Flexible impeller with overmolded hub

• US 5,655,884 A
• Filed: 03/14/1996
• Issued: 08/12/1997
• Est. Priority Date: 06/28/1995
• Status: Expired due to Fees

• Current Assignee: The Scott Fetzer Company (Berkshire Hathaway Incorporated)
• Original Assignee: The Scott Fetzer Company (Berkshire Hathaway Incorporated)
• Inventors: Rose, Mitchell
• Primary Examiner(s): Look, Edward K
• Assistant Examiner(s): Sgantzos, Mark
• Application Number:
  US08/615,982
• Time in Patent Office: 516 Days
• Field of Search: 416/132 R, 416/132 A, 416/213 A, 416/240, 416/241 A, 416/244 R
• US Class Current: 416/240
• CPC Class Codes: A47L 5/22 with rotary fans
• CPC Class Codes: F04D 29/023 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/305 Flexible vanes
• CPC Class Codes: F04D 29/382 Flexible blades
• CPC Class Codes: F05D 2300/43 Synthetic polymers, e.g. plastics; Rubber
• CPC Class Codes: F05D 2300/601 Fabrics

Abstract

A fan for a vacuum cleaner has a fan housing, motor and impeller. The fan housing has an inlet and outlet. The impeller has a overmolded hub and multiple flexible blades. This flexible blade fan provides better air performance, less noise, better durability, and easier impeller installation than conventional vacuum cleaner fans.

Claims

1. A fan impeller for a vacuum cleaner, comprising:

a plurality of pliable blades for centrifugally displacing a volume of air upon rotation of the impeller; and

a hub for retaining said plurality of blades, wherein said hub secures the impeller to a motor-driven shaft for producing rotation, and wherein the hub is formed of a moldable material which is overmolded around the blades to securely retain the blades within the hub.

2. The fan impeller of claim 1 wherein each blade has a shaped edge.

3. The fan impeller of claim 1 wherein each blade is formed of a flat piece of material which is shredded.

4. The fan impeller of claim 1 wherein each blade is comprised of multiple strands.

5. The fan impeller of claim 1 wherein the blades are between 1-5 inches long, and between 0.10-2.0 inches wide.

6. The fan impeller of claim 1 wherein the blade material comprises a synthetic fabric.

7. The fan impeller of claim 6 wherein the synthetic fabric is polyester and is coated with a polymer.

8. The fan impeller of claim 1 wherein the blades are formed from a plurality of straps, wherein each strap is folded at the center to provide a pair of blades, and wherein the center of each strap is secured within the hub.

9. The fan impeller of claim 1 wherein the hub is formed of an elastomeric material having a durometer of 60A-90D.

10. The fan impeller of claim 1 wherein the hub includes a bore for attaching to the motor-driven shaft and wherein the hub is formed of a flexible material in the area substantially around the bore and the remainder of the hub is formed of a rigid material.

11. The fan impeller of claim 1 wherein the hub includes a bore for attaching to the motor-driven shaft and wherein the hub includes a rigid tube to define the bore, and wherein the remainder of said hub is formed of a flexible material.

12. The fan impeller of claim 1 wherein strap and the hub are formed of respective materials selected to produce a chemical bond.

13. The fan impeller of claim 12 wherein the hub material is urethane and wherein the blade is a urethane-coated polyester.

14. A fan for a vacuum cleaner, comprising:

a fan housing for receiving an impeller, said fan housing having an inlet and an outlet for respectively receiving and discharging air;

a shaft, rotationally driven by a motor, and secured to the fan housing;

an impeller mounted on said shaft and received within said fan housing, for centrifugally drawing air from said inlet to said outlet, said impeller comprising;

a plurality of pliable blades for centrifugally displacing a volume of air upon rotation of the impeller; and

a hub for retaining said plurality of blades, wherein said hub secures the impeller to the shaft, wherein the hub is formed of a moldable material which is overmolded around the blades to securely retain the blades within the hub.

15. The fan of claim 14 wherein each blade has a shaped edge.

16. The fan of claim 14 wherein each blade is formed of a flat piece of material which is shredded.

17. The fan of claim 14 wherein each blade is comprised of multiple strands.

18. The fan of claim 14 wherein the blades are between 1-5 inches in length, and between 0.10-2.0 mm wide.

19. The fan of claim 14 wherein the blade material comprises a synthetic fabric.

20. The fan of claim 19 wherein the synthetic fabric is polyester and is coated with a polymer.

21. The fan of claim 14 wherein the blades are formed from a plurality of straps, wherein each strap is folded at the center to provide a pair of blades, and wherein the center of each strap is secured within the hub.

22. The fan impeller of claim 14 wherein the hub is formed of an elastomeric material having a durometer of 60A-90D.

23. The fan impeller of claim 14 wherein the hub includes a bore for attaching to the motor-driven shaft and wherein the hub is formed of a flexible material in the area substantially around the bore and the remainder of the hub is formed of a rigid material.

24. The fan impeller of claim 14 wherein the hub includes a bore for attaching to the motor-driven shaft and wherein the hub includes a rigid tube to define the bore, and wherein the remainder of said hub is formed of a flexible material.

25. The fan impeller of claim 14 wherein strap and the hub are formed of respective materials selected to produce a chemical bond.

26. The fan impeller of claim 25 wherein the hub material is urethane and wherein the blade is a urethane-coated polyester.