High-strength low-weight fan blade assembly

• US 7,331,764 B1
• Filed: 04/19/2004
• Issued: 02/19/2008
• Est. Priority Date: 04/19/2004
• Status: Active Grant

• Current Assignee: Vee Engineering, Inc.
• Original Assignee: Vee Engineering, Inc.
• Inventors: Reynolds, John R., Porter, Jay S.
• Primary Examiner(s): Edgar; Richard
• Application Number:
  US10/827,601
• Time in Patent Office: 1,401 Days
• Field of Search: 416/169.A, 416/203, 416/204.R, 416/213.A, 416/214.R, 416/230, 416/241.A, 416/237, 416/238, 416/223.R, 416/243, 428/297.4, 428/299.4, 428/301.4, 442/148, 442/180, 442/287, 442/288, 442/395, 442/396
• US Class Current: 416/204.00R
• CPC Class Codes: F04D 29/023 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/329 Details of the hub
• CPC Class Codes: F04D 29/34 Blade mountings for axial flow compressors F04D29/322
• CPC Class Codes: F04D 29/388 characterised by construction
• CPC Class Codes: F05D 2300/43 Synthetic polymers, e.g. plastics; Rubber
• CPC Class Codes: F05D 2300/603 Composites; e.g. fibre-reinforced

Abstract

An engine cooling fan system including a hub disc about which first and/or second pluralities of elongated fan blades characterized by a first and second respective pitch angles may be fastened. Each respective fan blade further comprises a hub-engaging portion, a twisted transition portion and an air-engaging portion. Each fan blade is formed from a composite material having a thermoset resin matrix phase and an evenly dispersed continuous fiber reinforcement phase.

Claims

1. A fan assembly, comprising:

a hub having a pattern of through-holes, said hub having a substantially planar face;

a plurality of fan blades positioned substantially evenly around said hub; and

a plurality of fasteners connecting said fan blades to said hub;

wherein each said fan blade further comprises;

an attachment portion having a substantially planar face and a plurality of through-holes; and

a curved air-engaging portion twisted relative to said attachment portion;

wherein each said fan blade is formed from a composite material having a thermoset resin matrix phase and a continuous fiber reinforcement phase;

wherein the continuous fiber reinforcement phase is substantially evenly dispersed in the thermoset resin matrix phase and

wherein the planar face of said hub is in contact with the planar face of each said blade, each said fastener extending through a hole of said hub and a corresponding hole of said blade.

2. The assembly of claim 1 wherein the thermoset resin phase is a vinyl ester.

3. The assembly of claim 1 wherein the continuous fiber reinforcement phase is a fabric.

4. The assembly of claim 1 wherein the continuous fiber reinforcement phase is glass.

5. The assembly of claim 1 wherein the continuous fiber reinforcement phase is woven.

6. The assembly of claim 1 wherein the continuous fiber reinforcement phase is mat.

7. The assembly of claim 1 wherein said fasteners are permanent.

8. The assembly of claim 1 wherein each said elongated fan blade is characterized by a strength to weight index of at least about 340 PSI per pound.