord to the outboard chord.
A fan blade configured to attach to a central hub of a fan, the fan blade comprising:
- a main airfoil having an outboard end portion;
- and
- a blade tip, including—
- an internal support structure projecting outwardly from the outboard end portion, wherein the internal support structure includes a plurality of cantilevered support elements, and
- a shaped body formed over the plurality of cantilevered support elements and defining an exterior surface of the blade tip, wherein the internal support structure comprises a molded plastic, and the shaped body comprises a foam material encasing the molded plastic.
A fan blade configured to attach to a central hub of a fan, the fan blade comprising:
- a main airfoil having an outboard end portion;
- and
- a blade tip, including—
- an internal support structure projecting outwardly from the outboard end portion, wherein the internal support structure includes a plurality of cantilevered support elements, and
- a shaped body formed over the plurality of cantilevered support elements and defining an exterior surface of the blade tip, wherein the shaped body has a planform shape of the blade tip, and wherein the cantilevered support elements are staggered in length such that they complement the planform shape.
A fan comprising a plurality of blades extending outwardly from a central hub configured to be suspended from a ceiling or other elevated structure, wherein each of the blades includes:
- a main airfoil having an inboard end portion disposed toward the central hub and an outboard end portion spaced apart from the central hub;
- and
- a blade tip attached to the outboard end portion of the main airfoil, wherein the blade lip includes—
- an internal support structure, and
- means for defining an exterior surface of the blade tip and its overall shape, wherein the means for defining encapsulates the internal support structure, and wherein the internal support structure includes a plurality of coplanar, elongate support elements that extend at least partially into the means for defining.
A method of manufacturing a fan blade tip having an exterior surface, the method comprising:
- positioning a support structure in a mold having a mold surface that defines the exterior surface of the blade tip, wherein the support structure includes a base member and a plurality of integral support elements projecting outwardly therefrom;
- flowing uncured body material into the mold and over the integral support elements, but not the base member;
- and
- allowing the body material to cure.
Dependencies are inferred from the claim text.